COMPOSITE TAPE APPLICATOR HEAD

Abstract

An applicator head (1) for the application of a composite tape (2) fed from a supply reel (3) to a surface for the deposition thereof; the tape (2) being formed by a layer of composite material (2.1) disposed on a supporting layer (2.2). The applicator head (1) comprises a cutting means (30), compaction means (40) and/or collection means (50). The cutting means (30) is displaced in a first direction of displacement of a first blade (31) at an angle with regard to a second direction of displacement of a second blade (32). The compaction means (40) has an application separator (41) configured to separate the layer of composite material (2.1) from the supporting layer (2.2) at a certain height from the surface for the deposition thereof. And the collection means (50) has a collection separator (52) configured to separate the unused layer of composite material (2.1) and to collect it in a collection container (53).

Claims

1. An applicator head for the application of a composite tape (2) fed from a supply reel (3) to a surface for the deposition thereof; the tape (2) being formed by a layer of composite material (2.1) disposed on a supporting layer (2.2); comprising cutting means (30) for cutting the fed layer of composite material (2.1) to be applied on the surface for the deposition thereof; the cutting means (30) comprising a first blade (31) longitudinally displaceable in a first direction of displacement being configured to cut the layer of composite material (2.1) and a second blade (32) to cut the layer of composite material displaceable in a second direction of displacement, characterised in that the first direction of displacement of the first blade (31) is at an angle with regard to the second direction of displacement of the second blade (32).

2. The applicator head (1) according to claim 1, characterised in that the direction of displacement of the first blade (31) or the second blade (32) is perpendicular to a feed direction of the composite tape (2).

3. The applicator head (1) according to claim 1 or 2, characterised in that the cutting means (30) comprise guiding means (33, 34) for the displacement of the blade (31, 32) longitudinally in the direction of displacement.

4. An applicator head for the application of a composite tape (2) fed from a supply reel (3) to a surface for the deposition thereof; the tape (2) being formed by a layer of composite material (2.1) disposed on a supporting layer (2.2); comprising compaction means (40) for the fed layer of composite material (2.1) to be applied to the surface for the deposition thereof; the compaction means (40) comprising a compaction roller (42) configured to apply compaction pressure on the layer of composite material (2.1) applied on the surface for the deposition thereof, characterised in that the compaction means (40) comprises an application separator (41) configured to separate a layer of composite material (2.1) from the supporting layer (2.2) by a cut edge of the layer of composite material (2.1) by applying a separation pressure on the tape (2) on the side of the supporting layer (2.2), so that the cut edge of the separated layer of composite material (2.1) points towards a contact area between the compaction roller (42) and the surface for deposition at a certain height of the application separator (41) from the surface for deposition.

5. The applicator head according to claim 4, characterised in that the application separator (41) is displaceable to apply the separation pressure.

6. The applicator head according to claim 5, characterised in that the application separator (41) is pivotable so that it goes towards the contact area to apply the separation pressure.

7. The applicator head according to any one of claims 4 to 6, characterised in that the application separator (41) is wedge-shaped to apply the separation pressure on the tape (2).

8. An applicator head for the application of a composite tape (2) fed from a supply reel (3) to a surface for the deposition thereof; the tape (2) being formed by a layer of composite material (2.1) disposed on a supporting layer (2.2); comprising collection means (50) for collecting the fed layer of composite material (2.1) not used on the surface for the deposition thereof; the collection means (50) comprising a collection separator (52) configured to separate the unused cut layer of composite material (2.1) from the supporting layer (2.2) by a cut edge of the layer of composite material (2.1) when applying a separation pressure on the tape (2) on the side of the supporting layer (2.2), and comprising a collection container (53) for collecting the separated layer of composite material (2.1).

9. The applicator head according to claim 8, characterised in that the application separator (52) is displaceable to apply the separation pressure on the tape (2).

10. The applicator head according to claim 8 or 9, characterised in that the collection means (50) comprises at least two positioning rollers (51) on which the tape (2) circulates to a stockpiling reel-holder (6), the actuator (52) being interposed between both positioning rollers (51) to apply the separation pressure on the tape (2).

11. The applicator head according to any one of claims 9 to 11, characterised in that the collection separator (52) comprises a protrusion (54) to apply separation pressure on the tape (2).

Description

DESCRIPTION OF THE FIGURES

[0027] FIG. 1 shows a schematic perspective view of an applicator head for applying composite tapes (1) with cutting means (30), compaction means (40) and collection means (50).

[0028] FIG. 2 shows a perspective view of the cutting means (30).

[0029] FIG. 3 shows a top view of the cutting means (30) in which only the first blade (31) is seen; however, the second blade (32) is also indicated, since it would be at the same height.

[0030] FIG. 4 shows a front view of the cutting means (30), where the direction of displacement of the blades (31, 32) on the spindles (33, 34) and the direction of displacement (9) of the tape (2) are indicated with arrows.

