Composite Edge Delamination for Lamination Uniformity
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Solution Overview
Problem
Conventional lamination processes often result in non-uniformities at the edges of composite materials, which can hinder downstream manufacturing processes and require costly solutions like discarding or using fixed-width nip rollers.
Innovation Solution
A method and system that involve a nip roller assembly for laminating composite materials and a delaminator to selectively delaminate edges of the laminated composite material, allowing it to lie flat and be processed effectively without wasting material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lamination processes are used with standard nip rollers, then the lamination of composite materials is achieved, but edge non-uniformities such as curling, wrinkles, and waves occur
Solution Approach 1:
The lamination process is segmented into two distinct stages: a first lamination pass that bonds the composite material layers, followed by a controlled delamination step that separates only the edge portions. This segmentation allows the main body to remain laminated while edges are treated separately to eliminate non-uniformities without affecting the overall lamination integrity.
Solution Approach 2:
Instead of attempting to prevent edge non-uniformities during the lamination process itself, the invention inverts the approach by deliberately delaminating the edges after lamination. This reverse approach removes the problematic edge portions that cause curling and wrinkles, then allows selective relamination if needed, achieving edge uniformity through removal rather than prevention.
2Manufacturing precision
If reduced-width nip rollers are used to avoid laminating edges, then edge non-uniformities are reduced, but the device complexity and cost increase due to fixed-size roller requirements
Solution Approach 1:
The invention transforms the static, fixed-width nip roller configuration into a dynamic system where the effective lamination width can be adjusted. By using full-width rollers followed by selective edge delamination, the system achieves variable edge treatment capability without requiring multiple fixed-size rollers, thereby reducing device complexity while maintaining edge uniformity.
Solution Approach 2:
The invention performs preliminary lamination of the entire composite material including edges, then subsequently removes only the problematic edge portions. This preliminary action of laminating everything first simplifies the roller configuration requirement, as standard full-width rollers can be used without needing specially designed reduced-width rollers.
3Manufacturing precision
If non-uniform edge portions are discarded by severing them, then edge non-uniformities are eliminated, but material waste and costs increase
Solution Approach 1:
The invention selectively discards only the problematic edge portions that exhibit non-uniformities through controlled delamination, while preserving and retaining the majority of the laminated composite material. This selective discarding approach minimizes material waste compared to severing entire edge portions, as only the specific delaminated edge sections are removed rather than larger amounts of usable material.
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 delamination process improves the flatness and consistency of composite materials, enhancing their usability in downstream manufacturing operations and reducing waste and costs associated with non-uniform edges.
Implementation Method 1
heat or pressure may be applied to two or more layers which cause them to adhere, bind, or otherwise become fixed together
Implementation Method 2
heat or pressure may be applied to two or more layers which cause them to adhere, bind, or otherwise become fixed together
Implementation Method 3
laminating, by the nip roller assembly, the first and second layer material to provide a laminated composite material
Data Source
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AI summary
Methods and systems according to one or more examples are provided for laminating composite materials. In one example, a method comprises receiving a first layer material and a second layer material at a nip roller assembly and laminating, by the nip roller assembly, the first and second layer material to provide a laminated composite material comprising a main portion and at least one edge portion. The method further comprises delaminating the at least one edge portion of the laminated composite material to provide a partially laminated composite material for use in manufacturing a composite product.