US-12623368-B2 - Systems and methods of automatic film removal

Abstract

A backing film removal system comprises a separating mechanism configured to separate a first portion of a first backing film on a first side of a material segment and a second portion of a second backing film on a second side of the material segment from a material layer of the material segment, wherein the second side is opposite the first side. The backing film removal system also includes a clamping mechanism that is actuatable to apply a clamping force to secure the material layer and the second portion together. A separator assembly includes a gripping mechanism configured to grip the first portion. At least one of the gripping mechanism or the clamping mechanism is movable to draw the first portion gripped by the gripping mechanism away from the material layer to remove a remaining portion of the first backing film from the material layer.

Inventors

• Shatil Sinha
• Younkoo Jeong
• Matthew HOCKEMEYER
• Chen Zhang
• Anirban Sinha

Assignees

• GENERAL ELECTRIC COMPANY

Dates

Publication Date

20260512

Application Date

20231023

Claims (20)

1. 1 . A backing film removal system, comprising: a separating mechanism configured to separate a first portion of a first backing film on a first side of a material segment and a second portion of a second backing film on a second side of the material segment from a material layer of the material segment while the material segment is retained in a cantilevered position, wherein the second side is opposite the first side; an end effector configured to secure the material segment in the cantilevered position, the end effector comprising a clamping mechanism that is actuatable to position at least a portion of the clamping mechanism between the first portion and the material layer to apply a clamping force to an exposed portion of the material layer to secure the material layer and the second portion together; and a separator assembly having a gripping mechanism configured to grip the first portion, wherein at least one of the gripping mechanism or the end effector is movable to draw the first portion gripped by the gripping mechanism away from the material layer secured to the second portion to remove a remaining portion of the first backing film from the material layer.
2. 2 . The backing film removal system of claim 1 , further comprising a support assembly configured to draw and retain the first portion of the first backing film after separating.
3. 3 . The backing film removal system of claim 2 , wherein the support assembly comprises an arm having at least one support assembly vacuum port fluidically coupled to a vacuum source from which a vacuum is selectively applied to the at least one support assembly vacuum port to secure the first portion spaced apart from the material layer.
4. 4 . The backing film removal system of claim 1 , wherein the separator assembly comprises at least one separator assembly vacuum port fluidically coupled to a vacuum source, wherein the vacuum source is actuatable to selectively apply a vacuum through the at least one separator assembly vacuum port to adhere the first portion to the separator assembly.
5. 5 . The backing film removal system of claim 1 , wherein the separating mechanism comprises at least one of: a bending mechanism configured to apply a bending force to the material segment; or a nozzle configured to discharge a fluid toward the material segment.
6. 6 . The backing film removal system of claim 1 , further comprising an imaging system configured to capture one or more images of the material segment, and wherein the imaging system comprises at least one processor configured to analyze the one or more images to verify separation of the first portion from the material layer.
7. 7 . The backing film removal system of claim 1 , wherein the clamping mechanism is actuatable to position the portion of the clamping mechanism in contact with the exposed portion of the material layer.
8. 8 . The backing film removal system of claim 1 , wherein the separator assembly includes a roller, and wherein the separator assembly is configured to position the roller against the first backing film while the remaining portion of the first backing film is being removed from the material layer.
9. 9 . The backing film removal system of claim 1 , wherein the separator assembly comprises: a frame assembly; a carriage moveably coupled to the frame assembly for selective translatable movement relative to the frame assembly; and a plate rotatably coupled to the carriage, and wherein the gripping mechanism is retractably coupled to the plate.
10. 10 . A method for removing a backing film from a material segment, the method comprising: securing the material segment with an end effector in a cantilevered position, the material segment comprising a material layer having a first backing film on a first side of the material layer and a second backing film on a second side of the material layer, the second side opposite the first side; separating, with a separating mechanism, a first portion of the first backing film and a second portion of the second backing film from the material layer; gripping the first portion with a gripping mechanism; applying a clamping force to an exposed portion of the material layer to clamp the material layer and the second portion to the end effector; and removing a remaining portion of the first backing film from the material layer by moving at least one of the gripping mechanism or the end effector to draw the first portion gripped by the gripping mechanism away from the material layer.
11. 11 . The method of claim 10 , wherein the separating further comprises discharging a fluid toward the material segment to cause separation of the first portion and the second portion from the material layer.
12. 12 . The method of claim 10 , further comprising: positioning an arm having at least one arm vacuum port proximate the first portion and spaced apart from the material layer; and drawing a vacuum through the at least one arm vacuum port to secure the first portion to the arm.
13. 13 . The method of claim 12 , further comprising verifying the first portion is secured to the arm based on at least one of: comparing a vacuum pressure pulled through the at least one arm vacuum port to a predetermined vacuum pressure; analyzing, via a processor, at least one image captured with an imaging system; or determining, via a proximity sensor, a location of the first portion with respect to the arm.
14. 14 . The method of claim 10 , further comprising applying roller against the first backing film while the remaining portion of the first backing film is being removed from the material layer.
15. 15 . The method of claim 10 , wherein the end effector comprises a clamping device configured to applying the clamping force to the exposed portion of the material layer, and further comprising: selectively placing the clamping device between the first portion and the exposed portion of the material layer; and retracting the clamping device against the exposed portion of the material layer to apply the clamping force to the exposed portion of the material layer.
16. 16 . A backing film removal system, comprising: an end effector configured to secure a material segment in a cantilevered position, the material segment comprising a material layer having a first backing film on a first side of the material layer, and wherein the end effector comprises a clamping mechanism actuatable to position at least a portion of the clamping mechanism between the first backing film and the material layer to secure the material layer to the end effector; at least one separating mechanism configured to separate a first portion of the first backing film from the material layer; and a separator assembly having at least one separator assembly vacuum port, the separator assembly configured to draw a vacuum through the at least one separator assembly vacuum port to draw the first portion away from the material layer, the separator assembly further comprising a gripping mechanism configured to grip the first portion, and wherein at least one of the gripping mechanism or the end effector is movable to draw the first portion gripped by the gripping mechanism away from the material layer.
17. 17 . The backing film removal system of claim 16 , wherein the separator assembly comprises a roller, and wherein the separator assembly is configured to position the roller against the first backing film while the remaining portion of the first backing film is being removed from the material layer.
18. 18 . The backing film removal system of claim 16 , wherein separator assembly comprises: a frame assembly; a carriage moveably coupled to the frame assembly for selective translatable movement relative to the frame assembly; and a plate rotatably coupled to the carriage, and wherein the gripping mechanism is retractably coupled to the plate.
19. 19 . The backing film removal system of claim 16 , wherein the clamping mechanism is selectively moveable to clamp against an exposed portion of the material layer to clamp the exposed portion of the material layer against the end effector.
20. 20 . The backing film removal system of claim 16 , further comprising an imaging system configured to capture one or more images of the material segment, and wherein the imaging system comprises at least one processor configured to analyze the one or more images to verify separation of the first portion from the material layer.

