US-12623449-B2 - Composite backing layer peel starter

US12623449B2US 12623449 B2US12623449 B2US 12623449B2US-12623449-B2

Abstract

A composite backing layer peel starter and methods of use are presented. A method of beginning removal of a backing layer from a composite material is presented. An impact force is applied to a corner of the backing layer with a polymeric material contact surface of a striker to adhere the polymeric material to the backing layer. The striker is pulled away from the backing layer to apply a lifting force to the backing layer.

Inventors

Travis Adams
Adam David Martinez

Assignees

THE BOEING COMPANY

Dates

Publication Date: 20260512
Application Date: 20231019

Claims (20)

1 . A method of beginning removal of a backing layer from a composite material, the method comprising: separating a corner of the backing layer away from the composite material by impacting, cyclically along a rotational axis of a first cylindrical rod, a polymeric material forming a contact surface of a striker connected to an end of the first cylindrical rod into the backing layer at a frequency breaking an adhesion between the backing layer and the composite material, wherein the first cylindrical rod is: rigid and applies a force along the rotational axis at a frequency breaking an adhesion between a backing layer and a composite material; and is connected to a second cylindrical rod that is rigid and comprises a diameter, greater than a diameter of the first cylindrical rod, that tapers to connect with the first cylindrical rod, wherein the second cylindrical rod comprises a contact surface, on an end of the second cylindrical rod opposite a tapered end connected to the first cylindrical rod, that comprises a polymeric material that comprises a flexibility and an adhesive property; and applying, from the second cylindrical rod, a lifting force pulling the backing layer away from the composite material.
2 . The method of claim 1 , wherein the impacting comprises a downward force creating an adhesion between the polymeric material and the backing layer.
3 . The method of claim 1 , wherein the impacting comprises a rotational force.
4 . The method of claim 1 , wherein the impacting comprises applying an impact force to the corner of the backing layer with a suction cup forming the contact surface, and wherein the striker is pulled away to break an adhesion between the suction cup and the backing layer.
5 . The method of claim 1 , further comprising bringing the composite material to an ambient temperature prior to the impacting.
6 . The method of claim 5 , further comprising locally reducing adhesion between the backing layer and the composite material prior to the impacting.
7 . The method of claim 5 , further comprising locally changing a temperature of the corner of the backing layer prior to the impacting.
8 . The method of claim 1 , further comprising: applying an electrostatic force to at least one of the contact surface of the striker or the backing layer.
9 . The method of claim 1 , wherein impacting comprises a predetermined frequency breaking adhesion between the backing layer and the composite material.
10 . A composite backing layer peel starter that comprises: a first cylindrical rod that is rigid and comprises a rotational axis, wherein the first cylindrical rod is configured to cyclically apply a force along the rotational axis at a frequency that breaks an adhesion between a backing layer and a composite material; and a second cylindrical rod that is rigid and comprises a diameter, greater than a diameter of the first cylindrical rod, that tapers to connect with the first cylindrical rod, wherein the second cylindrical rod comprises a contact surface, on an end of the second cylindrical rod opposite a tapered end connected to the first cylindrical rod, that comprises a polymeric material that comprises a flexibility and an adhesive property.
11 . The composite backing layer peel starter of claim 10 , wherein: the first cylindrical rod is further configured to rotate around the rotational axis; and the contact surface comprises a suction cup.
12 . The composite backing layer peel starter of claim 10 , wherein the flexibility of the polymeric material is configured to create an adhesion between the backing layer and the polymeric material.
13 . The composite backing layer peel starter of claim 10 , wherein the contact surface is approximately 0.5 inches in diameter.
14 . The composite backing layer peel starter of claim 10 , wherein the contact surface is circular.
15 . The composite backing layer peel starter of claim 10 , further comprising: an electrostatic force generator configured to apply an electrostatic force to the contact surface.
16 . The composite backing layer peel starter of claim 10 , wherein the contact surface is further configured to apply a rotational force about the rotational axis.
17 . A method of beginning removal of a backing layer from a composite material, the method comprising: cyclically applying an impact force, to a corner of the backing layer cyclically along a rotational axis of a first cylindrical rod connected to a second cylindrical rod comprising a contact surface comprising polymeric material, at a predetermined frequency and thereby breaking adhesion between the backing layer and the composite material, wherein the second cylindrical rod comprises a diameter, greater than a diameter of the first cylindrical rod, that tapers to connect with the first cylindrical rod, wherein the second cylindrical rod comprises the contact surface on an end of the second cylindrical rod opposite a tapered end connected to the first cylindrical rod and the polymeric material comprises a flexibility and an adhesive property; and applying a lifting force away from the composite material to the backing layer by pulling the contact surface away, along the rotational axis, from the backing layer.
18 . The method of claim 17 , wherein the impact force comprises at least one of a downward force or a rotational force.
19 . The method of claim 18 , wherein the downward force is sufficient to create an adhesion between the polymeric material and the backing layer.
20 . The method of claim 18 , wherein the rotational force is sufficient to locally break adhesion between the backing layer and the composite material.

