Backing Sheet Residue Removal via Controlled Heating
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Solution Overview
Problem
Current methods for manufacturing reinforced composite structures result in the contamination of backing sheet materials with resin residue, leading to their disposal after a single use, thus increasing waste and limiting the reuse of these materials.
Innovation Solution
A process involving the controlled heating of backing sheet materials to a temperature just above the resin's minimum viscosity, allowing the resin residue to soften and be removed without damaging the sheet or release coating, enabling the reuse of the sheet material for further pre-preg production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If backing sheet materials are discarded after single use due to resin residue contamination, then the manufacturing process is simple and quick, but waste increases and material reuse is limited
Solution Approach 1:
The patent applies parameter changes by controlling the temperature parameter to a specific range (5-15°C above the resin's minimum viscosity temperature) to achieve selective softening of resin residue without damaging the backing sheet or release coating. This controlled thermal parameter change enables resin removal while preserving the backing sheet for reuse, directly resolving the contradiction between manufacturing speed and waste reduction.
Solution Approach 2:
The patent utilizes phase transitions of the resin material, specifically the transition from solid to softened/liquid state through controlled heating. By heating to just above the minimum viscosity temperature, the resin undergoes phase change and becomes removable, while the backing sheet remains stable. This phase transition mechanism enables selective removal of resin residue, allowing backing sheet reuse and reducing waste.
2Ease of manufacture
If heating is applied to remove resin residue, then resin can be softened and removed, but the sheet material or release coating may be damaged if temperature is too high
Solution Approach 1:
The patent precisely controls the temperature parameter within a narrow range (5-15°C above minimum viscosity) to achieve the desired effect. This controlled parameter change ensures sufficient heat for resin softening while preventing thermal damage to the backing sheet and release coating, resolving the contradiction between ease of resin removal and prevention of thermal damage.
Solution Approach 2:
The patent converts the potentially harmful effect of heat into a beneficial process by carefully controlling temperature to exploit the resin's minimum viscosity point. The heat that could cause damage is instead used selectively to soften resin for removal, transforming a harmful factor into a useful tool for resin removal while preserving the backing sheet.
3Ease of manufacture
If conventional heating methods are used to remove resin, then resin can be removed, but the release coating may be damaged or degraded
Solution Approach 1:
The patent controls temperature parameters within a specific range (5-15°C above minimum viscosity) that is sufficient to soften resin but below the degradation threshold of the release coating. This precise parameter control ensures resin removal while maintaining release coating integrity, resolving the contradiction between ease of resin removal and coating reliability.
Solution Approach 2:
The patent applies local quality by targeting the heating effect specifically at the resin residue locations rather than uniformly heating the entire backing sheet. This localized thermal treatment softens resin for removal while leaving the release coating and backing sheet at lower temperatures that preserve their integrity and reliability.
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
This method allows for the effective removal of resin residue from backing sheet materials, enabling their reuse and reducing waste in the manufacturing process by maintaining the integrity of the sheet and release coating, thus optimizing the production of reinforced composite materials.
Implementation Method 1
A process involving the controlled heating of backing sheet materials to a temperature just above the resin's minimum viscosity, allowing the resin residue to soften and be removed
Data Source
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AI summary
Removal of resin residue from backing sheet Residual thermally softenable resin remaining from application of a temporary coating layer to a surface of a sheet material, which resin has a minimum viscosity at an elevated temperature, is removed from the surface by: (a) directing a non-contact heat source towards the surface so as to heat and reduce the viscosity of the residual resin on the surface, and (b) removing heated residual resin from the surface. The sheet material is preferably release coated paper, which can be reused after removal of the residual resin as a temporary backing layer in the production of reinforced composites.