[0031] FIG. 5 shows a schematic front view of the compaction means (40) with the application separator (41) in a higher retracted position in which it does not act on the tape (2).

[0032] FIG. 6 shows a schematic front view of the compaction means (40) with the application separator (41) in a working position in which it acts against the tape (2).

[0033] FIG. 7 shows a schematic front view of the compaction means (40) with the application separator (41) in an upper retracted position with the layer of composite material (2.1) being applied on the surface for the deposition thereof and separated from the supporting layer (2.2).

[0034] FIG. 8 shows a detailed view of the collection means (50) with the collection separator (52) in the standby position above the tape (2).

[0035] FIG. 9 shows a detailed view of the collection means (50) with the collection separator (52) in an actuation position in which it acts against the tape (2) releasing the unused layer of composite material (2.1) waste.

[0036] FIG. 10 shows a detailed view of the collection means (50) with the collection separator (52) in the standby position with the supporting layer (2.2) going to a reel-holder and the surplus layer of composite material (2.1) going to the collection container (53).

DETAILED DESCRIPTION OF THE INVENTION

[0037] In light of the aforementioned figures, and in accordance with the adopted numbering, one may observe therein a preferred exemplary embodiment of the invention, which comprises the parts and elements indicated and described in detail below.

[0038] FIG. 1 shows an applicator head (1) for the application of tapes (2) of the type used for the application by means of the compact superposition of layers of composite material (2.2) to form laminated parts that are mainly used in the aerospace industry. The applicator head (1) of a preferred embodiment shown in FIG. 1 comprises cutting means (30), compaction means (40) and collection means (50).

[0039] A mould is provided in which there is defined a surface for deposition on which the layers of composite material (2.2) will be applied. In a first step, a supply reel with a tape (2) made up of a layer of composite material (2.1) on a supporting layer (2.2) is disposed on a supply reel-holder (3), with the layer of composite material (2.1) having a greater rigidity than the supporting layer (2.2).

[0040] Next, the tape (2) is circulated through a guide (4). At the moment that the tape (2) reaches cutting means (30), knowing the shape of the surface for deposition where the layer of composite material (2.1) is going to be deposited, a cut is made to the tape (2). Said cut is made with a blade (31, 32) with such precision that it allows the cutting of the layer of composite material (2.1) to be applied without the cutting of the supporting layer (2.2).

[0041] To proceed with said cutting, the cutting means (30) comprises a first blade (31) and a second blade (32). As can be seen in FIG. 3, the first blade (31) is comprised in a first blade holder (37) which, as seen in FIGS. 2 and 4, is displaced longitudinally in a first direction on guiding means, the guiding means in this particular case being a first spindle (33), so that said first spindle (33) is at an angle with regard to the perpendicular to a feed direction of the composite tape (2). In the preferred embodiment illustrated in FIG. 1, the feed direction is vertical, advancing along the guide (4), so that the first spindle (33) is at an angle with regard to the horizontal defining a displacement of the blade (31) at an angle.

[0042] As can be seen in FIGS. 2 and 4, said cutting means (30) also comprises the second blade (32) comprised in a second blade holder (38) that is displaced longitudinally in a second direction of displacement on a second spindle (34) so that said second spindle (34) is in a horizontal position defining a horizontal displacement of the second blade (32).

[0043] In this way an actuator cylinder (36) transversely displaces the blade holder (37, 38) until the blade (31, 32) contacts the tape (2) and at that moment an actuator (35) causes the displacement of the blade holder (37, 38) along the spindle (33, 34) so that the blade (31, 32) produces a first cut on the tape (2). A blade or another device is used, as needed according to the shape of the mould of the part to be generated and generating for that purpose a cut edge of the layer of composite material (2.1) to be applied.

[0044] Next, the cut tape (2) goes to compaction means (40) for the application of the layer of composite material (2.1) on the surface for the deposition thereof.

[0045] FIGS. 5, 6 and 7 show the sequence carried out by the compaction means (40) for the application of the layer of composite material (2.1) on the surface for the deposition thereof.

[0046] At first, an application separator (41) is in the retracted position, advancing the tape (2) with the layer of composite material (2.1) and the supporting layer (2.2) without being applied, as can be seen in FIG. 5. As the applicator head (1) approaches the surface for the deposition thereof, the application separator (41) applies separation pressure on the tape (2). The movement of said application separator (41) is selected so that it separates the layer of composite material (2.1) by the previously generated cut edge. Thus, the application separator (41) pivots with regard to an articulation (7) by the action of a pneumatic actuator (8). Upon being pivotally displaced, it comes as close as possible to a contact area between a compaction roller (42) and the surface for deposition. To favour the separation between the layer of composite material (2.1) to be applied and the supporting layer (2.2), the application separator (41) is wedge-shaped.

