Automated system and method for forming laminate structures

Abstract

To provide a system and a method for automatically removing a backing paper from an uncured pre-impregnated fiber-reinforced polymer layer.SOLUTION: A method of removing a backing layer 120 from a panel 110 formed from an uncured pre-impregnated fiber-reinforced polymer includes orienting the panel in a backing-separation orientation relative to an edge-engagement tool 112. And, positioning the panel in a backing-separation position B relative to the edge-engagement tool. Further, when the panel is in the backing-separation orientation A and in the backing-separation position, moving the edge-engagement tool such that the backing-engagement features 114 of the edge-engagement tool engage the backing layer at only the edge portion of the backing layer, and only the edge portion 122 of the backing layer separates from the panel. The method further includes the step of moving the backing layer such that the entire backing layer separates from the panel when the edge portion of the backing layer is grasped.SELECTED DRAWING: Figure 13

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to forming laminate structures formed from fiber reinforced polymers, and more particularly to removing backing layers from panels formed from fiber reinforced polymers. [Background technology]

[0002] Laminate structures can be formed by stacking layers of fiber-reinforced polymer. Typically, each stacked layer is formed from uncured pre-impregnated fiber-reinforced polymer. Uncured pre-impregnated fiber-reinforced polymer is used because it can be molded into any of a variety of shapes before curing. To prevent damage or contamination of the uncured pre-impregnated fiber-reinforced polymer during transportation, storage, and handling, each stacked layer of uncured pre-impregnated fiber-reinforced polymer can have a backing paper affixed to the layer. Before curing the layer, the backing paper is removed. However, removing the backing paper in an efficient, automated manner without damaging the uncured pre-impregnated fiber-reinforced polymer can be difficult due to the tackiness of the uncured pre-impregnated fiber-reinforced polymer and the thinness of the backing paper. Summary of the Invention

[0003] The present subject matter addresses shortcomings in the current state of the art, particularly in methods for removing backing paper from layers of uncured, pre-impregnated, fiber-reinforced polymer that have not yet been fully addressed by currently available techniques. Accordingly, the present subject matter aims to provide an automated system and associated method for automatically removing backing paper from layers of uncured, pre-impregnated, fiber-reinforced polymer that overcomes at least some of the shortcomings in the prior art.

[0004] The following is a non-exhaustive list of claimed and unclaimed examples of the subject matter disclosed herein.

[0005] Disclosed herein is a method for removing a backing layer from a panel formed from an uncured pre-impregnated fiber-reinforced polymer. The backing layer is secured and flush against a large surface of the panel by tack forces between the backing layer and the uncured pre-impregnated fiber-reinforced polymer. The method includes orienting the panel in a backing separation direction relative to an edge-engagement tool. The method also includes positioning the panel in a backing separation position relative to the edge-engagement tool. The method further includes moving the edge-engagement tool relative to the panel when the panel is in the backing separation direction and in the backing separation position such that backing-engagement features of the edge-engagement tool engage the backing layer only at an edge portion of the backing layer, and only the edge portion of the backing layer separates from the panel. The method further includes gripping the edge portion of the backing layer after the edge portion separates from the panel, and moving the backing layer relative to the panel such that, when gripped, the entire backing layer separates from the panel. The foregoing subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0006] The edge engagement tool includes a plate, and the backing engagement features include a plurality of protrusions protruding from the plate. The step of moving the edge engagement tool includes reciprocating the plate along a plane angled at a plate angle relative to the panel and parallel to the leading edge of the edge portion when the panel is oriented in the backing separation direction and positioned in the backing separation position, such that only the plurality of protrusions of the plate engage only the edge portion of the backing layer as the plate moves along the plane. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, and Example 2 also includes the subject matter of Example 1 above.

[0007] The plate reciprocates in a forward direction and a rearward direction along the surface. The forward direction is opposite to the rearward direction. Each engagement between the plurality of protrusions and the edge portion of the backing layer results in at least partial separation of the backing layer from the panel. When the plate moves in the forward direction, the plurality of protrusions engage the edge portion. When the plate moves in the rearward direction, the plurality of protrusions do not substantially engage with the edge portion such that at least partial separation of the backing layer from the panel is maintained when the plate moves in the rearward direction. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, and Example 3 also includes the subject matter of Example 2 above.

[0008] Each of the plurality of protrusions includes a sharp side facing forward and a blunt side facing rearward. Engagement of the plurality of protrusions with the edge portion of the backing layer includes the sharp sides of the plurality of protrusions at least partially penetrating the edge portion of the backing layer. The foregoing subject matter of this paragraph characterizes Example 4 of the present disclosure, and Example 4 also includes the subject matter of Example 3 above.

[0009] The plate angle is an oblique angle. The aforementioned subject matter of this paragraph characterizes Example 5 of the present disclosure, and Example 5 also includes the subject matter of any of Examples 2 to 4 above.

[0010] The plate angle is an acute angle. The aforementioned subject matter of this paragraph characterizes Example 6 of the present disclosure, and Example 6 also includes the subject matter of Example 5 above.

[0011] Reciprocating the plate includes reciprocating the plate at least twice such that the plurality of protrusions of the plate engage only the edge portion of the backing layer at least twice. The foregoing subject matter of this paragraph characterizes Example 7 of the present disclosure, and Example 7 also includes the subject matter of any of Examples 2 to 6 above.

[0012] The edge engagement tool includes a wheel, and the backing engagement features include teeth circumferentially spaced around the wheel. The step of moving the edge engagement tool includes rotating the wheel about an axis parallel to a leading edge of the edge portion of the backing layer such that only the teeth of the wheel repeatedly engage the edge portion of the backing layer when the panel is oriented in a backing separation direction and positioned in a backing separation position, and translating the wheel in a wheel direction parallel to the broad surface of the panel as the wheel rotates. The foregoing subject matter of this paragraph characterizes Example 8 of the present disclosure, and Example 8 also includes the subject matter of Example 1 above.

[0013] The backing layer further includes a second edge portion at an opposite end of the panel relative to the edge portion. The edge engagement tool further includes a second wheel, and the backing engagement feature further includes second teeth circumferentially spaced about the second wheel. The step of moving the edge engagement tool further includes rotating the second wheel about a second axis parallel to the trailing edge of the second edge portion of the backing layer in a rotational direction opposite to the wheel rotational direction so that only the second teeth of the second wheel repeatedly engage the second edge portion of the backing layer and only the second edge portion of the backing layer separates from the panel, and translating the wheel in a second wheel direction parallel to the broad surface of the panel and opposite to the wheel direction as the second wheel rotates. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, and Example 9 also includes the subject matter of Example 8.

[0014] The method further includes gripping the second edge portion of the backing layer with a second gripping device while the gripper is gripping the edge portion of the backing layer and after the second edge portion separates from the panel. The method further includes moving the second gripping device relative to the panel such that the entire backing layer separates from the panel when gripped by the second gripping device and moving the gripping device relative to the panel. The foregoing subject matter of this paragraph characterizes Example 10 of the present disclosure, and Example 10 also includes the subject matter of Example 9 above.

[0015] The panel includes a second major surface opposite the major surface. The second backing layer is secured and flush against the second major surface of the panel by a second tack force between the second backing layer and the uncured pre-impregnated fiber-reinforced polymer. The method further includes at least one step of orienting the panel in a second backing separation direction relative to a second edge engagement tool after separating the entire backing layer from the panel and / or positioning the panel in a second backing separation position relative to the second edge engagement tool. The method also includes at least one step of moving the second edge engagement tool relative to the panel after separating the entire backing layer from the panel such that when the panel is in the second backing separation direction and / or the second backing separation position, a second tool backing engagement feature of the second edge engagement tool engages only a second backing layer edge portion of the second backing layer, and only the second backing layer edge portion of the second backing layer separates from the panel. The method further includes at least one of the steps of: after the entire backing layer has been separated from the panel, gripping the second backing layer edge portion of the second backing layer after the second backing layer edge portion has been separated from the panel; and, when gripped, moving the second backing layer edge portion relative to the panel such that the entire second backing layer is separated from the panel. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, and Example 11 also includes the subject matter of any of Examples 1 to 10 above.

[0016] The step of gripping the edge portion of the backing layer includes gripping the edge portion of the backing layer with a gripping device. The step of gripping the second backing layer edge portion of the second backing layer includes gripping the second backing layer edge portion with a second gripping device. The aforementioned subject matter of this paragraph characterizes Example 12 of the present disclosure, and Example 12 also includes the subject matter of Example 11.

[0017] The step of orienting the panel in the second backing separation direction relative to the second edge engagement tool includes flipping the panel over. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, and Example 13 also includes the subject matter of any of Examples 11-12 above.

[0018] The second edge engagement tool includes a second tool plate, and the second tool backing engagement feature includes a plurality of second tool projections protruding from the second tool plate. The moving the second edge engagement tool reciprocates the second tool plate along a second plane parallel to the second backing layer leading edge of the second backing layer edge portion, angled at a second plate angle relative to the panel, such that only a plurality of second root projections of the second tool plate engage only the second backing layer edge portion of the second backing layer when the panel is oriented in a second backing separation direction and positioned in a second backing separation position. The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, and Example 14 also includes subject matter according to any of Examples 11 to 13.

[0019] The reciprocating second tool plate is flush with or parallel to the reciprocating plate. The foregoing subject matter of this paragraph characterizes Example 15 of the present disclosure, which also includes the subject matter of Example 14 above.

[0020] The reciprocating second tool plate is angled relative to the reciprocating plate. The foregoing subject matter of this paragraph characterizes Example 16 of the present disclosure, which also includes the subject matter of Example 14 above.

[0021] The angle between the reciprocating second tool plate and the reciprocating plate is less than or equal to 90°. The aforementioned subject matter of this paragraph characterizes Example 17 of the present disclosure, and Example 17 also includes the subject matter of Example 16 above.

[0022] The steps of orienting the panel, positioning the panel, moving the edge engagement tool, and gripping the edge portion are automated. The aforementioned subject matter of this paragraph characterizes Example 18 of the present disclosure, and Example 18 also includes the subject matter of any of Examples 1 to 17 above.

[0023] The method further includes pressing the backing layer against a large surface of the panel after orienting the panel in the backing separation direction, after positioning the panel in the backing separation position, and before moving the edge engagement tool. The foregoing subject matter of this paragraph characterizes Example 19 of the present disclosure, and Example 19 also includes subject matter according to any of Examples 1 to 18 above.

[0024] Pressing the backing layer against the large surface includes rolling a roller along the backing layer. The aforementioned subject matter of this paragraph characterizes Example 20 of the present disclosure, which also includes the subject matter of Example 19 above.

[0025] The panel includes a plurality of layers in a stacked arrangement. Each of the plurality of layers includes unidirectional fibers. The unidirectional fibers of at least one of the plurality of layers are oriented in a different direction than the unidirectional fibers of at least one other of the plurality of layers. The foregoing subject matter of this paragraph characterizes Example 21 of the present disclosure, which also includes the subject matter of any of Examples 1 to 20 above.

[0026] The method further includes maintaining the temperature of the panel at or below 72° C. during the step of moving the edge engagement tool. The preceding subject matter of this paragraph characterizes Example 22 of the present disclosure, which also includes the subject matter of any of Examples 1 to 21 above.

[0027] The step of maintaining the temperature of the panel at or below 72° includes blowing air onto the panel at a temperature of or below 72° C. The foregoing subject matter of this paragraph characterizes Example 23 of the present disclosure, which also includes the subject matter of Example 22.

[0028] Further disclosed herein is an automated system for removing a backing layer from a panel formed from an uncured pre-impregnated fiber-reinforced polymer. The backing layer is secured and flush against a large surface of the panel by tack forces between the backing layer and the uncured pre-impregnated fiber-reinforced polymer. The automated system includes an edge engagement tool, the edge engagement tool including backing engagement features, and the edge engagement tool is movable relative to the panel such that the backing engagement features of the edge engagement tool engage only an edge portion of the backing layer and only the edge portion of the backing layer separates from the panel. The automated system also includes a gripping device configured to grip the edge portion when the edge portion separates from the panel, and movable relative to the panel such that the entire backing layer separates from the panel when the edge portion is gripped by the gripping device. The foregoing subject matter of this paragraph characterizes Example 24 of the present disclosure.

[0029] The edge engagement tool includes a plate. The backing engagement features include a plurality of protrusions extending from the plate. The plate is secured to the panel at a plate angle. The plate is angled relative to the panel at the plate angle and selectively operable to reciprocate along a plane parallel to the leading edge of the edge portion. The foregoing subject matter of this paragraph characterizes Example 25 of the present disclosure, and Example 25 also includes the subject matter of Example 24.

[0030] The plate reciprocates along the surface in a forward direction toward the panel and a rearward direction away from the panel. Each of the plurality of protrusions includes a sharp side facing forward and a blunt side facing rearward. The foregoing subject matter of this paragraph characterizes Example 26 of the present disclosure, and Example 26 also includes the subject matter of Example 25.

