Method and apparatus for handling plies of composite material

In a method of fabricating an article from a plurality of plies of fiber reinforced/resin matrix composite material, said method being of the type in which a cut ply is carried by and removably adhered to a web of backing material, an improved method of positioning said ply on a mold surface and detaching said ply from the backing material, comprising:

• tensioning the web of backing material;
• positioning the web and the mold surface relative to each other to locate said ply and the mold surface in oriented closely spaced positions relative to each other;
• after so positioning the web and the mold surface, applying a plurality of localized forces to the surface of the tensioned backing material opposite said ply to move said ply into contact with portions of the mold surface and adhere said ply to said portions of the mold surface;
• and
• while continuing said tensioning, removing said forces from the backing material and separating the backing material from said ply, including allowing said tensioning to detach said ply from the backing material;
• in which said localized forces are applied progressively to progressively adhere portions of said ply to the mold surface, and the backing material is progressively separated from said ply;
• and
• in which a plurality of vacuum cups are urged against said surface of the tensioned backing material to apply said localized forces, the vacuum cups are moved along the tensioned backing material to progressively adhere said ply to the mold surface, said localized forces are maintained essentially constant as the vacuum cups are moved along the tensioned backing material, and suction is applied to said surface of the tensioned backing material through the vacuum cups to assist said tensioning in detaching said ply from the backing material.

A method of fabricating an article from a plurality of plies of fiber reinforced/resin matrix composite material, comprising:

• positioning opposite ends of a web of composite material, which is removably adhered to a web of backing material, on spaced reels;
• cutting a ply from a portion of the web of composite material between the reels without cutting through the backing material;
• applying a torque to each of the reels to tension the web of backing material;
• moving a mold surface relative to the web of backing material to position the cut ply and the mold surface in oriented closely spaced positions relative to each other;
• after so positioning the cut ply and the mold surface, applying a plurality of localized forces to the surface of the tensioned backing material opposite said ply to move said ply into contact with portions of the mold surface and adhere said ply to said portions of the mold surface;
• and while continuing said tensioning, removing said forces from the backing material and separating the backing material from said ply, including allowing said tensioning to detach said ply from the backing material;
• moving the mold surface and the adhered cut ply away from the web of backing material, and then forming the adhered cut ply to the mold surface;
• rotating the reels to position the web of composite material for cutting another ply;
• and
• repeating the steps of cutting a ply, moving the mold surface to position the cut ply and the mold surface relative to each other, applying localized forces, and removing said localized forces and separating the backing material;
• in which said localized forces are applied progressively to progressively adhere portions of said ply to the mold surface, and the backing material is progressively separated from said ply;
• and
• in which a plurality of vacuum cups are urged against said surface of the tensioned backing material to apply said localized forces, the vacuum cups are moved along the tensioned backing material to progressively adhere said ply to the mold surface, said localized forces are maintained essentially constant as the vacuum cups are moved along the tensioned backing material, and suction is applied to said surface of the tensioned backing material through the vacuum cups to assist said tensioning in detaching said ply from the backing material.