Description:FIELD OF INVENTION

[0001]Embodiments of the present invention relate to a composite manufacturing device and more particularly relate to a device for tension control and resin coating on a fibre sheet in composite manufacturing.

BACKGROUND

[0002]In a realm of industrial manufacturing, particularly in processes like pre-impregnated (prepreg) manufacturing, achieving a precise control over a tension and a resin application is crucial for producing high-quality composite materials. Traditionally, systems are employed including brake rollers and tensioning devices to manage tension levels in a fibre sheet during processing. However, these solutions fall short of providing the necessary degree of control without causing stress or slippage in the fibre sheet. Additionally, the lack of consideration for a path of the fibre sheet leads to inefficiencies and inconsistencies in a production process, impacting an overall quality of the final composite material.

[0003]Existing solutions have attempted to address these challenges but have encountered several disadvantages. The brake rollers and tensioning devices may not provide sufficient precision in the tension control, leading to the uneven fibre sheet handling and potential quality issues. Moreover, traditional setups fail to account for the path of the fibre sheet adequately, resulting in slipping or bunching, which disrupts production and compromises the integrity of the finished composite material. Furthermore, fixed configurations for processes like kiss coating limit flexibility and control over the resin application, hindering the ability to tailor the process to different resin systems or the fibre sheet combinations effectively.

[0004]Conventional systems implement drag rollers and kiss coating rollers as separate modules within the manufacturing process. Nevertheless, having separate modules for the drag rollers and kiss coating rollers requires additional space within a manufacturing facility.

[0005]In the existing technology, an apparatus and method of manufacturing tow prepreg is disclosed. The apparatus integrates a spreading roller for adjusting an incident angle of the supplied fibre sheet and a plurality of coating rollers, including a first roller and a second roller, for the resin application. A shiftable design of the spreading roller allows for versatile positioning, while the adjustable incident angle enhances control over the coating process. Additionally, the inclusion of different roller materials and a control unit with a data table ensures precision and flexibility in the resin application. Supplementary components such as transfer devices and temperature control elements further optimise the manufacturing process for consistent product quality. Nevertheless, the apparatus lacks integrated tension control mechanisms for resin distribution optimisation resulting in reduced overall performance and efficiency in prepreg manufacturing processes.

[0006]There are various technical problems with the existing solutions in the prior art. In the existing technology, several technical challenges arise in achieving the precise control over the tension and the resin application in the prepreg manufacturing processes. One common issue involves inadequate tension control mechanisms, which results in inconsistent tension levels throughout the path of the fibre sheet. This inconsistency leads to material wrinkling, misalignment, or even delamination, compromising the structural integrity and quality of the final composite material. Additionally, existing tension control systems lack the responsiveness and accuracy needed to adapt to dynamic production conditions, further exacerbating the problem. Another technical problem lies in the limited adjustability and control over the resin application in traditional prepreg manufacturing setups. Many existing systems rely on fixed configurations for the resin application, which may not adequately accommodate variations in resin viscosity, fibre types, or processing conditions. As a result, manufacturers struggle to achieve the desired resin content and distribution within the composite material, leading to suboptimal mechanical properties and performance.

[0007]Furthermore, existing technology fails to consider the holistic interaction between the tension control and the resin application in the prepreg manufacturing. The lack of integrated solutions that address both aspects simultaneously leads to inefficiencies and inconsistencies in the production process. Without a comprehensive approach that optimises the tension control and the resin application in a tandem, the manufacturers encounter challenges in consistently producing the prepreg materials that meet stringent quality standards and performance requirements.

[0008]Therefore, there is a need for a device to address the aforementioned issues by providing innovative solutions for the precise tension control and the resin application in the prepreg manufacturing. There is also the need for the device to provide adjustable mechanisms to ensure the consistent tension levels and responsive controls for the resin application, thereby optimising the quality and performance of the final composite materials.

SUMMARY

[0009]This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the disclosure. This summary is neither intended to identify key or essential inventive concepts of the subject matter nor to determine the scope of the disclosure.

[0010]In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem by providing a device for tension control and a resin coating on a fibre sheet in composite manufacturing.

[0011]In accordance with an embodiment of the present invention, the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing is disclosed. The device comprises a fixture, a first drag roller, a second drag roller, a first driving unit, a brake roller, a kiss coating roller, and a pair of pressure rollers.

[0012]In an embodiment, the fixture is equipped with a slit at a first side. The fixture is configured to operatively connect the device to a pre-heater unit associated with the composite manufacturing, for receiving the fibre sheet through the slit. The fixture is configured with a pair of frame plates to form an enclosed structure. The pair of frame plates comprises a plurality of apertures to position and replace at least one of the: first drag roller, second drag roller, brake roller, kiss coating roller, and pair of pressure rollers. The first drag roller, second drag roller, brake roller, kiss coating roller, and pair of pressure rollers are mounted on bearing units. The bearing units are configured to provide a tolerance for averting an alignment between at least one of the: first drag roller, second drag roller, brake roller, kiss coating roller, and pair of pressure rollers and the pair of frame plates. The tolerance ranges between 4 degrees and 6 degrees.

