Corona-Treated Backing for Pre-Preg Composite Adhesion

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Solution Overview

Problem

Current methods for producing pre-impregnated (pre-preg) materials with specific fiber orientations are inefficient and costly, as they often require manual cutting and alignment of sheets, which can lead to issues like wrinkling, tearing, and poor adhesion to flexible backings, especially when forming complex shapes.

Innovation Solution

A method involving the use of a corona discharge treatment on a backing material to enhance surface adhesion, allowing pre-preg material to be applied and adhered effectively to the backing, which is then used to create sheets with desired orientations, using a flexible backing like polyethylene that can stretch and conform to tool shapes without tearing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pre-preg material sheets are manually cut and aligned to achieve specific fiber orientations, then the desired orientation can be obtained, but the process becomes inefficient and costly with increased material waste

Engineering Contradiction:

Improvefiber orientation precisionVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The backing material is pre-treated with corona discharge to enhance surface adhesion before the pre-preg material is applied. This preliminary treatment ensures proper bonding without requiring manual alignment operations later, streamlining the manufacturing process while maintaining orientation precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual mechanical process of cutting and aligning sheets is replaced by an automated corona discharge treatment process. The electrical discharge treatment creates a controlled surface condition that enables precise fiber orientation without manual intervention, significantly improving production efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If pre-preg material is applied to flexible backing to form complex shapes, then shape versatility is improved, but adhesion quality deteriorates due to wrinkling and tearing

Engineering Contradiction:

Improveshape adaptabilityVSAvoidadhesion reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The surface energy and chemical composition of the backing material are changed through corona discharge treatment. This parameter change enhances surface adhesion properties, allowing the flexible backing to be stretched and conformed to complex shapes without tearing or wrinkling, while maintaining strong adhesion to the pre-preg material

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system creates a composite structure combining the treated backing material and pre-preg material. The corona discharge treatment creates a chemically modified surface layer on the backing that forms a strong bond with the pre-preg material, enabling the composite to withstand the stresses of forming complex shapes without delamination

Inventive Principle:

Principle #40Composite materials

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 method enables the efficient production of pre-preg materials with select orientations, improving adhesion and reducing material waste, allowing for the formation of complex shapes without wrinkling or tearing, and maintaining strong peel strength during the forming process.

Implementation Method 1

treating a first surface of a backing with a corona discharge to enhance surface adhesion

Methodology Applied

Scientific EffectCorona discharge: Corona Discharge

Data Source

PatentUS11345066B2Composite structures, materials with a removable backing for composite structures and related devices and methods

Publication Date: 2022.05.31 NORTHROP GRUMMAN SYSTEMS CORP

AI summary

Composite structures and methods of forming composite structures may include at least one ply of material extending along a length of the composite structure. The at least one ply of material includes sections of material extending along the length of the composite structure.