Prepreg Tape Slitting with Polymer Film Liner
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Solution Overview
Problem
Current prepreg slitting processes require the removal of backing materials, which is labor-intensive, costly, and compromises the integrity and tolerances of slit tape, especially in high-tech applications like aerospace, due to issues with paper and polymer backings, leading to fibril formation, air pockets, and misalignment during slitting and winding.
Innovation Solution
A method and apparatus that allows for the slitting of prepreg sheet materials with a polymer film liner attached, which remains affixed during the process, preventing fibril formation, elongation, and misalignment, and maintains constant peel strength with the prepreg material, enabling precise slit tape production without the need for continuous liner interleafing or alignment systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If paper or polymer backings are used in conventional prepreg slitting processes, then the prepreg material can be handled and stored, but fibril formation, air pockets, and misalignment occur during slitting and winding
Solution Approach 1:
The patent changes the material parameter of the backing from conventional paper or polymer to a specifically engineered polymer film with controlled properties including elongation of 5-50%, tensile strength of 100-4000 psi, and thickness of 0.5-5 mils. These parameter changes prevent fibril formation while maintaining handling capabilities.
Solution Approach 2:
The patent creates a composite structure where the polymer film backing is integrated with the prepreg material through controlled adhesion. This composite approach combines the structural support of the backing with the composite material properties, preventing defects during processing.
2Productivity
If backing material is removed during slitting, then slit tape can be produced, but the process becomes labor-intensive and costly
Solution Approach 1:
The patent performs preliminary action by designing the polymer film backing to remain attached throughout the slitting and winding process. The backing is prepared in advance with appropriate adhesion properties that allow it to stay bonded to the prepreg material, eliminating the need for post-slitting removal operations.
Solution Approach 2:
The polymer film backing serves multiple functions simultaneously: it provides structural support during handling, prevents fibril formation during slitting, maintains alignment during winding, and eliminates the need for separate removal and replacement operations. This multi-functionality simplifies the overall manufacturing process.
3Manufacturing precision
If conventional backing materials are used, then prepreg can be manufactured, but misalignment and excess liner material occur during winding
Solution Approach 1:
The patent changes the physical parameters of the backing material to achieve optimal performance. The polymer film's elongation (5-50%) and thickness (0.5-5 mils) are specifically controlled to prevent misalignment during winding while minimizing excess material. The adhesion strength is tuned to maintain constant peel strength throughout the process.
4Quantity of substance
If paper backings are used in master rolls, then prepreg materials can be stored and shipped, but fibrils and air pockets are generated during slitting
Solution Approach 1:
The patent transitions from paper to polymer film backing, changing the material parameters to eliminate fibril formation. The polymer film's elasticity (elongation 5-50%) and smooth surface properties prevent the generation of harmful fibrils during slitting while maintaining the necessary quantity and storage capabilities of the prepreg material.
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 reduces capital costs, improves slit tape consistency and tolerances, enhances production efficiency, and minimizes cycle times and liner misalignment, resulting in higher productivity and reduced liner costs by allowing the use of stock master rolls and eliminating excess liner material.
Implementation Method 1
A method and apparatus that allows for the slitting of prepreg sheet materials with a polymer film liner attached, which remains affixed during the process, preventing fibril formation, elongation, and misalignment
Implementation Method 2
maintains constant peel strength with the prepreg material
Data Source
AI summary
Improved methods and apparatus are provided for the production of prepreg slit tape wherein master rolls of prepreg sheet are formed which are capable of being slit, with liner attached, at high precision.