[0013]In an embodiment, the first drag roller is operatively positioned in the fixture tangentially to the received fibre sheet. The first drag roller is configured to rotate in a clockwise direction for drawing the fibre sheet through the slit.

[0014]Yet in another embodiment, the second drag roller is operatively positioned in the fixture with a roll axis parallel to the first drag roller. The second drag roller is configured to rotate in a counterclockwise direction to impart an inverted S-shaped to the fibre sheet for maintaining a defined tension in the fibre sheet.

[0015]Yet in another embodiment, the first driving unit is operatively positioned at a second side of the fixture. The first driving unit is configured to rotate the first drag roller and the second drag roller indirectly through one or more transmission assemblies. The one or more transmission assemblies comprises a first compound assembly and a second compound assembly. The first compound assembly is operatively connected to the first driving unit through a transmission member and a gearbox. The first compound assembly is configured to rotate the second drag roller in the counterclockwise direction. The second compound assembly is operatively positioned between the first drag roller and the brake roller. The second compound assembly is operatively connected to the second drag roller through the transmission member via an intermediate roller. The second compound assembly is configured to rotate the first drag roller in the clockwise direction. The transmission member is selected from a group comprises one of a: belt, chain, gear system, and timing belt.

[0016]Yet in another embodiment, the brake roller is operatively positioned proximal to a third side of the fixture with the roll axis offset to the first drag roller. The brake roller is configured to provide an optimum overlap with the fibre sheet to avert a slippage of the received fibre sheet from the second drag roller for controlling the tension. The brake roller is positioned alongside the second compound assembly to control the tension in the received fibre sheet from the second drag roller by triggering a brake system based on feedback data obtained from a load cell associated with the composite manufacturing. The brake system is configured with one of a: pneumatic brake system and hydraulic brake system for the tension control.

[0017]Yet in another embodiment, the kiss coating roller is operatively positioned between the first driving unit and the brake roller proximal to the third side. The kiss coating roller is configured to coat the resin on the fibre sheet received from the brake roller. The kiss coating roller is operatively positioned on a resin tray. The resin tray is operatively connected to the third side of the fixture. The resin tray is configured to carry the resin for resin coating on the fibre sheet. The kiss coating roller is driven by a second driving unit through the transmission member and the gearbox. The first driving unit and the second driving unit are selected from a group that comprises one of a: induction motor, servo motor, brushless direct current (DC) motor, alternating current (AC) gear motor, hydraulic motor, and pneumatic motor.

[0018]Yet in another embodiment, the pair of pressure rollers is operatively positioned alongside the kiss coating roller. The pair of pressure rollers is configured to establish a pre-defined angle of contact between the kiss coating roller and the fibre sheet with a pre-defined pressure to eliminate entrapped air bubbles in the fibre sheet at the time of the resin coating. The pair of pressure rollers comprises a first pressure roller and a second pressure roller. The first pressure roller is operatively connected to the second drag roller through the intermediate roller driven by the first driving unit. The first pressure roller is configured to regulate one or more parameters of the received fibre sheet from the brake roller based on one of a: forward motion and backward motion of the first pressure roller. The one of the: forward motion and backward motion of the first pressure roller is controlled by a first movable lever.

[0019]The one or more parameters comprises at least one of a: diverse resin systems, resin coating thickness, and diverse fibre sheet types. The second pressure roller is operatively connected to a second movable lever. The second pressure roller is configured to move in one of an: upward motion and downward motion for receiving the fibre sheet with resin coating. The first movable lever and the second movable lever are operated by at least one of a: manual control and automated actuation unit. The first movable lever and the second movable lever are configured with worm gearboxes to lock the pair of pressure rollers at a determined position for overlapping the fibre sheet on the kiss coating roller to regulate the one or more parameters.

[0020]In accordance with an embodiment of the present invention, a method for the tension control and the resin coating on the fibre sheet in the composite manufacturing is disclosed. At the first step, the method includes receiving, by the fixture equipped with the slit, the fibre sheet from the pre-heater unit associated with the composite manufacturing. In the next step, the method includes drawing, by the first drag roller configured to rotate in the clockwise direction, the fibre sheet through the slit. In the next step, the method includes maintaining, by the second drag roller configured to rotate in the counterclockwise direction to impart the inverted S-shaped to the fibre sheet, a defined tension in the fibre sheet.

[0021]In the next step, the method includes providing, by the brake roller, the optimum overlap with the fibre sheet to avert the slippage of the received fibre sheet from the second drag roller to control the tension. In the next step, the method includes coating, by the kiss coating roller, the resin on the fibre sheet received from the brake roller.

