Composite Tape For Use In Tape Laying Machines

Abstract

A tape for use in automated tape laying machines that includes a multi-layer substrate composed of a plastic layer that includes at least one plastic film having an outer film surface and an inner film surface. The plastic film is adhered to a fibrous layer so that the inner surface of the fibrous layer is bonded to the inner film surface. An uncured composite material layer composed of a fibrous reinforcement and an uncured resin matrix is releasably adhered to either the plastic layer surface or the outer fiber layer surface to provide a tape suitable for use in an automatic tape layer.

1 . A tape for use in an automated tape laying machine wherein uncured composite material is applied to a mold, said tape comprising:
 A. a multi-layer substrate for supporting said uncured composite material during use of said tape in said automated tape laying machine, said multi-layer substrate comprising:
 a. a plastic layer comprising at least one plastic film having an outer film surface and an inner film surface; and 
 b. a fibrous layer having an outer fiber surface and an inner fiber surface wherein said inner fiber surface is adhered to said inner film surface; and 
   B. an uncured composite material layer comprising a fibrous reinforcement and an uncured resin matrix, said uncured composite material layer having a first composite surface that is located towards the mold when said uncured composite material is applied to said mold and a second composite surface that is releasably adhered to either said plastic layer or said outer fiber surface.   
     
     
         2 . A tape for use in an automated tape laying machine according to  claim 1  wherein said second composite surface is adhered to said outer fiber surface and wherein said outer fiber surface is coated with a release agent. 
     
     
         3 . A tape for use in an automated tape laying machine according to  claim 2  comprising a second plastic film having an inner surface and an outer surface wherein said inner surface of said second plastic film is adhered to the outer film surface of said plastic film that is adhered to said fibrous layer to form said plastic layer comprising two plastic films. 
     
     
         4 . A tape for use in an automated tape laying machine according to  claim 1  wherein said second composite surface is adhered to said outer film surface. 
     
     
         5 . A tape for use in an automated tape laying machine according to  claim 4  comprises a second plastic film having an inner surface and an outer surface wherein said inner surface is adhered to said outer fiber surface. 
     
     
         6 . A tape for use in an automated tape laying machine according to  claim 4  wherein said plastic layer comprises two plastic films. 
     
     
         7 . A tape for use in an automated tape laying machine according to  claim 5  wherein said outer surface of said second plastic film is coated with a release agent. 
     
     
         8 . A tape for use in an automated tape laying machine according to  claim 5  wherein said first plastic film has a cross directional tensile strength that is higher than the cross directional strength of said second plastic film. 
     
     
         9 . A roll of tape for use in an automated tape laying machine comprising a tape according to  claim 1  wherein said multi-layer substrate comprises a high adherence side and a low adherence side and wherein said low adherence side contacts said first composite surface of said uncured composite material layer only when said tape is in the form of a roll. 
     
     
         10 . A roll of tape for use in an automated tape laying machine comprising a tape according to  claim 3  wherein said multi-layer substrate comprises a high adherence side and a low adherence side, said low adherence side corresponding to the outer surface of said second plastic film and wherein said low adherence side contacts said first composite surface of said uncured composite material layer only when said tape is in the form of a roll. 
     
     
         11 . A roll of tape for use in an automated tape laying machine comprising a tape according to  claim 5  wherein said multi-layer substrate comprises a high adherence side and a low adherence side, said low adherence side corresponding to the outer surface of said second plastic film and wherein said low adherence side contacts said first composite surface of said uncured composite material layer only when said tape is in the form of a roll. 
     
     
         12 . A roll of tape for use in an automated tape laying machine comprising a tape according to  claim 6  wherein said multi-layer substrate comprises a high adherence side and a low adherence side, said low adherence side corresponding to the outer surface of said plastic layer and wherein said low adherence side contacts said first composite surface of said uncured composite material layer only when said tape is in the form of a roll. 
     
     
         13 . A method for making a tape for use in an automated tape laying machine wherein uncured composite material is applied to an automated tape laying machine table or a mold, said method comprising the steps of:
 providing a multi-layer substrate for supporting said uncured composite material during use of said tape in said automated tape laying machine, wherein said multi-layer substrate is made by adhering a plastic layer comprising at least one plastic film having an outer film surface and an inner film surface to a fibrous layer having a outer fiber surface and an inner fiber surface wherein said inner fiber surface is adhered to said inner film surface; and   providing an uncured composite material layer comprising a fibrous reinforcement and an uncured resin matrix, said uncured composite material layer having a first composite surface that is located towards the mold when said uncured composite material is applied to said mold and a second composite surface adhering said second composite surface to either said plastic layer or said outer fiber surface.   
     
     
         14 . A method for making a tape for use in an automated tape laying machine according to  claim 13  wherein said second composite surface is adhered to said outer fiber surface and wherein said outer fiber surface is coated with a release agent. 
     
     
         15 . A method for making a tape for use in an automated tape laying machine according to  claim 14  comprising the additional steps of providing a second plastic film having an inner surface and an outer surface and adhering said inner surface of said second plastic film to the outer film surface of said plastic film that is adhered to said fibrous layer. 
     
     
         16 . A method for making a tape for use in an automated tape laying machine according to  claim 13  wherein said second composite surface is adhered to said outer film surface. 
     
     
         17 . A method for making a tape for use in an automated tape laying machine according to  claim 16  comprising the additional steps of providing a second plastic film having an inner surface and an outer surface and adhering said inner surface of said second plastic film to said outer fiber surface. 
     
     
         18 . A method for applying an uncured composite material to a mold using an automated tape laying machine, said method comprising the steps of:
 providing a tape in accordance with  claim 1  for use in said automated tape laying machine; and   applying said uncured composite material to said mold using said automated tape laying machine; and   removing a portion or all of said multi-layer substrate from said uncured composite material.   
     
     
         19 . A method for applying an uncured composite material to a mold according to  claim 18  including the additional step of cutting through said uncured composite material while said uncured composite material is still adhered to said multi-layer substrate. 
     
     
         20 . An automated tape laying machine that comprises a tape in accordance with  claim 1 .