Vacuum Conformable Release Film for Composite Layup
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Solution Overview
Problem
The removal of composite laminates from base tools is challenging due to sticky pre-preg materials adhering to the tool surface, leading to damage and increased production costs and time, and existing release films provide inadequate support, resulting in slower laydown rates and scrapped parts.
Innovation Solution
A conformable thin sheet with a high tack surface and a non-tack surface is placed over the base tool, sealed at the perimeter, and a vacuum is applied to draw the non-tack surface into contact with the tool, allowing easy removal of the laminate without damage and facilitating accurate layup and deformation to tool contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If composite plies are applied directly to a base tool, then the composite laminate can be formed, but the sticky pre-preg materials adhere to the base tool surface making removal difficult and potentially damaging the composite
Solution Approach 1:
A release film is introduced as an intermediary layer between the composite laminate and the base tool. This release film has low surface energy and non-stick properties that prevent the sticky pre-preg materials from adhering to the base tool, while still allowing the composite to be formed and later removed easily without damage.
Solution Approach 2:
The release film is implemented as a thin, flexible film that can conform to the contours of the base tool surface while providing a non-stick interface. The film's flexibility allows it to adapt to complex tool geometries, and its thin nature minimizes interference with the composite layup process.
2Ease of operation
If release films are applied to the base tool to prevent adhesion, then composite removal is easier, but the films have low tack properties that do not provide stable support for layup resulting in slower laydown rates and increased scrap
Solution Approach 1:
The release film is designed with differentiated surface properties: one surface has low surface energy for easy release, while the other surface has higher tack or friction characteristics that provide stable support during the layup process. This local quality differentiation allows the film to simultaneously enable easy removal and provide adequate support for efficient laydown.
3Productivity
If composite plies are laid up on a base tool, then the process is efficient, but the heavy cure tool cannot be easily relocated and is more expensive with limited supply
Solution Approach 1:
The release film acts as a mediator that decouples the composite laminate from the base tool, allowing the composite to be formed on the lightweight, easily relocated base tool while maintaining the ability to transfer the composite to a cure tool for final curing. This eliminates the need to use heavy cure tools for the layup phase.
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 accurate and damage-free removal of composite laminates from base tools, improving laydown rates, reducing scrap parts, and simplifying the process by using a deformable carrier film to conform to tool contours and automate the layup process.
Implementation Method 1
a vacuum is drawn to cause the non-tack surface side of the thin sheet to be drawn downward into contact with the tooling surface
Implementation Method 2
the thin sheet is configured with one high tack surface side and an opposite side having a non-tack surface
Data Source
AI summary
A method and system of preparing a releasable underlying support for use in preparing a composite laminate is presented where a base tool is a covered with a conformable thin sheet on the tooling surface of a base tool, where the thin sheet is configured with one high tack surface side and an opposite side having a non-tack surface in contact with the tooling surface. The non-tack surface side will allow release of laid up pre-cure composite lamina that can then be cured on a separate curing tool. The thin sheet is positioned over the base tool and a vacuum source and sealed around the perimeter edge of the base tool. Drawing a vacuum causes the non-tack surface side of the film to be drawn downward into contact with the tooling surface. Plies of pre-cure lamina can then be added to the base tool covering and adhering to the high tack surface side.