Prepreg Ply-Backing Separation Using Corner Displacement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Automated systems face difficulties in separating thermoset prepreg fiber-reinforced plastic plies from their backings due to the aggressive adhesion of the resin, making manual techniques infeasible and requiring improved methods for initiating separation.

Innovation Solution

A system comprising a first and second support with a corner displacer that bends portions of the ply and backing apart, utilizing pivotable corner displacers to break the adhesive bond and facilitate separation, followed by a gripper to separate the remaining portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual techniques such as ruffling, flicking, or striking a corner are used to separate plies from backings, then separation can be initiated, but the process cannot be automated and lacks consistency

Engineering Contradiction:

Improveseparation initiationVSAvoidautomation capability

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The system uses the ply's own corner geometry and adhesive properties to initiate separation automatically. The corner displacer applies force to the corner, causing the ply to bend and the adhesive bond to fail naturally without requiring manual manipulation techniques

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical techniques (ruffling, flicking, striking) are replaced with an automated mechanical system consisting of a corner displacer, supports, and gripper that systematically apply controlled forces to initiate and complete separation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If automated systems attempt to separate plies from backings using conventional methods, then automation is achieved, but separation fails due to aggressive adhesion

Engineering Contradiction:

Improveautomation capabilityVSAvoidseparation success

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

Instead of applying force uniformly across the entire ply-backing interface, the system concentrates force locally at the corner region using the corner displacer. This localized application overcomes the adhesive bond at a specific point, initiating separation that then propagates easily across the rest of the interface

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The corner displacer performs preliminary action by breaking the adhesive bond at the corner before the main separation process. This preliminary breakthrough creates a starting point that makes the subsequent separation of the remaining ply-backing interface straightforward and reliable

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If excess backing protrudes past the edge of the ply, then separation is facilitated, but the ply and backing cannot be cut to shape together

Engineering Contradiction:

Improveseparation facilitationVSAvoidcut shape accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system extracts the separation initiation function from the edge/protruding backing region and relocates it to the corner region. By acting on the corner, the system achieves separation initiation without requiring excess backing to protrude beyond the ply edges, maintaining manufacturing precision

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

Effectively separates thermoset prepreg plies from their backings using automated methods, mimicking human techniques to initiate and complete the separation process efficiently.

Implementation Method 1

The corner displacer is configured to displace the corner in a first direction and an opposite second direction to thereby bend portions of the ply and the backing between the corner and the first support and the second support

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250276510A1Prepreg composite material ply and backing separation systems and methods

Publication Date: 2025.09.04 ACCUDYNE SYST

AI summary

A system for separating a prepreg composite material ply from a backing includes a first support configured to contact a first surface of the backing apart from a corner defined by the ply and the backing. A second support is configured to contact a second surface of the ply apart from the corner. A corner displacer is coupled to at least one of the first support and the second support. The corner displacer is configured to displace the corner in a first direction and an opposite second direction to thereby bend portions of the ply and the backing between the corner and the first support and the second support, and the portions of the ply and the backing thereby separate from each other.