[0031] The plate angle is an oblique angle. The aforementioned subject matter of this paragraph characterizes Example 27 of the present disclosure, and Example 27 also includes the subject matter of any of Examples 25 to 26 above.

[0032] The plate angle is an acute angle. The aforementioned subject matter of this paragraph characterizes Example 28 of the present disclosure, and Example 28 also includes the subject matter of Example 27 above.

[0033] The automated system further includes a second edge engagement tool including a second tool backing engagement feature. The panel includes a second major surface opposite the major surface. The second backing layer is secured and flush against the second major surface of the panel by tack forces between the second backing layer and the uncured pre-impregnated fiber-reinforced polymer. The foregoing subject matter of this paragraph characterizes Example 29 of the present disclosure, which also includes subject matter according to any of Examples 25 to 28 above.

[0034] The reciprocating second tool plate is flush with or parallel to the reciprocating plate. The foregoing subject matter of this paragraph characterizes Example 30 of the present disclosure, which also includes the subject matter of Example 29 above.

[0035] The reciprocating second tool plate is angled relative to the reciprocating plate. The foregoing subject matter of this paragraph characterizes Example 31 of the present disclosure, which also includes the subject matter of Example 29 above.

[0036] The edge engagement tool includes a wheel. The backing engagement features include teeth circumferentially spaced about the wheel. The wheel rotates about an axis parallel to the leading edge of the edge portion of the backing layer and is selectively operable to translate parallel to the broad surface of the panel while the wheel rotates. The foregoing subject matter of this paragraph characterizes Example 32 of the present disclosure, which also includes the subject matter of Example 24 above.

[0037] The backing layer further includes a second edge portion at an opposite end of the panel relative to the edge portion. The edge engagement tool further includes a second wheel. The backing engagement feature further includes second teeth circumferentially spaced about the second wheel. The second wheel rotates about an axis parallel to the trailing edge of the second edge portion of the backing layer in a rotational direction opposite to that of the wheel, and is selectively operable to translate parallel to the broad surface of the panel while the second wheel rotates. The foregoing subject matter of this paragraph characterizes Example 33 of the present disclosure, and Example 33 also includes the subject matter of Example 32.

[0038] The automated system further includes a roller selectively operable to roll along the backing layer when the backing layer is adhesively secured to the broad surface of the panel. The foregoing subject matter of this paragraph characterizes Example 34 of the present disclosure, which also includes the subject matter of any of Examples 24 to 33 above.

[0039] Also disclosed herein is a method of forming a laminate structure. The method includes orienting a first panel and a backing layer secured to the first panel in a backing separation direction relative to an edge engagement tool. The first panel is formed from an uncured pre-impregnated fiber-reinforced polymer, and the backing layer is secured to a first panel broad surface of the first panel by backing-to-panel tack forces between the backing layer and the uncured pre-impregnated fiber-reinforced polymer of the first panel. The method also includes positioning the first panel in a backing separation position relative to the edge engagement tool. The method further includes moving the edge engagement tool relative to the first panel such that, when the first panel is in the backing separation direction and in the backing separation position, backing engagement features of the edge engagement tool engage the backing layer only at an edge portion of the backing layer, and only the edge portion of the backing layer separates from the first panel. The method further includes laminating the first panel to a second panel formed from uncured pre-impregnated fiber reinforced polymer, wherein the first panel is directly secured to the second panel by inter-panel tack forces between the pre-impregnated fiber reinforced polymer of the first panel and the uncured pre-impregnated fiber reinforced polymer of the second panel, and the first panel and second panel form a laminate structure. The foregoing subject matter of this paragraph characterizes Example 35 of the present disclosure.

[0040] The step of laminating the first panel to the second panel includes laminating the first panel to the second panel such that the first panel's major surface is directly secured to the second panel's major surface by inter-panel tack forces. The foregoing subject matter of this paragraph characterizes Example 36 of the present disclosure, and Example 36 also includes the subject matter of Example 35.

[0041] The first panel includes a second first panel wide surface opposite the first panel wide surface. The second backing layer is secured flush against the second first panel wide surface of the panel by a second tack force between the second backing layer and the uncured pre-impregnated fiber-reinforced polymer. Laminating the first panel to the second panel includes positioning the first panel in a second backing separation position relative to a second edge engagement tool. The method further includes moving the second edge engagement tool relative to the first panel when the first panel is in the second backing separation position such that a second tool backing engagement feature of the second edge engagement tool engages only a second backing layer edge portion of the second backing layer and only the second backing layer edge portion of the second backing layer separates from the panel. The method also includes gripping the second backing layer edge portion of the second backing layer after the second backing layer edge portion separates from the first panel, and moving the second backing layer edge portion relative to the first panel when gripped, such that the entire second backing layer separates from the first panel. The foregoing subject matter of this paragraph characterizes Example 37 of the present disclosure, and Example 37 also includes the subject matter of Example 36.

[0042] The step of moving the edge engagement tool to grip the edge portion of the backing layer occurs after the step of laminating the first panel to the second panel. The preceding subject matter of this paragraph characterizes Example 38 of the present disclosure, and Example 38 also includes the subject matter of any of Examples 35 to 37.

[0043] Each of the first panel and the second panel includes a plurality of layers in a stacked arrangement. Each of the plurality of layers of the first panel and the second panel includes unidirectional fibers. The foregoing subject matter of this paragraph characterizes Example 39 of the present disclosure, which also includes the subject matter of any of Examples 35 to 38.

[0044] The unidirectional fibers of at least one of the layers of the first panel are oriented in a different direction than the unidirectional fibers of at least one other of the layers of the first panel. The unidirectional fibers of at least one of the layers of the second panel are oriented in a different direction than the unidirectional fibers of at least one other of the layers of the second panel. The foregoing subject matter of this paragraph characterizes Example 40 of the present disclosure, which also includes the subject matter of Example 39.

[0045] The plurality of layers of at least one of the first panel and the second panel consists of four layers, including a first layer having unidirectional fibers oriented at 0°, a second layer having unidirectional fibers oriented at +45°, a third layer having unidirectional fibers oriented at 90°, and a fourth layer having unidirectional fibers oriented at -45°. The foregoing subject matter of this paragraph characterizes Example 41 of the present disclosure, and Example 41 also includes the subject matter of Example 40.

[0046] The multiple layers of both the first panel and the second panel consist of four layers, including a first layer with unidirectional fibers oriented at 0°, a second layer with unidirectional fibers oriented at +45°, a third layer with unidirectional fibers oriented at 90°, and a fourth layer with unidirectional fibers oriented at -45°. The foregoing subject matter of this paragraph characterizes Example 42 of the present disclosure, and Example 42 also includes the subject matter of Example 40.

[0047] The plurality of layers of at least one of the first panel and the second panel consists of four layers, each having unidirectional fibers oriented at 0°. The foregoing subject matter of this paragraph characterizes Example 43 of the present disclosure, and Example 43 also includes the subject matter of Example 39.

[0048] The layers of the first panel are arranged as a first laminate and a second laminate. The second laminate is laminated to the first laminate. The layers of the first laminate are aligned. The layers of the second laminate are unaligned. Each layer of the second laminate includes an elongated strip. The elongated strips of the second laminate form a cluster. The first panel broad surface includes portions of the first laminate and the cluster such that the backing layer is secured to both portions of the first laminate and the cluster. The foregoing subject matter of this paragraph characterizes Example 44 of the present disclosure, which also includes subject matter according to any of Examples 39 to 43.

[0049] The method further includes automatically separately applying the elongated strips to the first laminate at different angles relative to each other to form a cluster of second laminates. The foregoing subject matter of this paragraph characterizes Example 45 of the present disclosure, which also includes the subject matter of Example 44 above.

[0050] The step of automatically and separately applying the elongated strips to the first laminate includes gradually rotating the first laminate relative to the elongated strips while maintaining the orientation of the elongated strips. The foregoing subject matter of this paragraph characterizes Example 46 of the present disclosure, which also includes the subject matter of Example 45.

[0051] The method further includes, before the step of moving the edge engagement tool, adjusting a distance between the edge engagement tool and the second panel in a stacking direction perpendicular to a broad surface of the first panel when the first panel is laminated to the second panel. The preceding subject matter of this paragraph characterizes Example 47 of the present disclosure, and Example 47 also includes the subject matter of any of Examples 35 to 46.

[0052] Each of the first and second panels includes a plurality of layers in a stacked arrangement. The method further includes ultrasonically cutting a sheet formed from the uncured pre-impregnated fiber-reinforced polymer into a plurality of layers, stacking a first set of the plurality of layers to form the first panel, and stacking a second set of the plurality of layers to form the second panel. The foregoing subject matter of this paragraph characterizes Example 48 of the present disclosure, which also includes the subject matter of any of Examples 35 to 47 above.

[0053] The method further includes pressing and heating the first and second panels together after the first panel is laminated to the second panel, such that the uncured pre-impregnated fiber-reinforced polymer is cured. The foregoing subject matter of this paragraph characterizes Example 49 of the present disclosure, which also includes the subject matter of Example 48.

[0054] The method includes, after pressing and heating the first and second panels, roughening the outer surface of one of the first and second panels to form a roughened outer surface, cleaning the roughened outer surface to form a cleaned roughened outer surface, applying a primer layer to the cleaned roughened outer surface, and applying ink to the primer layer. The foregoing subject matter of this paragraph characterizes Example 50 of the present disclosure, and Example 50 also includes the subject matter of Example 49.

[0055] The method further includes pressing a polymer layer onto the primer layer and the ink to form a pre-cut laminate structure. The foregoing subject matter of this paragraph characterizes Example 51 of the present disclosure, which also includes the subject matter of Example 50.

[0056] The method further includes cutting the pre-cut laminate structure to form a cut laminate structure having a predetermined shape. The foregoing subject matter of this paragraph characterizes Example 52 of the present disclosure, and Example 52 also includes the subject matter of Example 51 above.

[0057] After cutting, the laminate structure comprises a striking plate for a golf club head. The foregoing subject matter of this paragraph characterizes Example 53 of the present disclosure, which also includes the subject matter of Example 52 above.

[0058] The described features, structures, advantages, and / or characteristics of the presently disclosed subject matter may be combined in any suitable manner in one or more examples and / or implementations. In the following description, numerous specific details are provided to provide a thorough understanding of examples of the presently disclosed subject matter. Those skilled in the relevant art will recognize that the presently disclosed subject matter can be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular example or implementation. In other examples, particular examples and / or implementations may recognize additional features and advantages that may not be present in all examples or implementations. Moreover, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the presently disclosed subject matter. The features and advantages of the presently disclosed subject matter will become better apparent from the following description and appended claims or may be learned by practicing the subject matter set forth below.

[0059] In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be provided by reference to examples illustrated in the accompanying drawings, in which the subject matter will be described and explained with added specificity and detail through the use of these drawings, which are not necessarily drawn to scale, but which illustrate only particular examples of the subject matter and are not to be considered limiting of its scope. [Brief explanation of the drawings]

[0060] [Figure 1] FIG. 1 is a schematic side view of an edge engagement tool of an automated system for removing a backing layer from a panel, with the edge engagement tool in a first stage of movement, in accordance with one or more examples of the present invention.

[0061] [Figure 2A]2A is a schematic side view of the edge engagement tool of FIG. 1 in a second stage of movement, according to one or more examples of the present disclosure.

[0062] [Figure 2B] 2B is a schematic side close-up view of a portion of the edge engagement tool of FIG. 2A according to one or more examples of the present disclosure.

[0063] [Figure 3A] 3A is a schematic side view of the edge engagement tool of FIG. 1, with the edge engagement tool in a third stage of movement, according to one or more examples of the present disclosure.

[0064] [Figure 3B] 3B is a schematic side close-up view of a portion of the edge engagement tool of FIG. 3A according to one or more examples of the present disclosure.

[0065] [Figure 4A] 4A is a schematic side view of the edge engagement tool of FIG. 1 in a fourth stage of movement according to one or more examples of the present disclosure.

[0066] [Figure 4B] 4B is a schematic side close-up view of a portion of the edge engagement tool of FIG. 4A according to one or more examples of the present disclosure.

[0067] [Figure 5] 5 is a schematic side view of the edge engagement tool of FIG. 1 in a fifth stage of movement, according to one or more examples of the present disclosure.

[0068] [Figure 6] 6 is a schematic side view of the edge engagement tool of FIG. 1 in a sixth stage of movement, according to one or more examples of the present disclosure.

[0069] [Figure 7]7 is a schematic side view of the edge engagement tool of FIG. 1 in a seventh stage of movement, according to one or more examples of the present disclosure.

[0070] [Figure 8] 8 is a schematic side view of the edge engagement tool of FIG. 1 in an eighth stage of movement, according to one or more examples of the present disclosure.

[0071] [Figure 9] FIG. 9 is a schematic side view of a gripping device of an automated system for removing a backing layer from a panel, according to one or more examples of the present disclosure.