Description

TECHNICAL FIELD The present subject matter relates generally to materials having a film backing, or more particularly to systems and methods of automatic film removal. BACKGROUND Composite laminate components generally include a plurality of layers or plies of composite material assembled together to provide the composite component with improved engineering properties. Composite components are typically manufactured by stacking a plurality of plies on top of each other until a desired thickness and shape is achieved. For example, the manufacturing process typically includes cutting plies of composite material to a desired shape, stacking the plies layer by layer, compacting the plies after each additional ply is layered over the previously stacked plies, and then curing the material. The plies of composite material may be produced with a pre-impregnated resin, often referred to as a “prepreg,” covered by a backing or protective film (e.g., a polyfilm) extending over one or more sides of the plies that facilitate the handling of the material prior to or during layup. During manufacture of composite components, the backing film is removed from the plies of composite material. BRIEF DESCRIPTION OF THE DRAWINGS A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: FIG. 1 is a schematic view of an exemplary embodiment of a system for automatic film removal according to the present disclosure. FIG. 2 is a schematic view of another component of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 3 is a schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure viewed from the line 3-3 of FIG. 1. FIG. 4 is a close-up schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 5 is a schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure viewed from the line 5-5 of FIG. 1. FIG. 6. is a close-up, schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure FIG. 7 is a close-up, schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 8 is a schematic view of another component of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 9 is a close-up, schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 10 is a schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 11 is a schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 12 is a schematic view of the exemplary system for automatic film removal of FIG. 1 according to the present disclosure. FIG. 13 is a block diagram of a computing system in accordance with various aspects of the present disclosure. FIG. 14 is a block diagram depicting an embodiment of a method of automatically removing a backing film from a composite material segment in accordance with various aspects of the present disclosure. Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the disclosure, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner. DETAILED DESCRIPTION Reference will now be made in detail to present embodiments of the disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure. The following description is provided to enable those skilled in the art to make and use the described embodiments contemplated for carrying out the disclosure. Various modifications, equivalents, variations, and alternatives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the scope of the present disclosure. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary. For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left