[0022]Further, the method comprises establishing, by the pair of pressure rollers, the pre-defined angle of contact between the kiss coating roller and the fibre sheet with the pre-defined pressure to eliminate the entrapped air bubbles in the fibre sheet at the time of the resin coating. The first drag roller and the second drag roller are rotated by the first driving unit. The optimum overlap provided by the brake roller is 180 degrees.

[0023]To further clarify the advantages and features of the present invention, a more particular description of the invention will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the invention and are therefore not to be considered limiting in scope. The invention will be described and explained with additional specificity and detail with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

[0024]Figure 1A illustrates an exemplary detailed view of a device for tension control and a resin coating on a fibre sheet in composite manufacturing, in accordance with an embodiment of the present invention;

[0025]Figure 1B illustrates an exemplary rear view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0026]Figure 1C illustrates an exemplary front view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0027]Figure 1D illustrates an exemplary bottom view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0028]Figure 1E illustrates an exemplary left view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0029]Figure 1F illustrates an exemplary right view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0030]Figure 1G illustrates an exemplary top view of the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0031]Figure 1H illustrates an exemplary schematic view of one of a: first track assembly and second track assembly associated with the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention; and

[0032]Figure 2 illustrates an exemplary flow chart depicting a method for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention.

[0033]Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the method steps, chemical compounds, equipment and parameters used herein may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0034]For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0035]The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more components, compounds, and ingredients preceded by "comprises... a" does not, without more constraints, preclude the existence of other components or compounds or ingredients or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0036]Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0037]In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0038]Embodiments of the present invention relate to a device for tension control and a resin coating on a fibre sheet in composite manufacturing.

[0039]Figure 1A illustrates an exemplary detailed view of the device 100 for tension control and a resin coating on a fibre sheet in composite manufacturing, in accordance with an embodiment of the present invention;

[0040]Figure 1B illustrates an exemplary rear view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0041]Figure 1C illustrates an exemplary front view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0042]Figure 1D illustrates an exemplary bottom view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0043]Figure 1E illustrates an exemplary left view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0044]Figure 1F illustrates an exemplary right view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention;

[0045]Figure 1G illustrates an exemplary top view of the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention; and

[0046]Figure 1H illustrates an exemplary schematic view of one of a: first track assembly 154 and second track assembly 156 associated with the device 100 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention.

[0047]According to an exemplary embodiment of the disclosure, the device 100 for the tension control and the resin coating on the fibre sheet 122 in the composite manufacturing is disclosed. The device 100 comprises a fixture 102, a first drag roller 104, a second drag roller 106, a first driving unit 108, a brake roller 110, a kiss coating roller 112, and a pair of pressure rollers (114, 116). Herein in an exemplary embodiment, the composite may include, but not restricted to, pre-impregnated (prepreg) materials that comprise reinforcing fibres including carbon, glass, aramid fibres, and the like.

[0048]In an exemplary embodiment, the fixture 102 is configured with a slit 118 at a first side 120 for operatively connecting the device 100 to a pre-heater unit, thereby allowing the reception of the fibre sheet 122 through the slit 118. The pre-heater unit is associated with the composite manufacturing. The pre-heater unit is a piece of equipment that is configured to heat the fibre sheet 122 before the fibre sheet 122 undergoes subsequent processing steps including the tension control and the resin coating for the composite manufacturing. Structurally, the fixture 102 comprises a pair of frame plates forming an enclosed structure with a plurality of apertures.

[0049]In an exemplary embodiment, the plurality of apertures is configured to facilitate a positioning and a replacement of at least one of the: first drag roller 104, second drag roller 106, brake roller 110, kiss coating roller 112, pair of pressure rollers (114, 116), and the like. The first drag roller 104, the second drag roller 106, the brake roller 110, the kiss coating roller 112, and the pair of pressure rollers (114, 116) are mounted on bearing units, thereby ensuring a smooth operation. The bearing units are configured to maintain an alignment, with a tolerance range of 4 degrees to 6 degrees, thereby preventing a misalignment between the at least one of the: first drag roller 104, second drag roller 106, brake roller 110, kiss coating roller 112, and pair of pressure rollers (114, 116) and the pair of frame plates, thus ensuring the precise and reliable composite manufacturing. The tolerance range ensures that the minor misalignments between the at least one of the: first drag roller 104, second drag roller 106, brake roller 110, kiss coating roller 112, and pair of pressure rollers (114, 116) and the pair of frame plates do not adversely affect the operation and the efficiency of the device 100.

[0050]In an exemplary embodiment, the bearing units are configured to maintain the alignment, thereby preventing any deviations that compromise the quality and consistency of the composite manufacturing. Overall, the fixture 102 is configured to optimise efficiency and reliability by enabling easy component replacement and ensuring the precise alignment within the device 100.

[0051]In an exemplary embodiment, the first drag roller 104 is operatively positioned within the fixture 102 and is strategically positioned tangentially to the received fibre sheet 122. The first drag roller 104 is configured to rotate in a clockwise direction. The first drag roller 104 exerts a pulling force on the fibre sheet 122, drawing the fibre sheet 122 through the slit 118 into the device 100. This arrangement ensures a smooth and a controlled movement of the fibre sheet 122, facilitating the progression towards subsequent processing stages within the device 100.