Description

BACKGROUND INFORMATION 1. Field The present disclosure relates generally to composite manufacturing and more specifically to preparing a prepreg composite material. 2. Background Composite materials are strong, light-weight materials created by combining two or more functional components. For example, a composite material may include reinforcing fibers bound in polymer resin matrix. The fibers can take the form of a unidirectional tape, woven cloth or fabric, or a braid. The mechanical properties and other material properties of composite materials can be desirable for some implementations. Composite materials can be preimpregnated then stored in a roll or sheet with a backing layer. Prior to manufacturing a composite structure, the backing layer is removed. However, removal of the backing layer takes an undesirable amount of time and can result in undesirable effects on the composite material. Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. SUMMARY An embodiment of the present disclosure provides a method of beginning removal of a backing layer from a composite material. An impact force is applied to a corner of the backing layer with a polymeric material contact surface of a striker. The striker is pulled away from the backing layer to apply a lifting force to the backing layer. Another embodiment of the present disclosure provides a composite backing layer peel starter. The composite backing layer peel starter comprises a rigid hammer and a striker connected to the rigid hammer, the striker comprising a polymeric material contact surface configured to adhere to a backing layer of a composite material. Yet another embodiment of the present disclosure provides a method of beginning removal of a backing layer from a composite material. The composite material is brought to an ambient temperature. At least one of a downward force or a rotational force is applied to a corner of the backing layer with a polymeric material contact surface of a striker. The striker is pulled away from the backing layer to apply a lifting force to the backing layer. The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and features thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein: FIG. 1 is an illustration of an aircraft in accordance with an illustrative embodiment; FIG. 2 is an illustration of a block diagram of a manufacturing environment in accordance with an illustrative embodiment; FIG. 3 is an illustration of a composite backing layer peel starter moving relative to a composite material in accordance with an illustrative embodiment; FIG. 4 is an illustration of a composite backing layer peel starter moving relative to a composite material in accordance with an illustrative embodiment; FIG. 5 is a flowchart of a method of beginning removal of a backing layer from a composite material in accordance with an illustrative embodiment; FIG. 6 is a flowchart of a method of beginning removal of a backing layer from a composite material in accordance with an illustrative embodiment; FIG. 7 is an illustration of an aircraft manufacturing and service method in a form of a block diagram in accordance with an illustrative embodiment; and FIG. 8 is an illustration of an aircraft in a form of a block diagram in which an illustrative embodiment may be implemented. DETAILED DESCRIPTION The illustrative examples recognize and take into account one or more considerations. The illustrative examples recognize and take into account that a variety of methods may be used to remove a backing material from a composite material. The illustrative examples recognize and take into account that methods to remove a backing material may undesirably disturb the composite ply. The illustrative examples recognize and take into account that having a free edge of backing material aids in beginning removal of the backing material from a composite material for any removal method. The illustrative examples present a composite backing layer peel starter. The composite backing layer peel starter may also be referred to as a “release initiator.” The composite backing layer peel starter creates a free edge of backing material. Creating the free edge allows any form of automated backing removal to take place. The illustrative examples provide a composite backing layer peel sta