Automated Composite Lamina Backing Film Separation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The initial separation of backing paper from pre-impregnated composite materials is typically done manually, which is time-consuming and prone to damage or contamination, hindering the automation of composite ply handling and placement.

Innovation Solution

An automated method and system that applies a controlled mechanical impact force to the edge of the composite lamina using various mechanical devices, such as rotating filaments or air jets, to delaminate the backing film without damaging the composite material, enabling initial separation and subsequent full automation of the backing paper removal process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual backing paper removal is used, then the process is simple and requires minimal equipment, but it is time-consuming and prone to damage or contamination of the composite ply

Engineering Contradiction:

Improvebacking paper removal speedVSAvoiddamage and contamination risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces manual mechanical removal with an automated mechanical impact system that uses controlled impact forces to initiate delamination. The system employs an automated tool to apply precise mechanical impacts to the composite ply edge, causing the backing paper to separate without manual handling, thereby increasing both speed and reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies preliminary action by using impact forces to initiate delamination at the edge of the composite ply before the main removal process. This preliminary separation at the edge makes subsequent backing paper removal easier and more reliable, as the backing is already partially separated and can be removed more efficiently.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If automated tools are used for initial separation, then productivity increases and manual labor is reduced, but the complexity of the device increases

Engineering Contradiction:

Improveautomation levelVSAvoidseparation device complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent uses an intermediary approach by employing a support structure with a defined edge that facilitates the separation process. The support structure acts as an intermediary between the automated impact tool and the composite ply, providing a controlled environment for initiating delamination while keeping the overall system relatively simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the backing paper removal process into two distinct stages: (1) initial delamination at the edge using automated impact, and (2) subsequent removal of the separated backing. This segmentation allows each stage to be optimized independently, with the first stage using simple automated impacts and the second stage using various removal methods.

Inventive Principle:

Principle #1Segmentation

3Extent of automation

If impact force is applied to separate backing paper, then delamination is achieved without manual handling, but there is risk of damaging the composite lamina

Engineering Contradiction:

Improveinitial separation automationVSAvoidcomposite lamina integrity

Core Design Contradiction:

Extent of automationVSStrength

Solution Approach 1:

The patent applies local quality by concentrating the impact force specifically at the edge of the composite ply where delamination is needed, rather than applying force across the entire surface. This localized application of impact ensures separation occurs only where required while preserving the integrity of the main composite structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses partial action by applying impact forces only to initiate delamination at the edge, not to complete the entire removal process. The impact is sufficient to start the separation but not excessive enough to damage the composite, with the remaining removal accomplished by other means.

Inventive Principle:

Principle #16Partial or excessive action

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 approach automates the initial separation of backing paper, reducing manual labor, minimizing damage and contamination, and facilitating the total automation of composite ply handling, thereby enhancing production efficiency and reducing costs.

Implementation Method 1

applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS9358770B2System and method for automated initial separation of composite ply backing

Publication Date: 2016.06.07 THE BOEING CO

AI summary

A method for initial separation of an adhered backing film from an uncured pre-impregnated composite lamina having an edge includes exposing and supporting the edge of the composite lamina, and applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.