[0052]In an exemplary embodiment, the second drag roller 106 is operatively positioned within the fixture 102. The second drag roller 106 is oriented with a roll axis parallel to the roll axis of the first drag roller 104. In the illustrative embodiment, the second drag roller 106 is positioned below the first drag roller 104. The second drag roller 106 is configured to rotate in a counterclockwise direction, imparting an inverted S-shaped trajectory to the fibre sheet 122. The inverted S shaping of the fibre sheet 122 assists in maintaining the consistent and a defined tension throughout the fibre sheet 122 without damaging the fibre sheet 122. By working in conjunction with the first drag roller 104, this configuration ensures the precise control over the movement and the tension of the fibre sheet 122, optimising the quality and integrity of a final composite product.

[0053]The design and placement of the first drag roller 104 and the second drag roller 106 are configured to ensure that the fibre sheet 122 wraps around the first drag roller 104 and the second drag roller 106 at angles of approximately 160 degrees and 175 degrees respectively. In an alternative embodiment, the wrapping angles of the fibre sheet 122 around the first drag roller 104 and the second drag roller 106 may change according to the requirements and the conditions of the fibre sheet 122 and the final composite product. The diameter of the first drag roller 104 and the second drag roller 106 is 165 millimetre. In an alternative embodiment, the diameter of the first drag roller 104 and the second drag roller 106 may change according to the requirements and the conditions of the fibre sheet 122 and a speed of the production of the final composite product.

[0054]In an exemplary embodiment, the first driving unit 108 is located at a second side 124 of the fixture 102. The first driving unit 108 is configured to facilitate a rotation motion to the first drag roller 104 and the second drag roller 106 indirectly via one or more transmission assemblies (130, 132). The one or more transmission assemblies (130, 132) comprises a first compound assembly 130 and a second compound assembly 132.

[0055]The first compound assembly 130 is connected to the first driving unit 108 through a transmission member 134 and a gearbox 136. The first compound assembly 130 is configured to rotate the second drag roller 106 in the counterclockwise direction. Meanwhile, the second compound assembly 132 is positioned between the first drag roller 104 and the brake roller 110. The second compound assembly 132 is connected to the second drag roller 106 through the transmission member 134 through an intermediate roller 138. The second compound assembly 132 is configured to drive the first drag roller 104 in the clockwise direction. The combination of the transmission member 134 and the gearbox 136 is configured to reduce a noise level significantly.

[0056] The intermediate roller 138 is positioned between the second compound assembly 132 and the first drag roller 104 and facilitates the transfer of the rotational motion from the second compound assembly 132 to the first drag roller 104 through the transmission member 134. This allows for synchronised movement of the various components involved in the resin coating. By efficiently transmitting the rotational motion, the intermediate roller 138 is configured to ensure the smooth operation and precise control over the clockwise direction of the first drag roller 104. The transmission member 134 is selected from a group that may comprise, but not limited to, at least one of a: belt, chain, gear system, timing belt, and the like. The first compound assembly 130 and the second compound assembly 132 may comprise, but not limited to, sprockets, spur gears, belt rollers, belt pulley, friction wheels, and the like.

[0057]In an exemplary embodiment, the brake roller 110 is located proximal to a third side 126 of the fixture 102 and is strategically positioned with the roll axis offset from the first drag roller 104. The offset indicates that the roll axis of the brake roller 110 is intentionally positioned in a way that the brake roller 110 is not directly aligned or parallel with the roll axis of the first drag roller 104. Instead, the brake roller 110 is deliberately shifted to a defined degree. By offsetting the roll axis of the brake roller 110 from that of the first drag roller 104, it ensures that the brake roller 110 and the first drag roller 104 operate independently but in a coordinated manner to effectively control the tension and prevent a slippage of the fibre sheet 122 during the composite manufacturing. The diameter of the brake roller 110 is 110 millimetre. In another exemplary embodiment, the diameter of the brake roller 110 may change according to the requirements of the composite manufacturing.

[0058]The dimension of the brake roller 110 is chosen in a way that it ensures an optimal overlap with the fibre sheet 122 to prevent the slippage of the received fibre sheet 122 from the second drag roller 106, effectively controlling the tension. The brake roller 110 is positioned adjacent to the second compound assembly 132 to control the tension in the received fibre sheet 122 from the second drag roller 106. The tension control is achieved by activating a brake system 140 based on feedback data from a load cell associated with the composite manufacturing. The load cell provides real-time information about tension levels experienced by the fibre sheet 122. When the feedback data from the load cell indicates that the tension needs to be increased or decreased, the brake system 140 is activated accordingly. The optimum overlap provided by the brake roller 110 is 180 degrees. In another exemplary embodiment, the optimum overlap provided by the brake roller 110 may change according to the requirements in the composite manufacturing.