[0072] [Figure 10] 10 is a schematic side view of the gripping device of FIG. 9, with the gripping device gripping an edge portion of a backing layer, according to one or more examples of the present disclosure.

[0073] [Figure 11] FIG. 11 is a schematic side view of the gripping device of FIG. 9, with the gripping device gripping and pulling an edge portion of a backing layer, according to one or more examples of the present disclosure.

[0074] [Figure 12] 12 is a schematic side view of the gripping device of FIG. 9, the gripping device gripping and removing a backing layer from a panel, according to one or more examples of the present disclosure.

[0075] [Figure 13] FIG. 13 is a schematic side view of an automated system for removing a backing layer from a panel according to one or more examples of the present disclosure.

[0076] [Figure 14] FIG. 14 is a schematic side view of an automated system for removing a backing layer from a panel according to one or more examples of the present disclosure.

[0077] [Figure 15]FIG. 15 is a schematic side view of an edge engagement tool of an automated system for removing a backing layer from a panel, with the edge engagement tool in a first stage of movement, in accordance with one or more examples of the present invention.

[0078] [Figure 16] 16 is a schematic side view of the edge engagement tool of FIG. 15, with the edge engagement tool in a second stage of movement, according to one or more examples of the present disclosure.

[0079] [Figure 17] 17 is a schematic side view of the edge engagement tool of FIG. 15, with the edge engagement tool in a third stage of movement, according to one or more examples of the present disclosure.

[0080] [Figure 18] 18 is a schematic side view of the edge engagement tool of FIG. 15, with the edge engagement tool in a fourth stage of movement, according to one or more examples of the present disclosure.

[0081] [Figure 19] FIG. 19 is a schematic side view of a gripping device of an automated system for removing a backing layer from a panel, according to one or more examples of the present disclosure.

[0082] [Figure 20] 20 is a schematic side view of the gripping device of FIG. 19, with the gripping device gripping an edge portion of a backing layer, according to one or more examples of the present disclosure.

[0083] [Figure 21] 21 is a schematic side view of the gripping device of FIG. 19, the gripping device gripping and removing a backing layer from a panel, according to one or more examples of the present disclosure.

[0084] [Figure 22] FIG. 22 is a schematic side view of a roller of an automated system for removing a backing layer from a panel according to one or more examples of the present disclosure.

[0085] [Figure 23] FIG. 23 is a schematic isometric view of a panel according to one or more examples of the present disclosure.

[0086] [Figure 24] FIG. 24 is a schematic isometric exploded view of a panel according to one or more examples of the present disclosure.

[0087] [Figure 25] FIG. 25 is a schematic isometric view of a robotic arm and rotatable platform of an automated system for forming panels according to one or more examples of the present disclosure.

[0088] [Figure 26] FIG. 26 is a schematic isometric view of a panel according to one or more examples of the present disclosure.

[0089] [Figure 27] FIG. 27 is a schematic isometric view of the panel of FIG. 26 according to one or more examples of the present disclosure.

[0090] [Figure 28] FIG. 28 is a schematic isometric view of a golf club head according to one or more examples of the present disclosure.

[0091] [Figure 29] FIG. 29 is a simplified flowchart of a method of forming a laminate structure according to one or more examples of the present disclosure.

[0092] [Figure 30A] FIG. 30A is a schematic isometric view of a first panel laminated to a second panel according to one or more examples of the present disclosure.

[0093] [Figure 30B] FIG. 30B is a schematic isometric exploded view of a laminate structure according to one or more examples of the present disclosure.

[0094] [Figure 30C]FIG. 30C is a schematic top view of a panel according to one or more examples of the present disclosure.

[0095] [Figure 31] FIG. 31 is a schematic isometric view of a sheet of pre-impregnated reinforced polymer with a layer removed therefrom, according to one or more examples of the present disclosure.

[0096] [Figure 32] FIG. 32 is a schematic isometric view of multiple layers stacked to form a first panel and multiple layers stacked to form a second panel, according to one or more examples of the present disclosure.

[0097] [Figure 33] FIG. 33 is a schematic isometric view of a first panel and a second panel compressed together and heated, according to one or more examples of the present disclosure.

[0098] [Figure 34] FIG. 34 is a schematic isometric view of the first panel of FIG. 33 having a roughened surface according to one or more examples of the present disclosure.

[0099] [Figure 35] FIG. 35 is a schematic isometric view of the first panel of FIG. 34 being cleaned according to one or more examples of the present disclosure.

[0100] [Figure 36] FIG. 36 is a schematic isometric view of the first panel of FIG. 35 and a primer layer applied to the first panel according to one or more examples of the present disclosure.

[0101] [Figure 37] FIG. 37 is a schematic isometric view of the first panel and primer layer of FIG. 36, and ink applied to the primer layer, according to one or more examples of the present disclosure.

[0102] [Figure 38]FIG. 38 is a schematic isometric view of the first panel, primer layer, and ink of FIG. 37, and a polymer layer applied over the ink to form a pre-cut laminate structure, according to one or more examples of the present disclosure.

[0103] [Figure 39] FIG. 39 is a schematic isometric view of a post-cut laminate structure cut from the pre-cut laminate structure of FIG. 38 according to one or more examples of the present disclosure.

[0104] [Figure 40] FIG. 40 is a schematic side view of an edge engagement tool of an automated system for removing a backing layer from a panel according to one or more examples of the present disclosure.

[0105] Detailed Description Throughout this specification, the term "in one example," "example," or similar terms means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the present disclosure. Throughout this specification, the terms "in one example," "in an example," and similar terms may, but do not necessarily, all refer to the same example. Similarly, use of the term "implementation" means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the present disclosure, although an implementation may be associated with one or more examples unless a clear connection indicates otherwise.

[0106] Laminate structures formed from layers of uncured pre-impregnated fiber-reinforced polymer can be difficult to fabricate. In some cases, the difficulty in fabricating such laminate structures stems from the preparation, handling, and assembly of the layers of uncured pre-impregnated fiber-reinforced polymer. Disclosed herein are systems and manufacturing methods that overcome many of the challenges associated with manufacturing laminate structures. For example, the systems and manufacturing methods disclosed herein can be automated systems and manufacturing methods that provide an efficient method for automatically removing a backing layer from a panel formed from uncured pre-impregnated fiber-reinforced polymer. Efficient removal of the backing layer allows for efficient and accurate automated lamination of multiple panels. As a further example, the automated systems and manufacturing methods facilitate efficient and accurate automated lamination of multiple strips of uncured pre-impregnated fiber-reinforced polymer at different angles to form a panel. Furthermore, in some examples, the automated systems and manufacturing methods disclosed herein provide an efficient and accurate method for automating the manufacture of striking plates for golf club heads.

[0107] According to some examples, the automated system 100 of the present disclosure includes an edge engagement tool 112 and a gripping device 130. With reference to Figures 1-8 and 15-18, in certain examples, the edge engagement tool 112 is configured to facilitate partial removal of the backing layer 120 from the panel 110 (e.g., the first panel), such as in an automated manner. As shown in Figures 9-12 and 19-21, the gripping device 130 is configured to facilitate complete removal of the backing layer 120 from the panel 110.

[0108] The panel 110 is formed from an uncured pre-impregnated fiber-reinforced polymer. As used herein, an uncured pre-impregnated fiber-reinforced polymer is a material that includes fibers embedded in a polymer matrix, which may be curable and partially cured, but not fully cured, e.g., a so-called B-stage prepreg. In other words, the polymer matrix of an uncured pre-impregnated fiber-reinforced polymer partially cures, or is the site of the initiation of some chemical reaction, which helps to provide a degree of stiffness compared to a polymer matrix in a liquid or flowable state, but upon completion of the chemical reaction, the polymer matrix is ​​not yet fully cured. Thus, as used herein to describe the cured state of a pre-impregnated fiber-reinforced polymer, uncured means not fully cured or only partially cured. Thus, a partially cured polymer matrix is ​​in a cure state between an uncured state (e.g., A-stage), in which the polymer matrix is ​​in a liquid or flowable form and has not undergone a chemical reaction, and a fully cured state, in which the polymer matrix is ​​in a rigid form and has undergone a complete chemical reaction. The partially cured polymer matrix is ​​flexible, easily deformable, tacky, and easy to handle, allowing the fibers to be held in place by the polymer matrix and the pre-impregnated fiber-reinforced polymer to be molded into a desired shape prior to final curing of the polymer matrix. After the polymer matrix, which in certain examples can be a thermosetting epoxy or resin, is cured or hardened, the fiber-reinforced polymer becomes rigid, non-flexible, and non-tacky. In some examples, the epoxy can be various types of epoxy, and the fiber can be various fibers, such as carbon fiber, glass fiber, etc. In certain examples, the fiber volume fraction of the uncured pre-impregnated fiber-reinforced polymer is 50%, and the epoxy volume fraction of the uncured pre-impregnated fiber-reinforced polymer is 45%.

[0109] 23, an example of a panel 110 is shown. The panel 110 is formed from a pre-impregnated fiber-reinforced polymer. More specifically, the panel 110 includes unidirectional fibers 170 embedded in a polymer matrix 172.

[0110] In certain examples, the panel 110 includes one or fewer layers, while in other examples, the panel 110 includes multiple layers 129. Each of the layers 129 is formed from a pre-impregnated fiber-reinforced polymer. Thus, the unidirectional fibers 170 of each of the layers 129 are continuous and parallel to one another. The layers 129 of the panel 110 are laminated together in a stacked arrangement (e.g., forming a stack of layers). Because the polymer matrix of the layers 129 is only partially cured, the layers 129 of the panel 110 are bonded together or maintained in a stacked arrangement by the tackiness of the polymer matrix. As used herein, the adhesive force generated by the tackiness of the polymer matrix that bonds the layers 129 of the panel 110 to one another, to multiple panels to one another, and to the backing layer 120 to the layers 129 is known as tack. More specifically, the tack force adhesively bonding layers or panels to one another is considered inter-panel tack, and the tack force adhesively bonding a backing layer to a layer or panel is considered inter-backing / panel tack.

[0111] The plies 129 of a given panel 110 can be positioned relative to one another such that the unidirectional fibers 170 of a given ply 129 are parallel to or angled relative to the unidirectional fibers 170 of an adjacent one of the plies 129. In one example, the plies 129 of a panel 110 are positioned relative to one another such that the unidirectional fibers 170 of all of the plies 129 of the panel 110 are unidirectional, parallel to one another, or extend in the same direction. However, in other examples, the plies 129 of a panel 110 are positioned relative to one another such that the unidirectional fibers 170 of any one of the plies 129 are angled relative to any other one of the plies 129.

[0112] 23 and 32, the panel 110 includes four layers 129. The four layers 129 of the panel 110 of FIGS. 23 and 32 include a first layer 129A, a second layer 129B, a third layer 129C, and a fourth layer 129D. The unidirectional fibers 170 of the first layer 129A are oriented at 0°, the unidirectional fibers 170 of the second layer 129B are oriented at +45° relative to the unidirectional fibers 170 of the first layer 129A, the unidirectional fibers 170 of the third layer 129C are oriented at 90° relative to the unidirectional fibers 170 of the first layer 129A, and the unidirectional fibers 170 of the fourth layer 129D are oriented at −45° relative to the unidirectional fibers 170 of the first layer 129A.

[0113] As used herein, panel 110 having the ply arrangement shown in FIG. 23 is an example of a quasi-isotropic panel. Additionally, panel 110 of FIG. 23 is parallel with the broad surfaces of the plies and asymmetric with respect to the midplane that bisects panel 110. While plies 129 of panel 110 shown in FIGS. 23 and 32 have a [0°, +45°, 90°, −45°] layup configuration, in other examples, the layup configuration may be different, such as [0°, 90°, +45°, −45°]. It is recognized that the particular layup of panel 110 of FIGS. 23 and 32 is such that the fibers of adjacent plies are not angled more than 45° with respect to each other, which helps improve the strength and performance of the panel. According to some examples, the plies 129 of the panel 110 can have further different layup configurations, such as including a ply having unidirectional fibers 170 oriented at 0°, a ply having unidirectional fibers 170 oriented at +60°, and a ply having unidirectional fibers 170 oriented at -60°. In other words, with the above in mind, the panel 110 of the present disclosure can have one ply or any number of stacked plies having fibers in any of a variety of orientations relative to one another. The relative orientation of the fibers of the plies corresponds to the desired directional stiffness (e.g., x-axis stiffness or y-axis stiffness) and desired level of stiffness in such directions of the panel 110.

[0114] Although the unidirectional fibers 170 may not be parallel in different layers, the layers 129 of the example panel 110 shown in FIG. 23 are aligned. The layers 129 are aligned because the peripheral edges of the layers 129 are aligned or flush. As used herein, with respect to the alignment of the layers 129, the peripheral edges of the layers 129 are flush if the corresponding edges of the layers are substantially coplanar. Because the layers 129 are aligned, the thickness T of the panel 110 is constant or the same at any location on the panel 110.

