Composite Laminate Peel Ply Removal for Clean Bonding Surfaces

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Solution Overview

Problem

Traditional peel ply removal methods in composite laminates often result in breakage, residue, and damage to the bonding surface, making the process time-consuming and compromising the quality of the bond.

Innovation Solution

A method involving the selective removal of a portion of main body plies to create a lip from peel plies, allowing for crack initiation and peeling without direct contact, using structural peel plies that contribute to the laminate's strength and rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional peel plies are used and removed manually, then the bonding surface is exposed, but the peel plies break into multiple pieces and leave residue on the bonding surface

Engineering Contradiction:

Improvebonding surface qualityVSAvoidpeel ply removal difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The composite laminate is divided into distinct regions: a first region containing the bonding surface with peel plies, and a second region without peel plies. This segmentation allows the peel plies to be removed from the first region while the second region provides structural support and prevents breakage, thereby improving bonding surface quality without compromising ease of operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second region of the composite laminate acts as an intermediary element that provides mechanical support during the peel ply removal process. This intermediary structure prevents the peel plies from breaking into multiple pieces and leaving residue, enabling clean removal while maintaining ease of operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If traditional peel plies are removed by forcing tools between layers, then the peel plies can be separated, but the bonding surface may be damaged

Engineering Contradiction:

Improvepeel ply separationVSAvoidbonding surface integrity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

By segmenting the laminate into a first region with peel plies and a second region without peel plies, the invention enables easy peel ply separation in the first region while the second region remains intact and undamaged, preserving bonding surface integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The peel plies are selectively extracted from the first region of the laminate while leaving the second region intact. This extraction method allows for easy removal without requiring forceful tool insertion that could damage the bonding surface, thus maintaining bonding surface integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If peel plies are used to protect the bonding surface during fabrication, then adhesion is enhanced, but the removal process becomes time-consuming

Engineering Contradiction:

Improvebonding surface protectionVSAvoidpeel ply removal time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The laminate is segmented into a first region where peel plies provide protection during fabrication and a second region without peel plies. This segmentation enables rapid removal of peel plies from the first region while the second region provides structural support, reducing overall removal time without compromising bonding surface protection during fabrication.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The peel plies are selectively extracted from the first region after serving their protective function during fabrication. This extraction process is streamlined by the presence of the second region, which provides structural support and enables faster removal, thereby increasing productivity without sacrificing bonding surface protection.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Facilitates clean and efficient exposure of the bonding surface, reducing damage and residue, while maintaining the integrity of the laminate during the peel ply removal process.

Implementation Method 1

applying a force to the lip to initiate a crack between the peel plies and the main body plies within the interim composite laminate

Methodology Applied

Scientific EffectCrack initiation: Fracture Mechanics

Implementation Method 2

peeling the lip away from the main body plies to remove the peel plies from the main body plies to form the composite laminate and expose the bonding surface

Methodology Applied

Scientific EffectPeeling: Friction

Data Source

PatentUS20260077564A1Method of preparing a bonding surface on a composite laminate and associated composite laminate

Publication Date: 2026.03.19 THE BOEING CO

AI summary

Disclosed herein is a method of preparing a bonding surface on a composite laminate and an associated composite laminate. The method involves forming a layup of multiple fiber-reinforced plies, including main body plies with a first combined thickness and peel plies with a second combined thickness. The method also includes selectively removing a portion of the main body plies along an edge to create an interim composite laminate with a lip defined by the peel plies. A force is applied to the lip to initiate a crack between the peel plies and the main body plies. The lip is then peeled away from the main body plies to remove the peel plies and expose a bonding surface on the composite laminate.