Automated Backing Film Removal Using Mechanical Shear
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Solution Overview
Problem
The manual removal of backing films from pre-impregnated materials is time-consuming and prone to damage, and existing automated methods using vacuum grippers are unreliable in an industrial setting due to adhesive forces overcoming gripping forces.
Innovation Solution
A backing film removal system comprising a substrate support member, a backing film separating member, and a drive unit that moves the separating member between the substrate and backing film to apply shearing and tension forces for reliable separation, with a backing film collection unit to manage the removed film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If vacuum grippers are used to grip and pull the backing film and pre-impregnated material apart, then automation is improved, but reliability deteriorates because adhesive forces occasionally overcome gripping forces
Solution Approach 1:
A separating member is introduced as an intermediary element between the backing film and the pre-impregnated material. This separating member actively inserts itself between the bonded layers and uses mechanical motion to break the adhesive bond, providing a more reliable separation mechanism than vacuum grippers alone. The separating member acts as a mediator that directly addresses the adhesive force problem by physically interposing itself in the separation zone.
Solution Approach 2:
The patent replaces the vacuum-based gripping system with a mechanical separating system. Instead of relying on vacuum pressure to hold and pull apart the materials, the invention uses a mechanically actuated separating member that inserts between the layers and uses controlled mechanical motion to break the adhesive bond. This substitution provides more reliable separation by directly addressing the adhesive force through mechanical means rather than relying on vacuum grip strength.
2Manufacturing precision
If manual removal of backing film is performed, then damage and contamination are reduced, but productivity deteriorates due to time-consuming process
Solution Approach 1:
The patent replaces manual removal operations with an automated mechanical separating system. The separating member is mechanically actuated to insert between the backing film and pre-impregnated material, and controlled motion systems drive the separation process. This automation maintains the gentle, controlled separation needed to prevent damage while dramatically increasing productivity by eliminating manual labor.
Solution Approach 2:
The separating member is designed to automatically insert and perform the separation function without requiring manual intervention. The system uses self-contained mechanical actuation and control systems that enable the separating member to autonomously perform the backing film removal task, combining automated efficiency with the gentle handling characteristics of manual processes.
3Ease of operation
If two vacuum grippers are employed to grip from opposite directions, then ease of operation is improved, but reliability deteriorates when adhesive forces exceed gripping forces
Solution Approach 1:
The separating member serves as an active intermediary that inserts itself between the backing film and pre-impregnated material. Rather than relying on vacuum grippers to pull apart the bonded layers, the separating member directly engages the separation zone and uses controlled mechanical motion to break the adhesive bond. This provides more consistent and reliable separation while maintaining operational simplicity through automated actuation.
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
The system automates the removal process, ensuring efficient and reliable separation of backing films from pre-impregnated materials, reducing damage and increasing production efficiency by using controlled mechanical forces rather than vacuum grippers.
Implementation Method 1
moving the backing film separating member relative to the substrate so that the backing film separating member is passed between the backing film and the substrate from the first location along a length of the substrate to separate the backing film from the substrate
Implementation Method 2
apply shearing and tension forces for reliable separation
Data Source
AI summary
A backing film removal system including a substrate support member configured to support a substrate, where a backing film is attached to the substrate, a backing film separating member arranged operatively with respect to the substrate support member such that at least a portion of the backing film separating member is positionable between at least one portion of the substrate and backing film when the substrate is disposed on the substrate support member, a backing film holding member configured to maintain a separation between the substrate and backing film at the at least one portion of the substrate and backing film, and at least one drive unit connected to one or more of the substrate support member and the backing film separating member and operable to cause relative movement between the substrate support member and the backing film separating member.