[0059]For instance, if the tension is too high, the brake system 140 reduces a braking force, allowing the fibre sheet 122 to move more freely. Conversely, if the tension is too low, the brake system 140 increases the braking force, effectively slowing down the movement of the fibre sheet 122 to increase the tension. By dynamically adjusting the braking force based on the real-time feedback data, the brake system 140 ensures that the tension in the fibre sheet 122 remains within the desired range throughout the composite manufacturing.

[0060]In another exemplary embodiment, the triggering of the brake system 140 is achieved by at least one of: manual and automatic. In automatic, a control unit (not shown) is involved in managing an automatic adjustment of the brake system 140. The control unit processes the feedback data from the load cell and determines the appropriate actions to adjust the tension in the fibre sheet 122. The control unit is configured to regulate the brake system 140 autonomously, ensuring that the tension remains within the desired range throughout the composite manufacturing.

[0061]Manually adjusting the tension in the fibre sheet 122 involves direct intervention by an operator. In some cases, the manual adjustment knobs may be provided on the brake system 140 itself, allowing the operator is able to increase or decrease the braking force manually based on their observation of the feedback data from the load cell. Alternatively, the operator may adjust the tension by manipulating control interfaces on a separate control panel connected to the brake system 140. The interfaces may include buttons, switches, and digital displays that allow the operator to input specific tension values. The manual adjustment requires the operator to closely monitor the tension levels and make necessary adjustments as needed to ensure optimal performance during the composite manufacturing.

[0062]The load cell may comprise, but not limited to, at least one of: piezoelectric load cell, strain gauge load cell, and the like. The brake system 140 is configured with at least one of a: pneumatic brake system, hydraulic brake system, and the like for the tension control. In the pneumatic brake system, an air pressure is employed to engage or disengage a brake mechanism, exerting the braking force on the brake roller 110 to regulate the tension in the fibre sheet 122. On the other hand, the hydraulic brake system employs a hydraulic fluid pressure to achieve the same purpose, applying or releasing a pressure on the brake roller 110 as required to adjust the tension on the fibre sheet 122.

[0063]In an exemplary embodiment, the kiss coating roller 112 is strategically situated between the first driving unit 108 and the brake roller 110. The kiss coating roller 112 is positioned proximal to the third side 126 of the fixture 102. The kiss coating roller 112 is configured to apply a layer of the resin onto the fibre sheet 122 received from the brake roller 110. The kiss coating roller 112 is affixed onto a resin tray 142 and the resin tray 142 is connected to the third side 126 of the fixture 102. The resin tray 142 is configured to hold the resin for the resin coating on the fibre sheet 122. To facilitate its operation, the kiss coating roller 112 is powered by a second driving unit 144, which drives the kiss coating roller 112 through the transmission member 134 and the gearbox 136.

[0064]Both the first driving unit 108 and the second driving unit 144 are selected from a group that may comprise, but not limited to, at least one of a: induction motor, servo motor, brushless direct current (DC) motor, alternating current (AC) gear motor, hydraulic motor, pneumatic motor, and the like. This setup ensures the precise and efficient application of the resin onto the fibre sheet 122.

[0065]In an exemplary embodiment, the pair of pressure rollers (114, 116) is strategically positioned alongside the kiss coating roller 112 within the device 100. The pair of pressure rollers (114, 116) is configured to establish a pre-defined angle of contact between the kiss coating roller 112 and the fibre sheet 122, applying a pre-defined pressure to ensure the elimination of any entrapped air bubbles during the resin coating of the fibre sheet 122. As the fibre sheet 122 passes between the kiss coating roller 112 and the pair of pressure rollers (114, 116), the pressure exerted by the pair of pressure rollers (114, 116) assists in pressing out any trapped air bubbles within the fibre sheet 122. Additionally, the pre-defined angle of contact between the kiss coating roller 112 and the fibre sheet 122 ensures thorough coverage of the resin without trapping the air bubbles.

[0066]The pre-defined angle of contact is 38 degrees. In an alternative embodiment, the pre-defined angle of contact between the kiss coating roller 112 and the fibre sheet 122 may change according to the requirements and the conditions of the resin coating on the fibre sheet 122. In another exemplary embodiment, by adjusting the position of the pair of pressure rollers (114, 116) relative to the kiss coating roller 112, the angle of contact between the kiss coating roller 112 and the fibre sheet 122 is altered, potentially reaching a point of 0 degrees. Beyond this adjustment, the pair of pressure rollers (114, 116) is shifted even farther away, allowing the fibre sheet 122 to pass without contacting the kiss coating roller 112 at all. This flexibility streamlines a threading process initially and accommodates fabric-resin combinations that do not necessitate the application of the resin via the kiss coating roller 112.

