Automated system and method for forming a laminated structure

Patent metadata

Field	Value
Publication number	US-11633947-B2
Application number	US-202117321315-A
Country	US
Kind code	B2
Filing date	May 14, 2021
Priority date	May 14, 2021
Publication date	Apr 25, 2023
Grant date	Apr 25, 2023

Abstract

A method of removing a backing layer from a panel, made of an uncured pre-impregnated fiber-reinforced polymer, comprises a step of orienting the panel into a backing-separation orientation relative to an edge-engagement tool. The method also comprises a step of positioning the panel into a backing-separation position relative to the edge-engagement tool. The method further comprises a step of moving the edge-engagement tool, when the panel is in the backing-separation orientation and the backing-separation position, so that backing-engagement features of the edge-engagement tool engage the backing layer, at only an edge portion of the backing layer, and just the edge portion of the backing layer separates from the panel. The method additionally comprises a step of gripping the edge portion of the backing layer, and, when gripped, moving the backing layer relative to the panel so that an entirety of the backing layer separates from the panel.

First claim

What is claimed is:

1. A method of removing a backing layer from a panel, made of an uncured pre-impregnated fiber-reinforced polymer, wherein the backing layer is secured to, via a tack force between the backing layer and the uncured pre-impregnated fiber-reinforced polymer, and flush against a broad surface of the panel, the method comprising steps of:
orienting the panel into a backing-separation orientation relative to an edge-engagement tool;
positioning the panel into a backing-separation position relative to the edge-engagement tool;
moving the edge-engagement tool, relative to the panel and when the panel is in the backing-separation orientation and the backing-separation position, so that backing-engagement features of the edge-engagement tool engage the backing layer, at only an edge portion of the backing layer, and just the edge portion of the backing layer separates from the panel; and
gripping the edge portion of the backing layer, after the edge portion separates from the panel, and, when gripped, moving the backing layer relative to the panel so that an entirety of the backing layer separates from the panel,
wherein:
the edge-engagement tool comprises a plate and the backing-engagement features comprise a plurality of protrusions protruding from the plate; and
the step of moving the edge-engagement tool comprises reciprocating the plate along a plane, angled at a plate angle relative to the panel and parallel with a leading edge of the edge portion, when the panel is oriented in the backing-separation orientation and positioned in the backing-separation position, so that only the plurality of protrusions of the plate engage only the edge portion of the backing layer when the plate moves along the plane.

2. The method according to claim 1 , wherein:
the plate reciprocates along the plane in a forward direction and a backward direction;
the forward direction is opposite the backward direction;
each engagement between the plurality of protrusions and the edge portion of the backing layer results in an at least partial separation of the backing layer from the panel;
the plurality of protrusions engage the edge portion when the plate moves in the forward direction;
the plurality of protrusions do not substantially engage the edge portion when the plate moves in the backward direction such that the at least partial separation of the backing layer from the panel is maintained as the plate moves in the backward direction;
each one of the plurality of protrusions comprises a sharp side facing in the forward direction and a dull side facing in the backward direction;
engagement of the plurality of protrusions with the edge portion of the backing layer comprises the sharp side of the plurality of protrusions at least partially penetrating the edge portion of the backing layer; and
the plate angle is an acute angle.

3. The method according to claim 1 , wherein:
the panel comprises a second broad surface that is opposite the broad surface;
a second backing layer is secured to, via a second tack force between the second backing layer and the uncured pre-impregnated fiber-reinforced polymer, and flush against the second broad surface of the panel; and
the method further comprises, after separating the entirety of the backing layer from the panel, steps of:
at least one of:
orientating the panel into a second backing-separation orientation relative to a second edge-engagement tool; and
positioning the panel into a second backing-separation position relative to the second edge-engagement tool;

moving the second edge-engagement tool, relative to the panel and when the panel is in at least one of the second backing-separation orientation and the second backing-separation position, so that second-tool-backing-engagement features of the second edge-engagement tool engage only a second-backing-layer edge portion of the second backing layer and just the second-backing-layer edge portion of the second backing layer separates from the panel; and
gripping the second-backing-layer edge portion of the second backing layer, after the second-backing-layer edge portion separates from the panel, and, when gripped, moving the second-backing-layer edge portion relative to the panel so that an entirety of the second backing layer separates from the panel.

4. The method according to claim 3 , wherein:
the second edge-engagement tool comprises a second-tool plate and the second-tool-backing-engagement features comprise a plurality of second-tool protrusions protruding from the second-tool plate; and
the step of moving the second edge-engagement tool comprises reciprocating the second-tool plate along a second plane, angled at a second-plate angle relative to the panel and parallel with a second-backing-layer leading edge of the second-backing-layer edge portion, when the panel is oriented in the second backing-separation orientation and positioned in the second backing-separation position, so that only the plurality of second-tool protrusions of the second-tool plate engage only the second-backing-layer edge portion of the second backing layer.

5. The method according to claim 1 , wherein the steps of orienting the panel, positioning the panel, moving the edge-engagement tool, and gripping the edge portion are automated.

6. The method according to claim 1 , further comprising compressing the backing layer against the broad surface of the panel after orienting the panel into the backing-separation orientation, after positioning the panel into the backing-separation position, and before moving the edge-engagement tool.

7. The method according to claim 1 , wherein:
the panel comprises a plurality of plies in a stacked arrangement;
each one of the plurality of plies comprises unidirectional fibers; and
the unidirectional fibers of at least one of the plurality of plies are oriented in a direction that is different than the unidirectional fibers of at least another one of the plurality of plies.

8. An automated system for removing a backing layer from a panel, made of an uncured pre-impregnated fiber-reinforced polymer, wherein the backing layer is secured to, via a tack force between the backing layer and the uncured pre-impregnated fiber-reinforced polymer, and flush against a broad surface of the panel, the automated system comprising:
an edge-engagement tool, comprising backing-engagement features and movable relative to the panel so that backing-engagement features of the edge-engagement tool engage only an edge portion of the backing layer and just the edge portion of the backing layer separates from the panel; and
a gripper, configured to grip the edge portion, when the edge portion is separated from the panel, and movable relative to the panel, when the edge portion is gripped by the gripper, so that an entirety of the backing layer separates from the panel,
wherein:
the edge-engagement tool comprises a plate;
the backing-engagement features comprise a plurality of protrusions protruding from the plate;
the plate is fixed at a plate angle relative to the panel;
the plate is selectively operable to reciprocate along a plane, angled at the plate angle relative to the panel and parallel with a leading edge of the edge portion;
the plate reciprocates along the plane in a forward direction, toward the panel, and a backward direction, away from the panel; and
each one of the plurality of protrusions comprises a sharp side facing in the forward direction and a dull side facing in the backward direction.

9. The automated system according to claim 8 , wherein the plate angle is an acute angle.

10. The automated system according to claim 8 , further comprising a second edge-engagement tool that

Assignees

• Taylor Made Golf Co

Inventors

• Greaney Mark
• Beach Todd
• Kraus Stephen
• Hsiao Connie
• Hsiao Tyson
• Lin Pei-Yao

Classifications

• B29L2009/00

  Layered products · CPC title

• B29C43/52

  Heating or cooling · CPC title

• B29C43/32

  Component parts, details or accessories; Auxiliary operations · CPC title

• B29C43/02 Primary

  of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} · CPC title

• B32B37/02

  characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations · CPC title