[0115] 24, 26, and 27, in some examples, the panel 110 is considered a cluster panel because it includes clusters 165 of elongated strips 145. The clusters 165 are stacked on aligned layers, similar to that shown in FIG. 23, to form the panel 110. The clusters 165 define the second laminate 163 of the panel 110, and the aligned layers define the first laminate 161 of the panel 110. Thus, the layers 129 of the second laminate 163 are elongated strips 145. The elongated strips 145 are formed from an uncured pre-impregnated fiber-reinforced polymer. Furthermore, as shown in FIG. 24, each of the elongated strips 145 extends along a length L2 of the elongated strip 145, which can be the same as or shorter than the length L1 of the first laminate 161 (i.e., the length L1 of the panel 110). Thus, each of the elongated strips 145 has a length L2 that is greater than the width W2 of the elongated strip 145. The unidirectional fibers 170 of each of the elongated strips 145 extend parallel to the length L2 of the elongated strip 145. The elongated strips 145 are considered strips because the width W2 of each of the elongated strips 145 is less than the width W1 of the first laminate 161 of the panel 110 to which the elongated strips 145 are stacked to form the panel 110 (i.e., the width W1 of the panel 110). According to some examples, the width W2 of each of the elongated strips 145 is the same. However, in other examples, the width W2 of at least one of the elongated strips 145 may be different from the width W2 of at least one other of the elongated strips 145.

[0116] In certain examples, the elongated strips 145 are stacked in the first stack 161 such that the center (or midpoint) of each of the elongated strips 145 is aligned with the center of the first stack 161. Thus, in some examples, the cluster 165 or the second stack 163 is aligned with the center of the first stack 161. However, although the elongated strips 145 of the cluster 165 are aligned with the center of the first stack 161, the elongated strips 145 are angled with respect to each other such that the elongated strips 145 are considered misaligned. More specifically, the elongated strips 145 are misaligned because the peripheral edges of the layers 129 are misaligned or not flush. Each of the elongated strips 145 is angled with respect to a first adjacent one of the elongated strips 145 at a cluster angle θ3 and with respect to a second adjacent one of the elongated strips 145 at a cluster angle θ4. In some examples, the cluster angle θ3 is different from the cluster angle θ4. According to one example, cluster angle θ3 is 35° and cluster angle θ4 is 55°. However, in other examples, cluster angle θ3 is the same as cluster angle θ4. According to one example, where cluster 165 has four elongated strips 145, both cluster angle θ3 and cluster angle θ4 are 45°. In another example, such as when cluster 165 has eight elongated strips 145, both cluster angle θ3 and cluster angle θ4 are 22.5°. Thus, in some examples, cluster 165 forms a symmetrical star shape with first stack 161 at its center.

[0117] 26 and 27 include four elongated strips 145, in other examples, such as shown in Figure 30B, the cluster 165 includes more than four elongated strips 145. In one particular example, the cluster 165 includes seven elongated strips 145.

[0118] Alternatively, in some examples, the elongated strips 145 partially overlap one another but are not all centered on the first laminate 161. In such examples, the clusters 165 may not be symmetrical and may have various asymmetric shapes described by the angles and positions of the elongated strips 145 relative to one another. Alternatively, the elongated strips 145 may not be centered on the first laminate 162, but the clusters 165 may nevertheless be symmetrical about the center of the first laminate. For example, referring to FIG. 30C , the elongated strips 145 are applied to the broad surface 111 of the first laminate 161 of the panel 110 at positions offset from the center of the first laminate 161. In this manner, the clusters 165 forming the second laminate 163 can serve to increase the thickness of the striking plate 243 along the periphery (substantially as indicated by the outline on the panel 110).

[0119] For each cluster 165, only a portion of the elongated strips 145 overlap one another. Because the elongated strips 145 are not aligned on the first laminate 161, the thickness T of the cluster panel varies from one location to another on the cluster panel. In other words, the thickness of the cluster panel varies, as shown in FIGS. 26 and 27 , for example. For some clusters 165, such as symmetric clusters, the thickness of the cluster 165 varies away from the axis of symmetry or center of the cluster 165, but in the case of a cone or truncated cone, the thickness is the same at multiple locations that are the same distance from the center of the cluster 165. However, for other clusters 165, such as asymmetric clusters, the thickness of the cluster 165 may vary at different locations that are the same distance from the center of the cluster 165, with the cluster 165 having varying thicknesses.

[0120] In some examples, the elongated strips 145 are placed on the first stack 161 via an automated process. For example, as shown in FIG. 25 , the automated system 100 can further include a robotic arm 147 and a rotatable platform 149. The robotic arm 147 is configured to grasp the elongated strips 145 and maintain their orientation. With the first stack 161 supported on the rotatable platform 149 with the elongated strips 145 maintained in a predetermined orientation, the robotic arm 147 can translate relative to the rotatable platform 149 to apply the elongated strips 145 to the first stack 161. After applying one of the elongated strips 145 to the first stack 161, the rotatable platform 149 rotates a predetermined amount (corresponding to the desired angular difference between the elongated strips 145), and the robotic arm 147 applies another elongated strip 145 to the previously applied elongated strip 145 and the first stack. The rotation of the rotatable platform 149 is computer controlled, which helps ensure that the relative orientation of the applied elongated strips 145 to one another or the angular difference between them is within a predetermined minimum tolerance of the desired angular difference between the elongated strips 145.

[0121] According to a particular example, the automation system 100 supplies a continuous length of uncured pre-impregnated fiber reinforced material, such as from a roll, to the robotic arm 147. In one example, the robotic arm 147 grips an end of the continuous length of material, and while gripped, the automation system 100 cuts the material to lengths corresponding to the elongated strips 145 to form the elongated strips 145. Alternatively, in another example, the continuous length of material is cut to lengths corresponding to the elongated strips 145 by a cutter of the automation system 100 before the robotic arm 147 grips the elongated strips 145. In either example, the automation system 100 enables the continuous length of uncured pre-impregnated fiber reinforced material to be cut into the elongated strips 145 simultaneously or nearly simultaneously with gripping by the robotic arm 147. In this manner, the elongated strips 145 can be cut from the continuous length of material and applied to the panel 110 in a continuous, automated process.

[0122] With the foregoing in mind, the panel 110 of the present disclosure may, in some examples, be the same as or similar to the panel disclosed in U.S. Patent Application Publication No. 2012 / 0199882, published August 9, 2012, which is incorporated herein by reference. The panel 110 of the present disclosure, in some examples, is flat and has a generally rectangular perimeter shape. However, in other examples, the panel 110 may define and / or have a perimeter shape other than a rectangle, such as a square, triangle, polygon, etc.

[0123] Whether a quasi-isotropic panel or a cluster panel, a panel 110 of the present disclosure includes a first broad surface 111 (e.g., a first panel broad surface) and a second broad surface 113 (e.g., a second first panel broad surface) opposite the first broad surface 111. The first broad surface 111 is one or more first outwardly facing surfaces of one or more layers 129 of the panel 110 that are not adhesively bonded to another layer 129 of the panel 110. The second broad surface 113 is one or more second outwardly facing surfaces 129 of the panel that are not adhesively bonded to another layer 129 of the panel 110 and that face in the opposite direction from the one or more first outwardly facing surfaces. The first broad surface 111 and the second broad surface 113 are considered broad surfaces because they are parallel to the width and length of the panel and perpendicular to the thickness of the panel, which is less than the width or length of the panel. The first major surface 111 or the second major surface 113 can comprise the outward-facing surface of a single ply 129, as in the case of the quasi-isotropic panel of Figure 23. Alternatively, the first major surface 111 or the second major surface 113 can comprise the outward-facing surfaces of multiple plies 129, for example, the outward-facing surface of the outer ply 129 of the first laminate 161 and the multiple outward-facing surfaces of the elongated strips 145 of the second laminate 163 of the cluster panel of Figures 26 and 27. Thus, the major surface of the panel 110 need not be a single surface.

[0124] 23, 26, and 27, the backing layer 120 is secured to and substantially flush with one or both of the first major surface 111 and the second major surface 113 of the panel 110. As used herein, flush, with respect to the bond between the backing layer 120 and the major surface of the panel 110, means directly abutting or directly adjacent. Furthermore, the backing layer 120 is flush with the major surface if it is substantially flush or substantially flat with the major surface. Thus, even if some small portions of the backing layer 120 are not directly bonded to the major surface, for example, due to small air pockets, the backing layer 120 can still be considered flush with the major surface. 23, 26, and 27, one backing layer 120 (i.e., the first backing layer) is secured to the first broad surface 111 of the panel 110, and another backing layer 121 (i.e., the second backing layer) is secured to the second broad surface 113 of the panel 110. The backing layer 120 is secured to the first broad surface 111 by tack forces created by the adhesive properties of the uncured pre-impregnated fiber-reinforced polymer of the panel 110, which act to adhesively bond the backing layer 120 to the first broad surface 111. Similarly, the backing layer 121 is secured to the second broad surface 113 by tack forces created by the adhesive properties of the panel 110, which adhesively bond the backing layer 121 to the second broad surface 113. The tack provided by the adhesive properties of the pre-impregnated fiber-reinforced polymer is sufficient to hold the backing layer against a large surface, but it can be peeled away with a peel force greater than the tack force. Because the peel force is relatively small, it is possible to manually remove the backing layer, but manually applying a peel force to the backing layer can be difficult because the backing layer's thinness or low profile makes it difficult for it to grip sufficiently to be peeled away from the panel 110.

[0125] Furthermore, the tack force is proportional to the temperature of the pre-impregnated fiber-reinforced polymer. In other words, the higher the temperature, the greater the tack force. If the tack force is too high, the structural integrity of the pre-impregnated fiber-reinforced polymer may be adversely affected because the peel force required to remove the backing layer may be sufficient to pull off a portion of the pre-impregnated fiber-reinforced polymer along with the backing layer. Therefore, maintaining the temperature of the pre-impregnated fiber-reinforced polymer within a predetermined range can promote secure retention of the backing layer to the panel and facilitate removal of the backing layer from the panel 110 without damaging the panel.

[0126] According to some examples, backing layer 120 and backing layer 121 (e.g., second backing layer) are formed from a fibrous material such as paper, a polymeric material such as plastic, or any other type of release or protective film. Accordingly, as used herein, a backing layer can be any type of release film. The backing layer is secured to panel 110 to protect panel 110 from impact damage and contaminants (e.g., dust and debris) during shipping, storage, and handling of panel 110. In some examples, each of layers 129 of panel 110 is cut from a sheet of pre-impregnated fiber-reinforced polymer. The sheet of pre-impregnated fiber-reinforced polymer, which may take the form of a continuous roll of pre-impregnated fiber-reinforced polymer, includes a protective film on both sides of the sheet. After or before layer 129 is cut from the sheet, the protective film is removed from the sheet. Layers 129, including elongated strips 145, if applicable, and from which the protective film has been removed, are then laminated together as described above to form panel 110. After layers 129 are laminated together, backing layers 120 and 121 are secured to first major surface 111 and second major surface 113, respectively, with the backing layers substantially flush with the major surfaces. With the backing layers secured to panel 110, panel 110 is then ready to be assembled into laminate structure 180 using automated system 100.

[0127] 1-8 and 15-18 , various stages of movement of the edge engagement tool 112 relative to the panel 110 are shown. Movement of the edge engagement tool 112 relative to the panel 110 serves to separate only the edge portion 122 of the backing layer 120 from the panel 110. In some examples, the position and orientation of the edge engagement tool 112 relative to the panel 110 is fixed while the edge engagement tool 112 is moving. Thus, the panel 110 is oriented in a backing separation direction A and is located in a backing separation position B relative to the edge engagement tool 112, which allows the edge engagement tool 112 to engage only the edge portion 122 of the backing layer 120. Although not shown, the automated system 100 includes one or more automated tools (e.g., robotic arms or robotic actuators) that fix the panel 110 and move and maintain it in the backing separation direction A and the backing separation position B.

[0128] With the panel 110 in the backing separation direction A and the backing separation position B, the automated system 100 moves the edge engagement tool 112 relative to the panel 110 so that the backing engagement feature 114 of the backing engagement tool 112 engages the backing layer 120 only at the edge portion 122 of the backing layer 120, and only the edge portion 122 of the backing layer 120 separates from the panel 110. The edge portion 122 of the backing layer 120 is a portion of the backing layer 120 that includes a leading edge 124 of the backing layer 120. The leading edge 124 extends along and parallel to the overall width W1 of the panel. Furthermore, the edge portion 122 includes a portion of the backing layer 120 that extends away from the leading edge 124 in a direction parallel to the length L1 of the panel by a distance D that is less than the overall length L1 of the panel 110 (see, for example, FIG. 8 ). In some examples, the distance D is less than half of the overall length L1 of the panel 110. According to another example, the distance D is equal to or less than one-fourth of the total length L1 of the panel 110.

