US 11,745,440 B2
Automated lamination system and method for embedding printed electronic elements in a composite structure
Da Zhao, Everett, WA (US); and Keith Daniel Humfeld, Federal Way, WA (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Apr. 3, 2020, as Appl. No. 16/840,315.
Prior Publication US 2021/0308961 A1, Oct. 7, 2021
Int. Cl. B29C 70/38 (2006.01); B29C 33/02 (2006.01); B29C 33/38 (2006.01)
CPC B29C 70/38 (2013.01) [B29C 33/02 (2013.01); B29C 33/38 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An automated lamination system for embedding one or more printed electronic elements in a composite structure, the automated lamination system comprising:
a supply of composite prepreg material;
a layup tool assembly;
a modified automated lamination apparatus laying up one or more layers of the composite prepreg material on the layup tool assembly, to form the composite structure, the modified automated lamination apparatus comprising:
a composite tape laying machine (CTLM) having a first head with one or more spools, one or more compaction rollers, and a heater for heating and curing, with a final cure process, the composite structure, after it is formed on the layup tool assembly; and
a second head added to the CTLM, the second head comprising:
a section preparation pre-printing apparatus positioned on the second head to prepare one or more sections, each having a width in a range of 10 microns to 20 microns, on a top surface of a top layer of the one or more layers, to obtain one or more prepared sections, the section preparation pre-printing apparatus comprising one of,
an energy source apparatus separate from the heater on the CTLM, and comprising one of, a targeted infrared heater, or a laser apparatus, the energy source apparatus performing a localized partial cure operation on each of the one or more sections, to obtain the one or more prepared sections comprising one or more localized partially cured sections having a degree of cure in a range of 5% to 30%; or
a stamping apparatus stamping a substrate material in the form of a substrate platform onto each of the one or more sections that are uncured, to obtain the one or more prepared sections comprising one or more stamped substrate sections, the substrate platform having a width in a range of 15 microns to 25 microns; and
an aerosol jet printing apparatus mechanically coupled to the section preparation pre-printing apparatus and positioned on the second head downstream of the section preparation pre-printing apparatus, and positioned upstream of one of the compaction rollers, the aerosol jet printing apparatus having one or more printing heads; and
one or more supplies of electronic element materials, printed with the aerosol jet printing apparatus, on each of the one or more prepared sections, to obtain the one or more printed electronic elements,
wherein the modified automated lamination apparatus lays up one or more subsequent layers of the composite prepreg material over the one or more printed electronic elements, to embed the one or more printed electronic elements in the composite structure, prior to the composite structure being cured with the final cure process, and further wherein, when the composite structure is cured, the one or more printed electronic elements each maintain a mechanical stability;
a control system coupled to the modified automated lamination apparatus, the control system controlling one or more operations of the modified automated lamination apparatus; and
a power system coupled to the modified automated lamination apparatus, the power system providing a power source to the modified automated lamination apparatus.