[0067]The pair of pressure rollers (114, 116) comprises a first pressure roller 114 and a second pressure roller 116. In another exemplary embodiment, one or more pressure rollers is employed based on the specific requirements of the resin coating on the fibre sheet 122. The device 100 may be adapted to include the one or more pressure rollers if necessary. The first pressure roller 114 is linked to the second drag roller 106 via the intermediate roller 138, which is driven by the first driving unit 108. The first pressure roller 114 is configured to adjust one or more parameters of the fibre sheet 122 received from the brake roller 110 through one of a: forward motion and backward motion. The one or more parameters may comprise, but not limited to, at least one of a: diverse resin systems, resin coating thickness, diverse fabric sheet types, and the like.

[0068]The one of the: forward motion and backward motion of the first pressure roller 114 is controlled by a first movable lever 146. The second pressure roller 116 is linked to a second movable lever 128, enabling the second pressure roller 116 to move in one of an: upward motion and downward motion for receiving the fibre sheet 122 with the resin coating. The first movable lever 146 and the second movable lever 128 are equipped with worm gearboxes to facilitate precise locking of the pair of pressure rollers (114, 116) at a determined position, ensuring the optimal overlap of the fibre sheet 122 on the kiss coating roller 112 to regulate the one or more parameters effectively.

[0069]For instance, the first pressure roller 114 and the second pressure roller 116 are oriented such that the fibre sheet 122 dispenses in the upward motion from the first pressure roller 114 and the second pressure roller 116. The upward motion allows the fibre sheet 122 to be guided up for skying without bending the fibre sheet 122 sharply right after the resin coating. The fibre sheet 122 that is guided to the skying is configured with a sufficient time to absorb the resin which is coated by the kiss coating roller 112 before the further composite manufacturing. The first pressure roller 114 is driven to guide the fibre sheet 122 movement against gravity on this upward path.

[0070]The first movable lever 146 and the second movable lever 128 are operated by at least one of a: manual control and automated actuation unit. The manual control of the first movable lever 146 and the second movable lever 128 involves direct human intervention to adjust the position of the pair of pressure rollers (114, 116). This is achieved through the employment of the knobs, which allow the operators to physically manipulate the first movable lever 146 and the second movable lever 128.

[0071]In an exemplary embodiment, the device is configured with the first track assembly 154 and the second track assembly 156. The first track assembly 154 and the second track assembly 156 are configured with small track adjustment levers 148. Furthermore, the first track assembly 154 and the second track assembly 156 are configured with a first handwheel 158 and a second handwheel 150.

[0072]An output shaft 152 is configured to pass through an output of the gearbox 136 and hold small track adjustment levers 148 in front of the device 100 and behind the device 100. On rotating an input of the gearbox 136, the output shaft 152 rotates, in turn rotating the small track adjustment levers 148. The small track adjustment levers 148 are connected to the first movable lever 146 and the second movable lever 128 via turnbuckles. By rotating a grip in the centre, the length between the two ends is changed. Both the ends are provided with bushings to allow smooth rotation. The length changing allows the small track adjustment levers 148 to be connected. The small track adjustment levers are oriented in such a way that the turnbuckle pulls the small track adjustment levers 148 at almost a 90° angle. This way all the torque from the output shaft 152 goes into rotating the first movable lever 146 and the second movable lever 128 and not in longitudinal load along the first movable lever 146 and the second movable lever 128, which causes jamming.

[0073]Input shafts are rotated by hand by means of the first handwheel 158 and the second handwheel 150 is configured with the diameter of 160 mm. The first handwheel 158 and the second handwheel 150 are configured with a polished rim for easier cleaning. The first handwheel 158 and the second handwheel 150 are provided on the front of the device 100 for easier access. Due to the self-locking property, the output shaft 152 may not rotate itself under a weight of the pair of pressure rollers (114, 116), the first movable lever 146, and the second movable lever 128. Once the pair of pressure rollers (114, 116) is adjusted, the setting maintains itself until it is changed by rotating the first handwheel 158 and the second handwheel 150 by the operator.

[0074]Automatic control of the first movable lever 146 and the second movable lever 128 is achieved through the control unit integrated with the automated actuation unit. The control unit is equipped with one or more sensors (not shown) to monitor variables such as resin viscosity, fabric sheet type, coating thickness, and the like. The control unit receives sensor data from the one or more sensors and translates the sensor data into instructions for the automated actuation unit. Additionally, the control unit may receive input from the operators, providing commands on desired settings for the resin coating. The control unit translates the commands into the instructions for the automated actuation unit. Based on the instructions, the automated actuation unit is configured to adjust the position of the pair of pressure rollers (114, 116) accordingly.

[0075]Figure 2 illustrates an exemplary flow chart depicting a method 200 for the tension control and the resin coating on the fibre sheet in the composite manufacturing, in accordance with an embodiment of the present invention.

[0076]In accordance with an embodiment of the present invention, the method 200 for the tension control and the resin coating on the fibre sheet in the composite manufacturing is disclosed. At step 202, the method 200 includes the fixture, equipped with the slit, receiving the fibre sheet from the pre-heater unit that is integrated with the composite manufacturing. This pivotal action establishes the beginning of the resin coating and the tension control.