[0129] As shown in FIGS. 1-8 , in some examples, the edge engagement tool 112 includes a plate 116, and the backing engagement feature 114 includes a plurality of protrusions 118. In some examples, the plate 116 is flat and thin. Furthermore, the plate 116 defines an engagement surface 117. The protrusions 118 protrude or extend from the engagement surface 117 of the plate 116. In some examples, the protrusions 118 include a sharp side 126 that includes at least one sharp edge and a blunt side 128 (see, for example, FIGS. 2B, 3B, and 4B). The sharp side 126 is considered the sharp side because it is sharper than the blunt side 128, and the blunt side 128 is considered the blunt side because it is blunter or less sharp than the sharp side 126. The protrusions 118 are arranged on the plate 116 such that the sharp sides 126 of the protrusions 118 all face a first direction and the blunt sides 128 of the protrusions 118 all face a second direction opposite the first direction. The sharp sides 126 are configured to grip, pierce, or penetrate the backing layer 120, and the blunt sides 128 are configured not to pierce or penetrate the backing layer 120.

[0130] The plate 116 is secured to the panel 110 at a plate angle θ1 when the panel 110 is in the backing separation direction A and in the backing separation position B. The plate angle θ1 is the angle defined between the engagement surface 117 and the first broad surface 111 of the panel 110. Furthermore, because the backing layer 120 is flush with the first broad surface 111, the plate angle θ1 is also defined as the angle between the engagement surface 117 and the backing layer 120. The plate angle θ1 is selected so that the backing engagement feature 114 can engage the backing layer 120 and lift at least a portion of the edge portion 122 of the backing layer 120 away from the panel 110 without engaging the panel 110. The plate angle θ1 is an oblique angle, and more specifically, as shown in FIG. 1 , the plate angle θ1 is an acute angle.

[0131] The plate 116 of the edge engagement tool 112 is operably coupled to an actuator (not shown) that, when actuated, causes the plate 116 to move (e.g., reciprocate) along a surface. The surface is angled at a plate angle θ1 and is parallel to the leading edge 124 of the edge portion 122. The plate 116 moves along the surface in a forward direction 171 toward the panel 110 and in a rearward direction 173 opposite the forward direction 171, away from the panel 110. The protrusions 118 are arranged on the plate 116 such that the sharp sides 126 of the protrusions 118 all face in the forward direction 171 and the blunt sides 128 of the protrusions 118 all face in the rearward direction.

[0132] 1, the plate 116 is shown moving in a forward direction 171 toward the panel 110 at a plate angle θ1. As the plate 116 moves in the forward direction 171, the backing engagement features 114 eventually engage the leading edge 124 of the backing layer 120, as shown in FIGS. 2A and 3A. Initially, as shown in FIG. 2A, a first one or more of the backing engagement features 114 engage the leading edge 124 of the backing layer 120, and as the plate 116 moves further in the forward direction 171, additional one or more of the backing engagement features 114 engage the leading edge 124 and potentially the underside of the edge portion 122. In the illustrated example of FIG. 2B, as the plate 116 moves in the forward direction 171, at least a first one of the protrusions 118 at least partially penetrates (e.g., deforms) the leading edge 124 of the backing layer 120. The penetration or deformation of leading edge 124 by sharp side 126 imparts an upward force to leading edge 124, resulting in leading edge 124 partially separating from panel 110. Further movement of plate 116 in forward direction 171 causes a first one or more of protrusions 118 to disengage from backing layer 120 and causes sharp sides 126 of second one or more of protrusions 118 to penetrate or deform leading edge 124 (see, for example, FIG. 3B ). The penetration or deformation of leading edge 124 by sharp sides 126 of second one or more of protrusions 118 imparts an upward force to leading edge 124, resulting in leading edge 124 further separating from panel 110. Further movement of plate 116 in forward direction 171 causes a second one or more of protrusions 118 to disengage from backing layer 120, and the sharp side 126 of another one or more of protrusions 118 to penetrate or deform, lift, and similarly disengage leading edge 124.

[0133] After the plate 116 moves in the forward direction 171 so that the desired number of backing engagement features 114 engage the leading edge 124 of the backing layer 120, the movement of the plate 116 reverses. In other words, as shown in FIG. 8 , the plate 116 moves in the rearward direction 173. As the plate 116 moves in the rearward direction 173, the backing engagement features 114 move along the edge 122 of the backing layer 120 that has separated from the panel 110. More specifically, the blunt side 128 of the protrusion 118 may contact but not penetrate the backing layer 120 (as shown in FIG. 4B ). In this way, the separated portion of the backing layer 120 is not pressed down against the first broad surface 111 and remains separated as the plate 116 moves in the rearward direction 173. As shown in FIG. 5 , the plate 116 continues moving in the rearward direction 173 until the backing engagement features 114 separate from the separated portion of the backing layer 120.

[0134] At least a portion of the edge portion 122 of the backing layer 120 remains separated from the panel 110 after one pass of the plate 116 (i.e., movement of the plate 116 in the forward direction 171 and rearward direction 173). In other words, the edge portion 122 is separated from the leading edge 124 by a distance D'. However, if further separation of the edge portion 122 from the panel 110 is required, one or more additional passes of the plate 116 can be made. For example, as shown in FIGS. 6-8 , a second pass of the plate 116 in the forward direction 171 and rearward direction 173 is made to separate more of the edge portion 122 from the panel 110. In other words, the edge portion 122 is separated by a distance D in FIG. 8 , which is greater than the distance D' in FIG. 5 . Such reciprocating movement of the plate 116, or multiple passes of the plate 116 (i.e., at least two passes) of the plate 116, can be made until the desired separation of the edge portion 122 is achieved. The desired separation of the edge portion 122 corresponds to sufficient separation of the edge portion 122 that the gripping device 130 can grip the separated portion of the backing layer 120 and remove the remaining, unseparated portion of the backing layer 120, as described below.

[0135] In the illustrated example, the backing engagement features 114 of the plate 116 are protrusions having a particular shape, but in other examples, the backing engagement features 114 can be protrusions having various shapes, such as a textured or roughened surface formed on or applied to the plate 116. Alternatively, rather than being protrusions, the backing engagement features 114 can be adhesive films or other coatings that frictionally engage with the edge portions 122 of the panel 110 as the plate 116 moves in the forward direction 171.

[0136] After the desired separation of the edge portion 122 of the backing layer 120 is achieved by the edge engagement tool 112, the separated portion of the backing layer 120 can be manually grasped and removed by a gripping device 130 or automatically grasped and removed. Referring to FIGS. 9-12 , according to some examples, the gripping device 130 is a pinch device including a base 132 and fingers 134. The fingers 134 are operable toward and away from the base to open and close a receptacle 136 of the gripping device 130. Additionally, the base 132 and fingers 134 are movable together relative to the panel 110. As shown in FIGS. 9 and 10 , the gripping device 130 moves in a withdrawal direction relative to the panel 110, as indicated by the arrow, and is positioned to receive a portion of the separated portion of the backing layer 120 (e.g., the leading edge 124) within the receptacle when the receptacle is open. The fingers 134 can then be moved toward the base 132 such that the receptacle 136 is closed, sandwiching the separated portion of the backing layer 120 between the fingers 134 and the base 132. Once the separated portion of the backing layer 120 is sandwiched by the gripping device 130, the gripping device 130 can be moved relative to the panel 110, such as in a removal direction opposite the withdrawal direction, as shown by the arrows in FIG. 11 . As the gripping device 130 moves in the removal direction, the backing layer 120 is peeled and removed from the panel 110. Eventually, as shown in FIG. 12 , the entire backing layer 120 is removed from the panel 110 by the gripping device 130. The gripping device 130 can then peel the backing layer 120, allowing it to be disposed of (e.g., recycled or reused).

[0137] In some examples, the automated system 100 is configured to remove the backing layer from both sides of the panel. According to one example, after the backing layer 120 is removed from the first broad surface 111 of the panel 110, the automated system 100 is configured to invert the panel 110 (e.g., 180°), and the same plate 116 used to remove the backing layer 120 from the first broad surface 111 is used to remove the second backing layer 121 from the second broad surface 113. Alternatively, the panel 110 is not inverted, but is repositioned or reoriented before the plate 116 removes the second backing layer 121. However, in certain examples, as shown in FIGS. 13 and 14 , a second edge engagement tool 162 is used to separate the second backing layer 121 from the second broad surface 113 of the panel 110. The second edge engagement tool 162 is similar to the edge engagement tool 112. For example, the second edge engagement tool 162 includes a plate 166 (e.g., a second tool plate) and a backing engagement feature 115, which may be a protrusion 119. The panel 110 can be positioned and oriented relative to the plate 166 (e.g., at a second backing separation position B′ and a second backing separation direction A′, as shown in FIG. 14 ), and the plate 166 can be moved (e.g., reciprocated) relative to the panel 110 in a manner similar to the plate 116 to separate an edge portion 164 of the second backing layer 121 from the second broad surface 113 of the panel 110.

[0138] 14 , plate 166 is angled relative to plate 116, such that when plate 166 moves to separate edge portion 164 of second backing layer 121 from second broad surface 113 of panel 110, second backing separation direction A′ of panel 110 is the same as backing separation direction A of panel 110. The angle between plate 116 and plate 166 is 90° or less in some examples and less than 90° in other examples. For example, the angle between plate 116 and plate 166 can be less than 45° or less than 30°. Such an angle facilitates efficient separation of backing layer 120 and backing layer 121 from panel 110.

[0139] 14 , plate 166 is coplanar or parallel to plate 116, and when plate 166 separates edge portion 164 of backing layer 121 from second broad surface 113 of panel 110, second backing separation direction A′ of panel 110 differs from backing separation direction A of panel 110. In such examples, after backing layer 120 is removed from panel 110 and before plate 166 separates backing layer 121 from panel 110, panel 110 can be flipped, for example, by 180°. Thus, in some examples, second backing separation direction A′ of panel 110 differs from backing separation direction A of panel 110 by 180°.

[0140] 14 , the automated system 100 further includes a second gripping device 133 that is similar to the gripping device 130 (e.g., has the same features as the gripping device 130). After the edge portion 164 of the second backing layer 121 is separated from the second broad surface 113 of the panel 110, the second gripping device 133 is movable in a collection direction, as indicated by the arrow, and operable to grip the edge portion 164. After gripping the edge portion 164, the second gripping device 133 moves in a removal direction opposite the collection direction to peel the backing layer 121 from the panel 110 until the backing layer 121 is completely removed from the panel 110. The second gripping device 133 can then peel the backing layer 121, allowing the backing layer 121 to be disposed of.

[0141] As shown in FIGS. 15-18 , in some examples, the edge engagement tool 112 includes a wheel 150, and the backing engagement feature 114 includes a plurality of teeth 152. The teeth 152 are spaced circumferentially around the wheel 150, which may extend in a direction parallel to an axis 154 of the wheel 150. In some examples, the wheel 150 has a width at least as large as the width W1 of the panel 110. Further, in some examples, the teeth 152 are elongated such that each of the teeth 152 extends along the entire width of the wheel 150. The wheel 150 rotates in a rotational direction about the axis 154, as indicated by the arrow. Each of the teeth 152 includes a sharp side facing in the direction of rotation. The sharp side of each tooth 152 is configured to grip, pierce, or penetrate the backing layer 120.

[0142] With the panel 110 in the backing separation direction A and at the backing separation position B, the wheel 150 is rotatable about an axis 154, as shown in FIG. 15 , and is translatable toward the panel 110. As the wheel 150 moves above the panel 110 (see, for example, FIG. 16 ), the wheel 150 is positioned relative to the panel 110 such that the teeth 152 of the wheel 150 engage only the leading edge 124 and edge portion 122 of the backing layer 120. As the wheel rotates, the teeth 152 of the wheel 150 repeatedly engage the edge portion 122 of the backing layer 120. Furthermore, as the teeth 152 engage the backing layer 120 and then rotate above and away from it, the edge portion 122 is effectively lifted and separated from the first broad surface 111 of the panel 110. Further translation of wheel 150 along panel 110 results in engagement of teeth 152 with and separation of further portions of edge portion 122 (see, e.g., FIG. 17 ) until a desired amount of edge portion 122 is separated from panel 110 (see, e.g., FIG. 18 ). After the desired amount of edge portion 122 has been separated from panel 110, wheel 150 is pulled away from the separated portion of edge portion 122, as shown by the arrow in FIG. 18 .

[0143] With the wheel 150 pulled away from the panel 110, the separated portion of the backing layer 120 can be manually grasped and removed by the gripping device 130 or automatically grasped and removed. For example, the gripping device 130 can be moved in a collection direction, which can be perpendicular to the panel 110, as shown by the arrow in FIG. 19, and positioned to receive a portion of the separated portion of the backing layer 120 (e.g., the leading edge 124). The fingers 134 can then be moved toward the base 132 (see, e.g., FIG. 20) so that the backing layer 120 is sandwiched between the fingers 134 and the base 132. Once the separated portion of the backing layer 120 is sandwiched by the gripping device 130, the gripping device 130 can be moved relative to the panel 110, such as in a removal direction opposite the collection direction, as shown by the arrow in FIG. 21. As the gripping device 130 moves in the removal direction, the backing layer 120 is peeled off the panel 110. 21, the entire backing layer 120 is removed from the panel 110 by the gripping device 130. The gripping device 130 can then peel off the backing layer 120, which can be disposed of (e.g., recycled or reused).

