Automated Prepreg Backing Removal for Precise Lamination

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Solution Overview

Problem

Efficient automated removal of backing layers from uncured pre-impregnated fiber-reinforced polymer panels is challenging due to the tackiness and thinness of the backing paper, which can lead to damage during handling and processing.

Innovation Solution

An automated system and method using edge-engagement tools with protrusions and grippers to selectively engage and separate the backing layer from the panel, employing angled reciprocation and rotation to minimize contact and facilitate separation, followed by gripping and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If backing paper is removed manually or by conventional automated methods, then the backing layer can be separated from the panel, but the thinness and tackiness of the backing paper causes damage to the uncured pre-impregnated fiber-reinforced polymer during handling

Engineering Contradiction:

Improveintegrity of uncured pre-impregnated fiber-reinforced polymerVSAvoiddifficulty of automated backing paper removal

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The backing paper removal process is segmented into distinct phases: initial engagement at the edge portion, controlled separation of just the edge portion from the panel, and subsequent complete removal. This segmentation allows precise control over the separation process, preventing damage to the fragile uncured pre-impregnated fiber-reinforced polymer while enabling automated operation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The edge-engagement tool is designed to engage only the edge portion of the backing paper initially, not the entire backing layer. This localized engagement approach allows controlled separation starting from the edge, minimizing stress on the tacky uncured pre-impregnated fiber-reinforced polymer surface while progressively removing the thin backing paper

Inventive Principle:

Principle #3Local quality

2Productivity

If automated tools engage the entire backing layer, then removal efficiency increases, but the thinness of the backing paper causes it to tear or damage the polymer surface

Engineering Contradiction:

Improveefficiency of backing paper removalVSAvoidprecision of backing paper separation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The edge-engagement tool performs preliminary action by first engaging only the edge portion of the backing paper and separating it from the panel before complete removal. This preliminary separation creates a controlled starting point that prevents tearing and enables subsequent smooth, automated removal of the entire backing layer without damaging the uncured pre-impregnated fiber-reinforced polymer

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The automated system dynamically adjusts the engagement strategy: initially engaging only the edge portion with the edge-engagement tool, then transitioning to gripping and removing the separated edge portion, and finally completing the removal of the entire backing layer. This dynamic approach optimizes both precision during initial separation and productivity during complete removal

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient and precise removal of backing layers without damaging the underlying polymer, allowing for automated stacking and formation of laminated structures with improved precision and efficiency.

Implementation Method 1

backing-engagement features of the edge-engagement tool engage the backing layer, at only an edge portion of the backing layer, and just the edge portion of the backing layer separates from the panel

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

gripping the edge portion of the backing layer, after the edge portion separates from the panel, and, when gripped, moving the backing layer relative to the panel

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12403684B2Automated system and method for forming a laminated structure

Publication Date: 2025.09.02 TAYLOR MADE GOLF CO INC

AI summary

A method of removing a backing layer from a panel, made of an uncured pre-impregnated fiber-reinforced polymer, comprises a step of orienting the panel into a backing-separation orientation relative to an edge-engagement tool. The method also comprises a step of positioning the panel into a backing-separation position relative to the edge-engagement tool. The method further comprises a step of moving the edge-engagement tool, when the panel is in the backing-separation orientation and the backing-separation position, so that backing-engagement features of the edge-engagement tool engage the backing layer, at only an edge portion of the backing layer, and just the edge portion of the backing layer separates from the panel. The method additionally comprises a step of gripping the edge portion of the backing layer, and, when gripped, moving the backing layer relative to the panel so that an entirety of the backing layer separates from the panel.