[0077]At step 204, the method 200 progresses as the first drag roller is configured to rotate in the clockwise direction and draws the fibre sheet through the slit in the fixture. By rotating in the clockwise direction, the first drag roller effectively pulls the fibre sheet in the fixture. At step 206 the method 200 includes the second drag roller, which is configured to rotate in the counterclockwise direction, thereby imparting the inverted S-shaped trajectory to the fibre sheet. This motion is crucial for maintaining the defined tension in the fibre sheet. By rotating in the counterclockwise direction and guiding the fibre sheet in the inverted S-shaped path, the second drag roller is configured to ensure the consistent tension, preventing slack or excessive tightness in the fibre sheet.

[0078]At step 208, the method 200 includes the brake roller providing the optimal overlap with the fibre sheet to prevent the slippage of the received fibre sheet from the second drag roller and effectively control the tension. At step 210, the method 200 includes the kiss coating roller coating the resin onto the fibre sheet that is received from the brake roller. This action is essential for the resin coating, as the kiss coating roller evenly distributes the resin onto the fibre sheet.

[0079]Further, the method 200 includes the pair of pressure rollers establishing the pre-defined angle of contact between the kiss coating roller and the fibre sheet and applying the pre-defined pressure to eliminate the entrapped air bubbles in the fibre sheet during the resin coating. By regulating the angle of contact and applying the controlled pressure, the pair of pressure rollers contributes to the uniform distribution of the resin and the removal of the air bubbles.

[0080]Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the device for the tension control and the resin coating on the fibre sheet in the composite manufacturing is disclosed. The fixture of the device is bent into a box-like shape. The fixture is made of the pair of frame plates that allows all rollers and components to be mounted in any required location without worrying about having the transmission member under every component. This assists in creating a compact design and fitting of drag, tension adjustment, and kiss coating functions in the single device of 950 mm in length x 1997 mm in height. The box-like shape makes the pair of frame plates resistant to toppling and behaves like a cabinet for bearing housings, levers, chains, and the like.

[0081]The pair of frame plates is configured with cut-outs such that all rollers are inserted into the device after the fixture is welded and assembled. Then all rollers are kept in position and locked from coming out by employing aligning plates bolted on the pair of frame plates. All rollers are disassembled and taken out for maintenance or replacement in the same way without dismantling the fixture. The bearing units are configured with bearings with a spherical outer ring that is fitted into the fixture with a similar spherical surface. This allows the bearing to slide into the fixture and get oriented at a defined angle to the fixture. The bearing units handle around 5 degrees of an initial static misalignment. This ensures that all the rollers are mounted in the bearings even if there are small manufacturing variations between the front frame plate and the back frame plates of the pair of frame plates. The diameters of all the rollers are so chosen that standard pipes are machined to the final diameters with less than 5 mm of machining. This assists in reducing a wastage and is also cost-effective.