[0144] 15-18 , in some examples, the edge engagement tool 112 includes a second wheel 151, and the backing engagement feature 114 includes a plurality of second teeth 153. The second wheel 151 is similar to the wheel 150. For example, the second teeth 153 can be circumferentially spaced apart around the second wheel 151, and the second wheel 151 can extend in a direction parallel to an axis 155 of the second wheel 151. In some examples, the second wheel 151 has a width at least equal to the width W1 of the panel 110. Furthermore, in some examples, the teeth 153 are elongated such that each of the second teeth 153 extends along the entire width of the second wheel 151. The second wheel 151 rotates about the axis 155 in a second rotational direction, as indicated by the arrow, which is opposite the rotational direction of the wheel 150. Each of the second teeth 153 includes a sharp side facing in the second rotational direction. The sharp side of each of the teeth 152 is configured to grip, pierce, or penetrate the backing layer 120.

[0145] With the panel 110 in the backing separation direction A and in the backing separation position B, the second wheel 151 is rotatable about an axis 155 and translatable toward the panel 110 and the wheel 150, as shown in FIG. 15 . As the second wheel 151 moves above the panel 110 (see, for example, FIG. 16 ), the second wheel 151 is positioned relative to the panel 110 such that the teeth 153 of the second wheel 151 engage only the trailing edge 125 and the second edge portion 123 of the backing layer 120. As the second wheel rotates, the teeth 153 of the second wheel 151 repeatedly engage the second edge portion 123 of the backing layer 120. Furthermore, after engaging the backing layer 120, the teeth 152 rotate upward and away, effectively lifting and separating the second edge portion 123 from the first broad surface 111 of the panel 110. Further translation of the second wheel 151 along the panel 110 causes the second teeth 153 to engage the second edge portion 123 and separate further portions of the edge portion 123 (see, e.g., FIG. 17 ) until a desired amount of the second edge portion 123 is separated from the panel 110 (see, e.g., FIG. 18 ). After the desired amount of the second edge portion 123 has been separated from the panel 110, the second wheel 151 is pulled away from the separated portion of the second edge portion 123, as shown by the arrow in FIG. 18 .

[0146] With the wheel 150 and the second wheel 151 pulled away from the panel 110, the separated portion of the backing layer 120 can be manually grasped and removed by the gripping device 130 or automatically grasped and removed. For example, the gripping device 130 can have a second finger 135 operable relative to the base 132. The second finger 135 can then be moved toward the base 132 so that the separated portion of the second edge portion 123 is sandwiched between the second finger 135 and the base 132 (see, for example, FIG. 20 ). Once both separated portions of the backing layer 120 are sandwiched by the gripping device 130, the gripping device 130 can be moved relative to the panel 110, such as in a removal direction opposite the collection direction, as shown by the arrows in FIG. 21 .

[0147] 15 , in which two wheels are used to separate the edge portion 122 and the second edge portion 123 of the backing layer 120, as shown in FIG. 40 , according to some examples, two plates can be used to separate the edge portion 122 and the second edge portion 123 of the backing layer 120. More specifically, as disclosed above, the plate 116 of the edge engagement tool 112 can be moved relative to the panel 110 to separate the edge portion 122 of the backing layer 120 from the panel 110, and in certain examples, the plate 166 of the second edge engagement tool 162 can be moved relative to the panel 110 simultaneously with the plate 116 to separate the second edge portion 123 of the backing layer 120. In this manner, the two plates and corresponding backing engagement features can be moved (e.g., reciprocated) to simultaneously separate opposite edge portions of the same backing layer.

[0148] In some examples, the panel 110 is a quasi-isotropic panel, and after the backing layer 120 is removed by the gripping device 130, the panel 110 receives the elongated strips 145, converting the quasi-isotropic panel into a cluster panel.

[0149] 22 , the automated system 100 further includes at least one roller 140. The roller 140 is selectively and automatically operable to roll along the backing layer 120, which is then adhesively secured to the broad surface 111 of the panel 110. Thus, the roller 140 rolls along the backing layer 120 before the backing layer 120 is separated by the edge engagement tool 112 and removed by the gripping device 130. Rolling the roller 140 along the backing layer 120 presses the backing layer 120 against the broad surface 111, promoting flush engagement between the backing layer 120 and the broad surface 111 of the panel 110, which is useful for eliminating waviness in the panel 110 and backing layer 120, and reducing air pockets between the backing layer 120 and the panel 110. Although one roller 140 is shown, the automated system 100 can include a second roller that rolls along the second backing layer 121 secured to the second broad surface 113 of the panel 110 before the second backing layer 121 is separated and removed from the panel 110.

[0150] 29 , according to some examples, a method 300 of forming a laminate structure 180 using an automated system 100 includes (block 310) orienting a first panel 110 and a backing layer 120 secured to the first panel 110 in a backing separation direction A relative to an edge engagement tool 112. The method 300 further includes (block 320) positioning the panel 110 in a backing separation position B relative to the edge engagement tool 112. The method 300 also includes (block 330) moving the edge engagement tool 112 relative to the first panel 110 such that, when the first panel 110 is in the backing separation direction A and in the backing separation position B, the backing engagement features 114 of the edge engagement tool 112 engage the backing layer 120 only at an edge portion 122 of the backing layer 120, and only the edge portion 122 of the backing layer 120 separates from the first panel 110. According to some examples, the temperature of the panel 110 is maintained below a predetermined temperature (e.g., room temperature or 66°F to 72°F (e.g., 68°F)). Maintaining the temperature of the panel 110 below the predetermined temperature is accomplished by blowing air 168, such as from a blower 169 (see, e.g., FIG. 1 ), having a temperature below the predetermined temperature. The method 300 further includes (block 340) gripping the edge portion 122 of the backing layer 120 after the edge portion 122 separates from the first panel 110 and moving the backing layer 120 relative to the panel 110 such that, upon gripping, the entire backing layer 120 separates from the broad surface 111 of the first panel 110. As shown in FIG. 30A , the method 300 further includes (block 350) laminating the first panel 110 to the second panel 184 such that the first panel 110 is directly secured to the second panel 184 by inter-panel tack forces between the pre-impregnated fiber reinforced polymer of the first panel 110 and the pre-impregnated fiber reinforced polymer of the second panel 184, and the first panel 110 and the second panel 184 form at least a portion of the laminate structure 180.

[0151] Referring to FIG. 30B , in some examples, laminate structure 180 includes a plurality of panels 110 (some of which include one of a plurality of clusters 165) that are laminated together as shown, according to block 350 of method 300. In some examples, each of the clusters 165 is applied to a corresponding one of the panels 110 to form a portion of the panel before the panels are laminated together. As shown, laminate structure 180 can include a plurality of panels 110, some of which have clusters 165, each of the panels including multiple layers. Thus, in some examples, laminate structure 180 can include a large number of layers, such as at least 10 layers in certain examples, at least 60 layers in other examples, and 20 to 80 layers in still other examples. The thickness of each layer can be such that the overall thickness of laminate structure 180 is between 3 mm and 6.5 mm. Additionally, because some laminate structures are formed from multiple panels, each having at least one backing layer adhesively attached thereto before being laminated together, a single laminate structure may require multiple backing layer removal processes without degrading the quality of the panels. The automated system 100 and corresponding method 300 of the present disclosure allows for the clean, controlled, and efficient removal of multiple backing layers from multiple panels, making it particularly useful for assembling laminate structures formed from multiple panels. In certain examples, other panels, such as a fiberglass layer 187 formed from a fiberglass material, a single layer 189 formed from a fiber-reinforced polymer other than fiberglass, and a second fiberglass layer 191 formed from a fiberglass material, can be laminated with the illustrated panel 110 and cluster 165.

[0152] In some examples, the method 300 further includes automatically and separately applying the elongated strips 145 to the first stack 161 at different angles to each other to form the clusters 165 of the second stack 163. Automatically and separately applying the elongated strips 145 may include gradually rotating the first stack 161 relative to the elongated strips 145 while maintaining the orientation of the elongated strips 145. Thus, in some examples, automatically and separately applying the elongated strips 145 to the first stack 161 includes gradually rotating the first stack 161 relative to the elongated strips 145 while maintaining the orientation of the elongated strips 145.

[0153] 1 , the method 300 may additionally or alternatively include adjusting the distance between the edge engagement tool 112 and the second panel 184 in a stacking direction 167 perpendicular to the broad surface 111 of the first panel 110 when it is laminated onto the second panel 184 prior to the step of moving the edge engagement tool 112. As the panels are laminated together, the height of the laminate structure 180 changes. The position of the edge engagement tool 112 is adjusted to compensate for the adjustment to the height of the laminate structure 180 and to ensure that the edge engagement tool 112 is properly positioned to engage only the backing layer 120 on the top panel of the laminate structure. Each adjustment to the position of the edge engagement tool 112 may be equal to the thickness of a panel added to the stack of panels forming the laminate structure 180.

[0154] In some examples, the method 300 further includes steps for forming each panel before stacking the panels. For example, the method 300 may include ultrasonically cutting a sheet 360 of pre-impregnated fiber-reinforced polymer into a plurality of layers 129 using a cutter 362, which may be an ultrasonic cutter 362 (see, e.g., FIG. 31 ), stacking a first set of the plurality of layers 129 (e.g., first layer 129A, second layer 129B, third layer 129C, and fourth layer 129D) to form the first panel 110, and stacking a second set of the plurality of layers 129 (e.g., first layer 129A, second layer 129B, third layer 129C, and fourth layer 129D) to form the second panel 184 (see, e.g., FIG. 32 ).

[0155] After laminating the first and second panels, in some examples, the method 300 also includes compressing the first and second panels 110 and 184 using a press 366 (such as a molding press) and heating the first and second panels 110 and 184 with heat 364 to cure the pre-impregnated fiber-reinforced polymer (see, for example, FIG. 33 ). The press 366, in some examples, includes a mold that forms the panels into a desired final shape.

[0156] After curing the first panel 110 and the second panel 184, the method 300 can include roughening an outer surface (e.g., one of the larger surfaces) of one of the first panel 110 or the second panel 184, e.g., with a surface roughening device 368 (e.g., a grinder) to form a roughened outer surface 369 (see, e.g., FIG. 34 ), cleaning the roughened outer surface 369, e.g., with a cleaning agent 372 (e.g., water or chemicals) to form a cleaned roughened outer surface 374 (see, e.g., FIG. 35 ), applying a primer layer 376 to the cleaned roughened outer surface 374 (see, e.g., FIG. 36 ), and applying an ink 378 to the primer layer 376 (see, e.g., FIG. 37 ). The application of the primer layer 376 and the ink 378 can be performed as a single step, such as when the ink 378 can function as the primer layer. In some examples, applying primer layer 376 and / or applying ink 378 can be accomplished in a manner similar to that disclosed in U.S. Patent Application Publication No. 2014 / 0274446, published September 18, 2014, which is incorporated herein by reference in its entirety. In one example, ink 378 includes registration aids, or additional color contrast, or image indicia, printed on one of the exterior surfaces of first panel 110 or second panel 184 using halftone printing, relief printing, thermal transfer printing, inkjet printing, pad printing, or other techniques. These techniques are described in detail in U.S. Patent Application No. 14 / 210,000, filed March 13, 2014, which is incorporated herein by reference in its entirety. Additionally or alternatively, ink 378 includes registration aids, or additional color contrast, or image indicia printed on one of the exterior surfaces of first panel 110 or second panel 184 using inkjet printing, single-pass inkjet printing, or other techniques. These techniques are described in detail in U.S. Patent Application Nos. 17 / 156,205, filed January 22, 2021, 62 / 965,129, filed January 23, 2020, and 63 / 066,033, filed August 14, 2020, which are incorporated by reference herein in their entireties.

[0157] After applying ink 378 to primer layer 376, in some examples, method 300 further includes pressing polymer layer 380 over primer layer 376 and ink 378 to form pre-cut laminate structure 382 (see, e.g., FIG. 38). Method 300 further includes, in some examples, cutting pre-cut laminate structure 382 to form post-cut laminate structure 384 having a predetermined shape (see, e.g., FIG. 39).

[0158] The post-cut laminate structure 384, in some examples, is a striking plate of a golf club head, such as the striking plate 243 of the golf club head 200 of FIG. 28 . The golf club head 200 includes a body 210 defining an opening 237. The striking plate 243 is attached (e.g., glued) to the body 210 through the opening 237, effectively closing the opening 237. The striking plate 243 includes a striking face 245 configured to impact a golf ball during a proper golf shot. In such examples, compressing the first panel 110 and the second panel 184, such as by a press-molding technique, can include shaping the striking plate 243 to incorporate various features into the striking plate 243, such as a desired bulge and roll radius and / or a twisted striking face.

