Composite Tape Lamination Scrap Removal Apparatus
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Solution Overview
Problem
Existing methods for preparing cassette spools with tape material, such as prepeg unidirectional tape, face issues like loss of tacking ability, alignment problems, poor adhesion, and increased costs due to the transfer of tape material to new backing paper, which can lead to inefficiencies and quality issues in laminate formation.
Innovation Solution
An apparatus is retrofitted onto a composite tape lamination machine with moveable members, a detection system, and a high tack roller with adhesive strips to selectively remove scrap tape material from the backing paper, maintaining tension and alignment, and disposing of it efficiently without requiring new backing paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tape material is transferred to new backing paper, then tape material can be prepared for cassette spool, but tacking ability is lost and adhesion problems occur
Solution Approach 1:
The invention extracts and removes the problematic transfer step from the process. By using a release film that allows tape to be cleanly separated without transferring to new backing paper, the patent eliminates the source of adhesion problems while maintaining the ability to prepare tape for cassette spools.
Solution Approach 2:
The patent introduces a release film as an intermediary between the tape material and the backing paper. This release film enables clean separation and transfer of tape without compromising tacking ability, serving as a mediator that resolves the adhesion conflict.
2Productivity
If tape material is transferred to new backing paper, then tape can be wound onto cassette spool, but alignment problems and placement errors occur
Solution Approach 1:
The invention removes the transfer-to-new-backing-paper step that causes alignment issues. By maintaining the original backing paper and using a release film mechanism, the patent preserves alignment information while enabling cassette spool preparation.
3Ease of manufacture
If tape material is transferred to new backing paper, then tape can be prepared for layup, but wrinkles and tension problems occur
Solution Approach 1:
The patent extracts the problematic transfer operation that causes wrinkles and tension issues. By using a release film mechanism that allows clean separation without re-adhesion, the original backing paper and tape composition remain stable and wrinkle-free.
4Ease of manufacture
If multiple machines are used for tape transfer process, then tape material can be prepared, but costs and time increase
Solution Approach 1:
The patent merges multiple separate operations (tape transfer, backing paper removal, and cassette spool preparation) into a single integrated process using a release film mechanism. This consolidation eliminates the need for multiple machines while maintaining full tape preparation capability.
Solution Approach 2:
The release film mechanism serves multiple functions simultaneously: it enables tape separation, maintains backing paper integrity, allows clean transfer to cassette spool, and eliminates the need for additional transfer machines. This multi-functionality reduces device complexity while preserving manufacturing capability.
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 solution reduces costs, time, and inefficiencies by eliminating the need for new backing paper, improving tape adhesion and alignment, and reducing wrinkles and tacking issues, thereby enhancing the tape layup process and overall efficiency.
Implementation Method 1
a high tack roller with adhesive strips to selectively remove scrap tape material from the backing paper
Data Source
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AI summary
Apparatus (10) are provided for attaching to a composite tape lamination machine (12) in order to remove composite scrap tape material (72) from a backing paper (30). When a moveable member (14) is in one position composite non-scrap tape material on a backing paper is directed along a path to avoid a removing member and keep composite non-scrap tape material (56) on a backing paper (30). When the moveable member (14) is in another position composite scrap tape material (72) on a backing paper (30) is directed along a different path to contact the removing member (40) and remove composite scrap tape material (72) from a backing paper (30). Composite scrap tape material (72) may be disposed in a scrap disposal member (46). Backing paper (30) having attached composite non-scrap tape material (36) and not having attached composite scrap tape material (72) may be spooled using a spool roller (50).