[0082]While specific language has been used to describe the invention, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0083]The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:I/ We Claim:
1. A device (100) for tension control and a resin coating on a fibre sheet (122) in composite manufacturing, comprising:
a fixture (102) equipped with a slit (118) at a first side (120), configured to operatively connect the device (100) to a pre-heater unit associated with the composite manufacturing, for receiving the fibre sheet (122) through the slit (118);
a first drag roller (104) operatively positioned in the fixture (102) tangentially to the received fibre sheet (122), configured to rotate in a clockwise direction for drawing the fibre sheet (122) through the slit (118);
a second drag roller (106) operatively positioned in the fixture (102) with a roll axis parallel to the first drag roller (104), configured to rotate in a counterclockwise direction to impart an inverted S-shaped to the fibre sheet (122) for maintaining a defined tension in the fibre sheet (122);
a first driving unit (108) operatively positioned at a second side (124) of the fixture (102), configured to rotate the first drag roller (104) and the second drag roller (106) indirectly through one or more transmission assemblies (130, 132);
a brake roller (110) operatively positioned proximal to a third side (126) of the fixture (102) with the roll axis offset to the first drag roller (104), configured to provide an optimum overlap with the fibre sheet (122) to avert a slippage of the received fibre sheet (122) from the second drag roller (106) for controlling the tension;
a kiss coating roller (112) operatively positioned between the first driving unit (108) and the brake roller (110) proximal to the third side (126), configured to coat the resin on the fibre sheet (122) received from the brake roller (110); and
a pair of pressure rollers (114, 116) operatively positioned alongside the kiss coating roller (112), configured to establish a pre-defined angle of contact between the kiss coating roller (112) and the fibre sheet (122) with a pre-defined pressure to eliminate entrapped air bubbles in the fibre sheet (122) at the time of the resin coating.
2. The device (100) as claimed in claim 1, wherein the fixture (102) is configured with a pair of frame plates to form an enclosed structure,
the pair of frame plates comprises a plurality of apertures to position and replace at least one of the: first drag roller (104), second drag roller (106), brake roller (110), kiss coating roller (112), and pair of pressure rollers (114, 116).
3. The device (100) as claimed in claim 1, wherein the first drag roller (104), second drag roller (106), brake roller (110), kiss coating roller (112), and pair of pressure rollers (114, 116) are mounted on bearing units,
the bearing units configured to provide a tolerance for averting an alignment between at least one of the: first drag roller (104), second drag roller (106), brake roller (110), kiss coating roller (112), and pair of pressure rollers (114, 116) and the pair of frame plates,
the tolerance ranges between 4 degrees and 6 degrees.
4. The device (100) as claimed in claim 1, wherein the one or more transmission assemblies (130, 132) comprises:
a first compound assembly (130) operatively connected to the first driving unit (108) through a transmission member (134) and a gearbox (136), configured to rotate the second drag roller (106) in the counterclockwise direction; and
a second compound assembly (132) operatively positioned between the first drag roller (104) and the brake roller (110) and operatively connected to the second drag roller (106) through the transmission member (134) via an intermediate roller (138), configured to rotate the first drag roller (104) in the clockwise direction,
the transmission member (134) is selected from a group comprises one of a: belt, chain, gear system, and timing belt.
5. The device (100) as claimed in claim 1, wherein the brake roller (110) is positioned alongside the second compound assembly (132) to control the tension in the received fibre sheet (122) from the second drag roller (106) by triggering a brake system (140) based on feedback data obtained from a load cell associated with the composite manufacturing,
the brake system (140) is configured with one of a: pneumatic brake system and hydraulic brake system for the tension control.
6. The device (100) as claimed in claim 1, wherein the kiss coating roller (112) operatively positioned on a resin tray (142),
the resin tray (142) operatively connected to the third side (126) of the fixture (102), configured to carry the resin for resin coating on the fibre sheet (122).
7. The device (100) as claimed in claim 1, wherein the kiss coating roller (112) is driven by a second driving unit (144) through the transmission member (134) and the gearbox (136).
8. The device (100) as claimed in claim 1, wherein the first driving unit (108) and the second driving unit (144) are selected from a group comprises one of a: induction motor, servo motor, brushless direct current (DC) motor, alternating current (AC) gear motor, hydraulic motor, and pneumatic motor.
9. The device (100) as claimed in claim 1, wherein the pair of pressure rollers (114, 116) comprises a first pressure roller (114) and a second pressure roller (116),
the first pressure roller (114) is operatively connected to the second drag roller (106) through the intermediate roller (138) driven by the first driving unit (108), configured to regulate one or more parameters of the received fibre sheet (122) from the brake roller (110) based on one of a: forward motion and backward motion of the first pressure roller (114),
one of the: forward motion and backward motion of the first pressure roller (114) is controlled by a first movable lever (146),
the one or more parameters comprises at least one of a: diverse resin systems, resin coating thickness, and diverse fabric sheet types; and
the second pressure roller (116) is operatively connected to a second movable lever (128), configured to move in one of an: upward motion and downward motion for receiving the fibre sheet (122) with resin coating.
10. The device (100) claimed in claim 9, wherein the first movable lever (146) and the second movable lever (128) operated by at least one of a: manual control and automated actuation unit,
the first movable lever (146) and the second movable lever (128) are configured with worm gearboxes to lock the pair of pressure rollers (114, 116) at a determined position for overlapping the fibre sheet (122) on the kiss coating roller (112) to regulate the one or more parameters.
11. A method (200) for tension control and a resin coating on a fibre sheet (122) in composite manufacturing, comprising:
receiving, by a fixture (102) equipped with a slit (118), the fibre sheet (122) from a pre-heater unit associated with the composite manufacturing;
drawing, by a first drag roller (104) configured to rotate in a clockwise direction, the fibre sheet (122) through the slit (118);
maintaining, by a second drag roller (106) configured to rotate in a counterclockwise direction to impart an inverted S-shaped to the fibre sheet (122), a defined tension in the fibre sheet (122);
providing, by a brake roller (110), an optimum overlap with the fibre sheet (122) to avert a slippage of the received fibre sheet (122) from the second drag roller (106) to control the tension; and
coating, by a kiss coating roller (112), the resin on the fibre sheet (122) received from the brake roller (110).
12. The method (200) as claimed in claim 11, comprises:
establishing, by a pair of pressure rollers (114, 116), a pre-defined angle of contact between the kiss coating roller (112) and the fibre sheet (122) with a pre-defined pressure to eliminate entrapped air bubbles in the fibre sheet (122) at the time of the resin coating.
13. The method (200) as claimed in claim 11, wherein the first drag roller (104) and the second drag roller (106) are rotated by a first driving unit (108).
14. The method (200) as claimed in claim 11, wherein the optimum overlap provided by the brake roller (110) is 180 degrees.

Dated this 06th day of May, 2024

Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
IPexcel Services Private Limited
AGENT FOR APPLICANT