[0159] The bulge and roll radius features that may be incorporated into the striking plate 243 during pressing may be similar to the bulge and roll radius features disclosed in U.S. Pat. No. 8,012,039, issued Sep. 6, 2011, which is incorporated herein by reference in its entirety.

[0160] Twisted striking surface features that can be incorporated into striking plate 243 can be similar to the striking surface features disclosed in U.S. Patent No. 10,881,916, issued January 5, 2021, which is incorporated by reference herein in its entirety. For example, striking surface 245 of striking plate 243 can be twisted such that an upper toe portion of striking surface 245 is more open than a lower toe portion of striking surface 245, and such that a lower heel portion of striking surface 245 is more closed than an upper heel portion of striking surface 245. In certain examples, the golf club head 200 has a volume between 50 cubic centimeters (cc) and 500 cc, between 390 cc and 490 cc, between 100 cc and 430 cc, between 100 cc and 400 cc, between 100 cc and 350 cc, between 100 cc and 300 cc, between 100 cc and 299 cc, between 100 cc and 250 cc, between 100 cc and 200 cc, between 140 cc and 160 cc, or between 149 cc and 154 cc. In certain examples, the golf club head 200 has a volume of 456.6 cc. In particular examples, the ball striking face 245 and / or golf club head 200 has a bulge curvature or radius between 100 millimeters (mm) and 500 mm, between 190 mm and 500 mm, between 200 mm and 450 mm, between 203 mm and 407 mm, between 250 mm and 460 mm, between 224 mm and 355 mm, between 250 mm and 355 mm, between 203 mm and 305 mm, or between 230 mm and 280 mm. In particular examples, the golf club head 200 has a bulge radius of 254 mm or 300 mm. In some examples, the ball striking face 245 and / or golf club head 200 has a roll radius of curvature between 100 mm and 510 mm, between 120 mm and 500 mm, between 150 mm and 500 mm, between 200 mm and 450 mm, between 203 mm and 407 mm, between 224 mm and 355 mm, between 250 mm and 355 mm, between 203 mm and 305 mm, or between 230 mm and 280 mm. In particular examples, the golf club head 200 has a roll radius of 254 mm or 300 mm. The above bulge and roll radius values ​​are applicable to golf club heads having a fiber-reinforced polymer striking plate with a "twisted" bulge and roll radius or without a twisted bulge and roll radius ("non-twist").

[0161] In some examples, the post-cut laminate structure 384 is one of a crown insert, a sole insert, or other portion of a fiber-reinforced polymer golf club head. Alternatively, according to certain examples, the post-cut laminate structure 384 forms at least a portion of a shaft of a golf club. Thus, the same process for making the striking plate 243 can be followed to make the crown insert or sole insert of a golf club head, or the shaft of a golf club.

[0162] In some examples, the methods disclosed herein may be performed manually, while in other examples, the methods are automated. Herein, automated means are operated at least in part by automated devices such as computer numerically controlled (CNC) machines. In some examples, as shown in FIGS. 13, 14, and 25, automated system 100 includes electronic controller 103. The automated devices of automated system 100, which in certain examples can include edge engagement tools, gripping devices, robotic arms, rotatable platforms, and other manufacturing tools disclosed herein, are controlled by electronic controller 103. Additionally, any movement or operation of the functions of automated system 100 disclosed herein may be enabled by a variety of movable automated devices such as actuators (e.g., motors, cylinders, gears, rails, etc.) powered by electrical, pneumatic, magnetic, or hydraulic means.

[0163] The electronic controller 103 may be implemented as a hardware circuit including custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. The electronic controller 103 may also be implemented in a programmable hardware device such as a field programmable gate array, programmable array logic, programmable logic device, or the like.

[0164] The electronic controller 103 may be implemented in code and / or software for execution by various types of processors. An identified module of code may, for example, include one or more physical or logical blocks of executable code, which may be organized as, for example, an object, a procedure, or a function. Nevertheless, the executable files of the electronic controller 103 need not be physically located together, but may include separate instructions stored in various locations that, when logically coupled together, comprise the electronic controller 103 and achieve the described purpose of the electronic controller.

[0165] Indeed, the code of the electronic controller 103 can be a single instruction or many instructions, and can be distributed across several different code segments, among different programs, and across several memory devices. Similarly, operational data can be identified and illustrated herein within the electronic controller 103 and can be embodied in any suitable form and organized within any suitable type of data structure. The operational data can be collected as a single data set or distributed across various locations, including various computer-readable storage devices. When the electronic controller 103 or portions of the electronic controller are implemented as software, the software portions are stored in one or more computer-readable storage devices.

[0166] Any combination of one or more computer readable mediums may be utilized. The computer readable medium may be a computer readable storage medium. The computer readable storage medium may be a storage device that stores code. The storage device may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, holographic, micromechanical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.

[0167] More specific examples of storage devices (a non-exhaustive list) include an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this specification, a computer-readable storage medium can be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0168] Code for carrying out operations of embodiments may be written in a combination of one or more programming languages, including object-oriented programming languages ​​such as Python, Ruby, Java, Smalltalk, C++, etc.; conventional procedural programming languages ​​such as the "C" programming language; and / or machine languages ​​such as assembly language. The code may run entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (e.g., via the Internet using an Internet Service Provider).

[0169] The example aspects are described above with reference to schematic flowchart illustrations and / or schematic block diagrams of example methods, apparatus, systems, and program products. It will be understood that each block of the schematic flowchart illustrations and / or schematic block diagrams, and combinations of blocks in the schematic flowchart illustrations and / or schematic block diagrams, can be implemented by code. Such code can be provided to a processor of the electronic controller 103, which can be a general-purpose computer, a special-purpose computer, or other programmable data processing apparatus, to create a machine such that the instructions, when executed via the processor of the computer or other programmable data processing apparatus, create means for performing the functions / acts specified in one or more blocks of the schematic flowchart illustrations and / or schematic block diagrams.

[0170] The code may also be stored in a storage device that can direct a computer, other programmable data processing apparatus, or other device to function in a particular manner, producing an article of manufacture where the instructions stored in the storage device include instructions that perform the functions / acts specified in one or more blocks of the schematic flowchart diagrams and / or schematic block diagrams.

[0171] The code may also be loaded into a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other device, generating a computer-implemented process in which the code executing on the computer or other programmable apparatus provides a process for performing the functions / acts specified in one or more blocks of the flowcharts and / or block diagrams.

[0172] The schematic flowchart diagrams and / or schematic block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of apparatus, systems, methods, and program products according to various embodiments. In this regard, each block in the schematic flowchart diagrams and / or schematic block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions of code for performing specified logical functions.

[0173] In the foregoing description, certain terms may be used, such as "upper," "lower," "top," "bottom," "horizontal," "vertical," "left," "right," "above," and "below." These terms are used for clarity when dealing with relative relationships, where applicable. However, these terms are not intended to imply absolute relationships, positions, and / or directions. For example, with respect to an object, an "upper" surface may become a "lower" surface simply by flipping the object over. Nevertheless, the object is still the same object. Furthermore, the terms "including," "comprising," "having," and variations thereof mean "including, but not limited to," unless otherwise specified. A listing of enumerated items does not imply that some or all of the items are mutually exclusive and / or mutually inclusive unless otherwise specified. The terms "a," "an," and "the" also mean "one or more" unless otherwise specified. Furthermore, the term "plurality" may be defined as "at least two." Furthermore, unless otherwise specified, a plurality of particular features as defined herein does not necessarily refer to all of the particular features of a particular set or class of features.

[0174] Furthermore, examples herein of an element being "coupled" to another element can include direct coupling and indirect coupling. Direct coupling can be defined as an element being coupled to another element and being in some degree of contact. Indirect coupling can be defined as coupling between two elements that are not in direct contact with each other but have one or more additional elements between the coupled elements. Furthermore, herein, fixing an element to another element can include direct fixing and indirect fixing. Furthermore, herein, "adjacent" does not necessarily mean in contact. For example, an element can be adjacent to another element without being in contact with the other element.

[0175] As used herein, the phrase "at least one," when used in conjunction with a list of items, means that one or more different combinations of the items in the list can be used, and that only one of the items in the list may be required. An item may be a specific object, thing, or category. In other words, "at least one" means that any combination of items, or any number of items, from the list can be used, but not all items in the list are required. For example, "at least one of item A, item B, and item C" may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" may mean, for example, but not limited to, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

[0176] Unless otherwise specified, the terms "first," "second," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which they refer. Furthermore, a reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first," i.e., lower-numbered item, and / or, for example, a "third," i.e., higher-numbered item.

[0177] As used herein, a system, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is in fact capable of performing the particular function without any modification, rather than merely having the capability to perform the particular function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is specifically selected, made, implemented, utilized, programmed, and / or designed for the purpose of performing the particular function. As used herein, "configured" refers to existing characteristics of a system, device, structure, article, element, component, or hardware that enable the system, device, structure, article, element, component, or hardware to perform a particular function without further modification. For purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operable" to perform that function.

[0178] The schematic flowchart diagrams included herein are generally presented as logical flowchart diagrams. As such, the illustrated order and labeled steps represent one example of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Furthermore, it is understood that the format and symbols used are provided to describe the logical steps of the method and do not limit the scope of the method. Various arrow types and line types may be used in the flowchart diagrams, but it is understood that they do not limit the scope of the corresponding method. In fact, some arrows or other connectors may be used to indicate only the logical flow of the method. For example, arrows may indicate wait or monitoring periods of indefinite duration between listed steps of the illustrated method. Furthermore, the order in which a particular method is performed may or may not strictly follow the order of the corresponding steps shown.

[0179] The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced within their scope.

Claims

1. 1. A method for removing a backing layer from a panel formed from an uncured pre-impregnated fiber reinforced polymer, wherein the backing layer is secured and flush against a large surface of the panel by tack forces between the backing layer and the uncured pre-impregnated fiber reinforced polymer; orienting the panel relative to an edge engagement tool in a backing separation direction; positioning the panel in a backing separation position relative to the edge engagement tool; moving the edge engagement tool relative to the panel such that, when the panel is in the backing separation orientation and in the backing separation position, backing engagement features of the edge engagement tool engage the backing layer at only an edge portion of the backing layer, and only the edge portion of the backing layer separates from the panel; gripping the edge portion of the backing layer after the edge portion separates from the panel and moving the backing layer relative to the panel such that, when gripped, the entire backing layer separates from the panel; A method comprising:

2. the edge engagement tool includes a plate, and the backing engagement feature includes a plurality of protrusions extending from the plate; 2. The method of claim 1, wherein the step of moving the edge engagement tool includes reciprocating the plate along a plane angled at a plate angle relative to the panel and parallel to a leading edge of the edge portion when the panel is oriented in the backing separation direction and positioned in the backing separation position, such that only the plurality of protrusions of the plate engage only the edge portion of the backing layer as the plate moves along the plane.

3. The plate reciprocates forward and backward along the surface; the forward direction is opposite to the rearward direction, each engagement between the plurality of projections and the edge portion of the backing layer results in at least partial separation of the backing layer from the panel; When the plate moves in the forward direction, the plurality of protrusions engage with the edge portion; 3. The method of claim 2, wherein the plurality of protrusions do not substantially engage the edge portion as the plate moves in the rearward direction, such that the backing layer is maintained at least partially separated from the panel as the plate moves in the rearward direction.

4. each of the plurality of protrusions includes a sharp side facing the forward direction and a blunt side facing the rearward direction; The method of claim 3 , wherein the engagement of the plurality of protrusions with the edge portion of the backing layer includes sharp sides of the plurality of protrusions at least partially penetrating the edge portion of the backing layer.

5. The method of claim 2 , wherein the plate angle is a bevel angle.

6. The method of claim 5 , wherein the plate angle is an acute angle.

7. 3. The method of claim 2, wherein reciprocating the plate comprises reciprocating the plate at least twice such that the plurality of protrusions of the plate engage only the edge portion of the backing layer at least twice.

8. the edge engagement tool includes a wheel, and the backing engagement features include teeth circumferentially spaced about the wheel; 2. The method of claim 1, wherein the step of moving the edge engagement tool includes: rotating the wheel about an axis parallel to a leading edge of the edge portion of the backing layer such that only teeth of the wheel repeatedly engage the edge portion of the backing layer when the panel is oriented in the backing separation direction and positioned in the backing separation position; and translating the wheel in a wheel direction parallel to the broad surface of the panel as the wheel rotates.