[0047] As can be seen in FIG. 6, with the compaction roller (42) already in contact with the surface for deposition due to the movement of the applicator head (1), the application spreader (41) applies pressure to the tape (2 ) in a working position in which the wedge-shaped end of the application separator (41) is located between the compaction roller (42) and the surface for deposition. A separation pressure is then applied on the tape (2) without acting on surface for deposition, that is, at a height of the application separator (41) from the surface for deposition such that the tension of the supporting layer (2.2) in the applicator head (1) is not lost. When acting on the tape (2) and given that the layer of composite material (2.1) has a greater rigidity than the supporting layer (2.2), when the separation pressure is applied, the tensioned tape (2) deforms upon reaching a detachment angle with the help of support on a guide roller (5). The separation of the layer of composite material (2.1) from the paper supporting layer (2.2) is thereby achieved.

[0048] With this configuration, the application separator (41) directs the layer of composite material with its cut edge towards the contact area between the compaction roller (42) so that the separated layer of composite material (2.1) contacts the compaction roller (42) before said layer of composite material (2.1) contacts the surface for the deposition thereof. Thus, the compaction roller (42) contacts the contacting layer of composite material (2.1) between the compaction roller (42) and the surface for the deposition thereof, depositing the layer of composite material (2.1) on the surface for the deposition thereof and applying a compaction force. The formation of bubbles that cause the final part to present defects and lose properties or be discarded is thereby prevented.

[0049] As can be seen in FIG. 7, the layer of composite material (2.1) has already been separated from the supporting layer (2.2), and the layer of composite material (2.1) is being applied on the surface for the deposition thereof, being compacted by the compaction roller. (42); at this time, the application separator (41) returns to its retracted position.

[0050] The application of the layer of composite material (2.1) continues with the advance of the applicator head (1) until reaching the edge where the mould ends, where the layer of composite material (2.1) is applied. For this purpose, moments before reaching the end of the application of the layer of composite material (2.1), the cutting means (30) cuts the layer of composite material (2.1) so that the direction of the cut coincides with the shape of the mould or surface for deposition.

[0051] For this purpose, if it is necessary to make a cut of the tape (2) at an angle, the advance of the head (1) is synchronised with the displacement of the second blade (32) so that the edge of the cut layer of composite material (2.1) coincides with the shape of the edge of the mould without it being necessary to stop the advance of the head (1). However, this is not possible when the cut to be made is horizontal and not at an angle. To do this, if the second blade (32) were to be used, it would be necessary to stop the head (1) and make the cut by displacing the second blade ( 32), which increases manufacturing times.

[0052] In order to solve this problem, the advance movement of the head (1) is synchronised with the displacement of the first blade (31), so that a straight cut is achieved without having to stop the advance of the head (1) when the displacement of the first blade (31) is at an angle. It furthermore allows the cut to be made for the next application, and for the advance of the head (1) not to stop.

[0053] Once the layer of composite material (2.1) has been deposited on the surface for the deposition thereof, the tape (2) goes to a stockpiling reel-holder (6). Sometimes surpluses of layer of composite material (2.1) are generated between one cut and the next of the tape (2), and said surplus remains on the tape (2) that goes to the stockpiling reel-holder (6). These surpluses are commonly removed manually once the reel is removed from the stockpiling reel-holder (6), and other times they are deposited on a table outside the application area. This requires an additional process and the consequent increase in manufacturing times.

[0054] According to a preferred feature of the invention, the head (1) comprises collection means (50) for collecting the fed layer of composite material (2.1) not used on the surface for the deposition thereof. The sequence of separating surpluses of layer of composite material (2.1) from the supporting layer (2.2) can be seen in FIGS. 8, 9 and 10.

[0055] At first, a collection separator (52) configured to separate the unused cut layer of composite material (2.1) from the supporting layer (2.2), is placed in an upper standby position above the tape (2), as can be seen in FIG. 8.

[0056] It can be seen in FIG. 9 how the collection separator (52) acts on a cut edge of the layer of composite material (2.1) by applying a separation pressure on the tape (2) on the side of the supporting layer (2.2) by the action of a pneumatic actuator. Said collection separator (52) is located between two positioning rollers (51) so that the tape (2) forms a certain angle that allows the separation of the layer of composite material (2.1) as it is more rigid than the supporting layer (2.2) that follows its path to the stockpiling reel-holder (6). The collection separator (52) is thereby displaced to the working position in which it applies pressure on the tape (2), preferably with a protrusion (54), achieving the separation of the layer of composite material (2.1).

[0057] It can be seen in FIG. 10 how the collection separator (52) has returned to its standby position in which it does not apply pressure on the tape (2) and the layer of composite material (2.1) is separated, going to a collection container (53) to collect the surplus layer of composite material (2.1).

[0058] A reel comprising only a supporting layer is thereby collected on the stockpiling reel-holder (6) for later use or recycling.

[0059] The deposition of a first layer of composite material (2.1) is thus completed, leaving the head (1) ready for the application of the next layer of composite material (2.1) on the surface for the deposition thereof.