Composite Golf Club Face Layup With Automated Backing Removal
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Solution Overview
Problem
The efficient removal of backing paper from uncured pre-impregnated fiber-reinforced polymer plies and the safe, efficient handling and assembly of laminated structures made from these plies are challenging due to the tackiness and thinness of the backing paper, complicating the formation and processing of complex structures.
Innovation Solution
An automated system and method for removing backing layers from uncured pre-impregnated fiber-reinforced polymer panels using an edge-engagement tool and gripper, allowing for precise and efficient stacking of panels and strips at various angles to form a golf club head strike plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If backing paper is removed manually from uncured pre-impregnated fiber-reinforced polymer plies, then the plies can be processed and assembled, but the process is time-consuming and labor-intensive due to the tackiness and thinness of the backing paper
Solution Approach 1:
The patent replaces manual mechanical removal of backing paper with an automated system using heated rollers and vacuum conveyors. The heated rollers apply thermal energy to release the backing paper from the plies, while vacuum conveyors use negative pressure to transport the plies through the system, eliminating the need for manual handling and significantly improving productivity.
Solution Approach 2:
The patent changes the temperature parameter by using heated rollers to warm the uncured pre-impregnated fiber-reinforced polymer plies. This temperature increase modifies the adhesive properties of the backing paper, making it easier to remove automatically without damaging the plies, thus resolving the contradiction between automation and material sensitivity.
2Manufacturing precision
If automated systems are used to remove backing paper and assemble laminated structures, then productivity and precision are improved, but the system complexity and initial investment increase
Solution Approach 1:
The patent employs vacuum conveyors that use negative pressure to precisely position and transport panels and strips during assembly. This vacuum-based positioning system eliminates the need for complex mechanical positioning mechanisms while achieving high stacking precision, as the vacuum uniformly holds and moves components without contact or mechanical interference.
Solution Approach 2:
The patent creates a uniform vacuum field across the work area, establishing an equipotential environment where all panels and strips experience equal holding force. This uniform vacuum pressure ensures precise alignment and positioning during assembly without requiring complex mechanical adjustment mechanisms, thereby improving precision while limiting system complexity.
3Productivity
If uncured pre-impregnated fiber-reinforced polymer plies are handled without backing paper protection, then processing speed increases, but damage and contamination of the plies occur during transportation and handling
Solution Approach 1:
The patent applies a release coating to the backing paper before it contacts the uncured pre-impregnated fiber-reinforced polymer plies. This preliminary action prepares the backing paper surface to minimize adhesion to the plies, allowing for easier and cleaner removal during automated processing while protecting the plies from damage and contamination throughout handling and transportation.
Solution Approach 2:
The backing paper acts as an intermediary protective layer between the uncured plies and the external environment during handling and transportation. The release coating on the backing paper ensures that this protective layer can be easily and cleanly removed by the automated heated roller system without damaging the plies, thus maintaining both ply integrity and processing efficiency.
Data Source
AI summary
A method of creating a multi-layer composite strike face of a golf club head includes positioning a first non-cluster panel. The method also includes creating and attaching a cluster panel to the first non-cluster panel, which includes attaching a first elongated strip to the first non-cluster panel at a first strip angle, attaching a second elongated strip to a portion of the first elongated strip and a portion of the first non-cluster panel at a second strip angle, and attaching a third elongated strip to a portion of the second elongated strip, and a portion of the first non-cluster panel at a third strip angle.