9. the backing layer further includes a second edge portion at an opposite end of the panel from the edge portion; the edge engagement tool further includes a second wheel, and the backing engagement feature further includes second teeth circumferentially spaced about the second wheel; 9. The method of claim 8, wherein the step of moving the edge engagement tool further includes: rotating the second wheel in a rotational direction opposite to the wheel rotational direction about a second axis parallel to a trailing edge of the second edge portion of the backing layer such that only the second teeth of the second wheel repeatedly engage the second edge portion of the backing layer and only the second edge portion of the backing layer separates from the panel; and translating the wheel in a second wheel direction parallel to the broad surface of the panel and opposite to the wheel direction as the second wheel is rotated.

10. further gripping the second edge portion of the backing layer with a second gripping device after the second edge portion separates from the panel while the gripping device is gripping the edge portion of the backing layer; 10. The method of claim 9, further comprising: moving the second gripping device relative to the panel such that the entire backing layer separates from the panel when gripped by the second gripping device and when moving the gripping device relative to the panel.

11. the panel includes a second major surface opposite the major surface; a second backing layer secured and flush against the second broad surface of the panel by a second tack force between the second backing layer and the uncured pre-impregnated fiber reinforced polymer; Furthermore, after the entire backing layer is separated from the panel, orienting the panel in a second backing separation direction relative to a second edge engagement tool; and positioning the panel in a second backing separation position relative to the second edge engagement tool; At least one of the steps; moving the second edge engagement tool relative to the panel such that, when the panel is in the second backing separation orientation and / or the second backing separation position, a second tool backing engagement feature of the second edge engagement tool engages only the second backing layer edge portion of the second backing layer, causing only the second backing layer edge portion of the second backing layer to separate from the panel; 2. The method of claim 1, further comprising: after the second backing layer edge portion has separated from the panel, gripping the second backing layer edge portion of the second backing layer and, when gripped, moving the second backing layer edge portion relative to the panel such that the entire second backing layer separates from the panel.

12. the step of gripping the edge portion of the backing layer includes gripping the edge portion of the backing layer with a gripping device; 12. The method of claim 11, wherein gripping the second backing layer edge portion of the second backing layer comprises gripping the second backing layer edge portion with a second gripping device.

13. The method of claim 11 , wherein orienting the panel in the second backing separation direction relative to the second edge engagement tool comprises flipping the panel over.

14. the second edge engagement tool includes a second tool plate, and the second tool backing engagement feature includes a plurality of second tool protrusions projecting from the second tool plate; 12. The method of claim 11 , wherein moving the second edge engagement tool comprises reciprocating the second tool plate along a second plane angled at a second plate angle relative to the panel and parallel to a second backing layer leading edge of the second backing layer edge portion such that when the panel is oriented in the second backing separation direction and positioned in the second backing separation position, the plurality of second tool protrusions of the second tool plate only engage the second backing layer edge portion of the second backing layer.

15. The method of claim 14 , wherein the second tool plate when reciprocated is flush with or parallel to the plate when reciprocated.

16. The method of claim 14 , wherein the reciprocating second tool plate is angled relative to the reciprocating plate.

17. 17. The method of claim 16, wherein the angle between the reciprocating second tool plate and the reciprocating plate is less than or equal to 90 degrees.

18. The method of claim 1 , wherein the steps of orienting the panel, positioning the panel, moving the edge engagement tool, and gripping the edge portion are automated.

19. 10. The method of claim 1, further comprising pressing the backing layer against the large surface of the panel after orienting the panel in the backing separation direction, after positioning the panel in the backing separation position, and before moving the edge engagement tool.

20. 20. The method of claim 19, wherein pressing the backing layer against the large surface comprises rolling a roller along the backing layer.

21. the panel includes a plurality of layers in a stacked arrangement; each of the plurality of layers includes unidirectional fibers; The method of claim 1 , wherein the unidirectional fibers of at least one of the layers are oriented in a different direction than the unidirectional fibers of at least another one of the layers.

22. The method of claim 1 , further comprising the step of maintaining a temperature of the panel at or below 72° C. during the step of moving the edge engagement tool.

23. 23. The method of claim 22, wherein maintaining the temperature of the panel at or below 72° comprises blowing air onto the panel at a temperature less than 68°.

24. 1. An automated system for removing a backing layer from a panel formed from an uncured pre-impregnated fiber reinforced polymer, the backing layer being secured and flush against a large surface of the panel by tack forces between the backing layer and the uncured pre-impregnated fiber reinforced polymer, the automated system comprising: an edge engagement tool; a gripping device, the edge engagement tool includes a backing engagement feature, the edge engagement tool being movable relative to the panel such that the backing engagement feature of the edge engagement tool engages only an edge portion of the backing layer such that only the edge portion of the backing layer separates from the panel; the gripping device is configured to grip the edge portion when the edge portion is separated from the panel, and is movable relative to the panel such that the entire backing layer separates from the panel when the edge portion is gripped by the gripping device.

25. the edge engagement tool includes a plate; the backing engagement feature includes a plurality of protrusions extending from the plate; the plate is fixed at a plate angle relative to the panel; 25. The automated system of claim 24, wherein the plate is angled relative to the panel at the plate angle and selectively operable to reciprocate along a plane parallel to a leading edge of the edge portion.

26. the plate reciprocates along the surface in a forward direction toward the panel and a rearward direction away from the panel; 26. The automated system of claim 25, wherein each of the plurality of protrusions includes a sharp side facing the forward direction and a blunt side facing the rearward direction.

27. 26. The automated system of claim 25, wherein the plate angle is a bevel angle.

28. 28. The automated system of claim 27, wherein the plate angle is an acute angle.

29. further comprising a second edge engagement tool including a second tool backing engagement feature; the panel includes a second major surface opposite the major surface; a second backing layer secured and flush against the second broad surface of the panel by tack forces between the second backing layer and the uncured pre-impregnated fiber reinforced polymer; the second edge engagement tool includes a second tool plate, and the second tool backing engagement feature includes a plurality of second tool protrusions projecting from the second tool plate; the second tool plate is fixed at a second plate angle relative to the panel; 26. The automated system of claim 25, wherein the second tool plate is angled relative to the panel at the second plate angle and selectively operable to reciprocate along a plane parallel to a second backing layer leading edge of a second backing layer edge portion of the second backing layer.

30. 30. The automated system of claim 29, wherein the second tool plate when reciprocated is flush with or parallel to the plate when reciprocated.

31. 30. The automated system of claim 29, wherein the reciprocating second tool plate is angled relative to the reciprocating plate.

32. the edge engagement tool includes a wheel; the backing engagement features include teeth spaced circumferentially around the wheel; 25. The automated system of claim 24, wherein the wheel rotates about an axis parallel to a leading edge of the edge portion of the backing layer and is selectively operable to translate parallel to the broad surface of the panel while the wheel rotates.

33. the backing layer further includes a second edge portion at an opposite end of the panel from the edge portion; the edge engagement tool further includes a second wheel; the backing engagement feature further includes second teeth spaced circumferentially around the second wheel; 33. The automated system of claim 32, wherein the second wheel rotates about an axis parallel to the trailing edge of the second edge portion of the backing layer in a rotational direction opposite to that of the wheel, and is selectively operable to translate parallel to the broad surface of the panel while the second wheel rotates.

34. 25. The automated system of claim 24, further comprising a roller selectively operable to roll along the backing layer when the backing layer is adhesively secured to the extensive surface of the panel.

35. 1. A method of forming a laminate structure, comprising: orienting a first panel and a backing layer secured to the first panel in a backing separation direction relative to an edge engagement tool, the first panel being formed from an uncured pre-impregnated fiber reinforced polymer, and the backing layer being secured to the first panel broad surface of the first panel by backing-to-panel tack forces between the backing layer and the uncured pre-impregnated fiber reinforced polymer of the first panel; positioning the first panel in a backing separation position relative to the edge engagement tool; moving the edge engagement tool relative to the first panel such that, when the first panel is in the backing separation orientation and in the backing separation position, backing engagement features of the edge engagement tool engage the backing layer at only an edge portion of the backing layer and only the edge portion of the backing layer separates from the first panel; After the edge portion separates from the first panel, grasping the edge portion of the backing layer and moving the backing layer relative to the first panel such that, when grasped, the entire backing layer separates from the first panel broad surface of the first panel; laminating the first panel to a second panel formed from the uncured pre-impregnated fiber reinforced polymer such that the first panel is directly secured to the second panel by inter-panel tack forces between the pre-impregnated fiber reinforced polymer of the first panel and the uncured pre-impregnated fiber reinforced polymer of the second panel, the first panel and the second panel forming the laminate structure.

36. 36. The method of claim 35, wherein the step of laminating the first panel to the second panel comprises laminating the first panel to the second panel such that the first panel major surface is directly secured to the second panel major surface of the second panel by the inter-panel tack force.

37. the first panel includes a second first panel major surface opposite the first panel major surface; a second backing layer is secured and flush against the second first panel broad surface of the panel by a second tack force between the second backing layer and the uncured pre-impregnated fiber reinforced polymer; laminating the first panel to the second panel includes positioning the first panel in a second backing separation position relative to a second edge engagement tool; Furthermore, moving the second edge engagement tool relative to the first panel when the first panel is in the second backing separation position such that a second tool backing engagement feature of the second edge engagement tool engages only a second backing layer edge portion of the second backing layer and only the second backing layer edge portion of the second backing layer separates from the panel; 37. The method of claim 36, including gripping the second backing layer edge portion of the second backing layer after the second backing layer edge portion has separated from the first panel, and, when gripped, moving the second backing layer edge portion relative to the first panel such that the entire second backing layer separates from the first panel.

38. 36. The method of claim 35, wherein the step of moving the edge engagement tool to grip the edge portion of the backing layer occurs after the step of laminating the first panel to the second panel.

39. each of the first panel and the second panel includes a plurality of layers in a stacked arrangement; 36. The method of claim 35, wherein each of the plurality of layers of the first panel and the second panel comprises unidirectional fibers.

40. the unidirectional fibers of at least one of the layers of the first panel are oriented in a different direction than the unidirectional fibers of at least another one of the layers of the first panel; 40. The method of claim 39, wherein the unidirectional fibers of at least one of the layers of the second panel are oriented in a different direction than the unidirectional fibers of at least another one of the layers of the second panel.

41. 41. The method of claim 40, wherein the plurality of layers of at least one of the first panel and the second panel consists of four layers including a first layer in which the unidirectional fibers are oriented at 0°, a second layer in which the unidirectional fibers are oriented at +45°, a third layer in which the unidirectional fibers are oriented at 90°, and a fourth layer in which the unidirectional fibers are oriented at −45°.

42. 41. The method of claim 40, wherein the plurality of layers of both the first panel and the second panel consists of four layers including a first layer in which the unidirectional fibers are oriented at 0°, a second layer in which the unidirectional fibers are oriented at +45°, a third layer in which the unidirectional fibers are oriented at 90°, and a fourth layer in which the unidirectional fibers are oriented at −45°.

43. 40. The method of claim 39, wherein the plurality of layers of the first panel and / or the second panel consists of four layers each having unidirectional fibers oriented at 0°.

44. the layers of the first panel are arranged as a first stack and a second stack; the second stack is stacked on the first stack, the layers of the first stack are aligned; the layers of said second stack are not aligned; each of the layers of the second laminate includes an elongated strip; the elongated strips of the second stack form clusters; 40. The method of claim 39, wherein the first panel broad surface includes portions of the first laminate and the cluster such that the backing layer is secured to portions of both the first laminate and the cluster.

45. 45. The method of claim 44, further comprising automatically separately applying the elongated strips to the first stack at different angles relative to each other to form the clusters of the second stack.

46. 46. ​​The method of claim 45, wherein automatically separately applying the elongated strips to the first stack comprises gradually rotating the first stack relative to the elongated strips while maintaining an orientation of the elongated strips.

47. 36. The method of claim 35, further comprising, before the step of moving the edge engagement tool, adjusting a distance between the edge engagement tool and the second panel in a stacking direction perpendicular to a broad surface of the first panel when the first panel is laminated to the second panel.

48. each of the first panel and the second panel includes a plurality of layers in a stacked arrangement; Furthermore, ultrasonically cutting a sheet formed from the uncured pre-impregnated fiber reinforced polymer into a plurality of layers; laminating the first set of layers to form the first panel; and laminating the second set of layers to form the second panel.

49. 49. The method of claim 48, further comprising pressing the first panel and the second panel together and applying heat after the first panel is laminated to the second panel so that the uncured pre-impregnated fiber reinforced polymer is cured.

50. Furthermore, after the step of pressing and heating the first panel and the second panel, roughening an exterior surface of one of the first panel or the second panel to form a roughened exterior surface; cleaning the roughened outer surface to form a cleaned roughened outer surface; applying a primer layer to the cleaned, roughened exterior surface; and applying ink to the primer layer.

51. 51. The method of claim 50, further comprising pressing a polymer layer onto the primer layer and the ink to form a pre-cut laminate structure.

52. 52. The method of claim 51, further comprising cutting the pre-cut laminate structure to form a post-cut laminate structure having a predetermined shape.

53. 53. The method of claim 52, wherein the post-cut laminate structure comprises a striking plate of a golf club head.

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