Material preparation device and related methods

Patent metadata

Field	Value
Publication number	US-10987882-B2
Application number	US-201816221052-A
Country	US
Kind code	B2
Filing date	Dec 14, 2018
Priority date	Apr 13, 2010
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

Material preparation devices and related methods include a material or substrate assembly and an application assembly for applying a fiber material.

First claim

What is claimed is:

1. A bias-ply material preparation device, the device comprising:
a backing material assembly configured to pass bias-ply backing material along a first path, wherein the bias-ply backing material is configured to be removed from the bias-ply material;
an application assembly configured relative to the bias-ply backing material, the application assembly configured to:
apply a first section of fiber-reinforced material feedstock directly on the bias-ply backing material in a forming area at a first angle relative to the first path;
cut off the first section of fiber-reinforced material feedstock;
move the first section of fiber-reinforced material feedstock at least partially out of the forming area with the bias-ply backing material; and
apply at least a second section of fiber-reinforced material feedstock directly on the bias-ply backing material at the first angle relative to the first path in the forming area to prepare the bias-ply material.

2. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at various angles relative to the first path.

3. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at an oblique angle relative to the first path.

4. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at a perpendicular angle relative to the first path.

5. A method of preparing a fiber-reinforced material for use with a composite structure, the method comprising:
passing a bias-ply backing material along a first path with a backing material assembly, wherein the bias-ply backing material is configured to be removed from the fiber-reinforced material for use with a composite structure;
applying a first section of fiber-reinforced material directly on the bias-ply backing material in a forming area at a first angle relative to the first path;
cutting off the first section of fiber-reinforced material;
moving the first section of fiber-reinforced material at least partially out of the forming area with the bias-ply backing material; and
applying at least a second section of fiber-reinforced material directly on the bias-ply backing material in the forming area at the first angle to prepare the fiber-reinforced material for use with a composite structure.

6. The method of claim 5 , further comprising orienting the first angle in a direction offset from the first path.

7. The method of claim 5 , further comprising orienting the first angle at an oblique angle relative to the first path.

8. The method of claim 5 , further comprising orienting the first angle at a perpendicular angle relative to the first path.

9. The method of claim 5 , further comprising overlapping the first section of fiber-reinforced material and the at least a second section of fiber-reinforced material.

10. The method of claim 5 , further comprising positioning the at least a second section of fiber-reinforced material adjacent the first section of fiber-reinforced material with no overlap.

11. The method of claim 5 , further comprising defining a fabric with at least the first section of fiber-reinforced material and the at least a second section of fiber-reinforced material.

12. The method of claim 5 , further comprising applying a layer of fiber-reinforced material over the first section and the at least a second section at a second angle relative to the first path, wherein the first angle and the second angle are offset from each other.

13. A material preparation device, the device comprising:
a substrate assembly configured to pass a base substrate along a first path; and
a movable application assembly carrying a supply of fiber material feedstock, the movable application assembly configured to move relative to the base substrate to apply a layer of the fiber material feedstock comprising multiple individual sections of the fiber material feedstock directly on the base substrate at an offset angle relative to the first path; and
wherein the base substrate is configured to be removed from the layer of fiber material feedstock.

14. The device of claim 13 , wherein the movable application assembly is configured to apply a first individual section of fiber material feedstock directly on the substrate at a position adjacent to a second individual section of fiber material feedstock.

15. The device of claim 14 , wherein the material preparation device is configured to connect the first individual section to the second individual section of fiber material feedstock to define a sheet of fiber material.

16. The device of claim 13 , wherein the movable application assembly is configured to apply the layer of fiber material feedstock comprising fibers in at least some resin.

17. A method of preparing a fiber-reinforced material for use with a composite structure, the method comprising:
passing a base substrate along a first path with a substrate assembly wherein the base substrate is configured to be removed from the fiber-reinforced material for use with a composite structure;
applying a first layer of fiber material directly on the substrate at an offset angle relative to the first path with a movable application head; and
applying a second layer of fiber material directly on the substrate at a position adjacent to the first layer of fiber material with the movable application head.

18. The method of claim 17 , further comprising applying a third layer of fiber material on the substrate at a position adjacent to the second layer of fiber material feedstock with the movable application head.

19. The method of claim 18 , further comprising connecting the first layer, the second layer, and the third layer to define a sheet of fiber material.

20. The method of claim 18 , further comprising connecting the first layer, the second layer, and the third layer with a tape material to define a sheet of fiber material.

21. The method of claim 18 , further comprising selecting the first layer, the second layer, and the third layer of the fiber material to comprise fibers in at least some resin.

Assignees

• Northrop Grumman Innovation Systems Inc
• Northrop Grumman Systems Corp

Inventors

• Slack Jason K
• Madsen Christopher J
• Jones Don C
• Benson Vernon M
• Turner Peter G
• Cope Ralph Douglas
• Ferrara Kimberly Ann
• Johnson Anthony Dale
• Case Michael James
• Brown Jesse Paul
• Gargel James
• Cope Steven Andrew
• Tarry Kyle Putnam

Classifications

• B29C70/22

  oriented in at least two directions forming a two-dimensional [2D] structure · CPC title

• B29C70/38

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title

• B29C2793/0072

  combined with rearranging and joining the cut parts · CPC title

• Y10T156/1052

  with cutting, punching, tearing or severing · CPC title

• B29K2105/243

  Partially cured · CPC title