Systems and methods for curing thermoset composites

Abstract

The present invention relates to systems and methods for curing thermoset composites. A system for curing thermoset composites may include: a processing mold configured to receive and support an uncured thermoset composite part and heat the uncured thermoset composite part; a pressure medium bag configured to be placed over the uncured thermoset composite part disposed on the processing mold and including a pressure medium; and a mechanical press configured to apply a consolidation pressure to the uncured thermoset composite part disposed on the processing mold, the pressure medium bag being configured to distribute the consolidation pressure applied by the mechanical press to the uncured thermoset composite part disposed on the processing mold.

Description

Field of the Invention

[0001] The present disclosure generally relates to the manufacture of thermoset composites and, more particularly, to systems and methods for thermally curing and pressure curing thermoset composites. Background Art

[0002] Polymer composites are tough, lightweight materials produced by combining two or more functional components, such as reinforcing fibers, within a polymer resin matrix. The manufacture of thermoset composite parts typically requires the application of pressure and heat to complete the curing and consolidation process. For example, different pressure and temperature profiles, i.e., variations as a function of time, can be used to process uncured thermoset composite parts or preforms.

[0003] Typically, the curing of uncured thermoset composite parts is carried out in a pressurized autoclave, where a heat source, such as a resistive heating element, supplies heat to the uncured thermoset composite part by convection before or while applying the consolidation pressure. The production rate is significantly affected by the time required to heat the autoclave to a certain temperature and heat the uncured thermoset composite part before applying the consolidation pressure throughout the curing cycle time. Additionally, the use of an autoclave requires additional space and infrastructure and may increase the production cost of thermoset composites because of the high energy and consumable consumption when using an autoclave.

[0004] Alternatives to autoclave curing of composites include oven curing or heated matched die curing. However, the pressure in oven curing is limited to vacuum, which is typically not sufficient to remove all voids; and oven curing still requires heating processing. Similarly, local variations in thickness can cause pressure differentials in matched die processing. For example, surfaces (near) perpendicular to the pressing direction in matched die processing typically do not receive sufficient pressure to properly cure the composite.

[0005] Accordingly, there is a need to reduce the curing cycle time of uncured thermoset composite parts by providing more efficient systems and methods for processing uncured thermoset composite parts, systems and methods that can effectively apply heat and pressure to uncured thermoset composite parts, and, in particular, systems and methods for curing thermoset composites that do not require an autoclave, allowing rapid heating of the process and allowing more uniform pressure to be applied to all surfaces of the uncured thermoset composite part during curing, including at pressures above 1 bar. Summary of the Invention

[0006] This Summary of the Invention is only intended to introduce some aspects of one or more implementations of the present disclosure in a simplified form. This Summary of the Invention is not an extensive review, nor is it intended to identify key or important elements of the teachings, nor to depict the scope of the present disclosure. Instead, its purpose is only to present one or more concepts in a simplified form as a prelude to the following detailed description.

[0007] The foregoing and / or other aspects and utilities embodied in the present disclosure can be achieved by providing a system for curing a thermosetting composite material, the system comprising: a processing mold configured to receive and support an uncured thermosetting composite part and heat the uncured thermosetting composite part; a pressure medium bag configured to be placed on top of the uncured thermosetting composite part disposed on the processing mold and comprising a pressure medium; and a mechanical press configured to apply a consolidation pressure to the uncured thermosetting composite part disposed on the processing mold, wherein the pressure medium bag is configured to distribute the consolidation pressure applied by the mechanical press to the uncured thermosetting composite part disposed on the processing mold.

[0008] The processing mold may include a heating surface configured to contact at least a portion of the uncured thermosetting composite part supported by the processing mold and heat at least a portion of the uncured thermosetting composite part to a predetermined temperature.

[0009] The heating surface of the processing mold may include a smart sensor, and wherein the smart sensor may have a Curie temperature corresponding to the predetermined temperature.

[0010] The pressure medium bag may include a heating surface configured to contact at least a portion of the uncured thermosetting composite part and heat at least said portion of the uncured thermosetting composite part to a predetermined temperature.

[0011] The heating surface of the pressure medium bag may include a smart sensor, and wherein the smart sensor may have a Curie temperature corresponding to the predetermined temperature.

[0012] The pressure medium bag may be configured to hold the pressure medium, and wherein the pressure medium bag includes a flexible material configured to withstand and distribute the consolidation pressure applied by the mechanical press.

[0013] The pressure medium bag may include one or more vacuum ports, and the pressure medium bag may be configured to function as a vacuum bag when placed on top of the uncured thermosetting composite part and the processing mold.

[0014] The pressure medium may include a plurality of pressure media.

[0015] The pressure medium may include an average particle size of about 0.5 mm to about 5 mm or less.

[0016] The pressure medium may include a thermal insulation material.

[0017] The pressure medium may include a gel-like medium.

[0018] The pressure medium may include one or more of sand, glass, and ceramic materials.

[0019] The pressure medium bag may include a flexible material configured to withstand and distribute the consolidation pressure applied by a mechanical press.

[0020] The pressure medium bag may include one or more dividing portions, and wherein the one or more dividing portions may be configured to restrict the movement of the pressure medium to maintain the consolidation pressure within the one or more dividing portions.

[0021] The system may further include a compactor, wherein the compactor may include a shape corresponding to at least one of the processing mold and the uncured thermosetting composite part, and wherein the compactor may be configured to distribute the consolidation pressure applied by the mechanical press to the pressure medium bag and the uncured thermosetting composite part.

[0022] The foregoing and / or other aspects and utilities embodied in the present disclosure may also be achieved by providing a method for curing a thermosetting composite material, the method comprising: placing an uncured thermosetting composite part on a processing mold; placing a pressure medium bag on top of the uncured thermosetting composite part disposed on the processing mold, the pressure medium bag containing a pressure medium; heating the uncured thermosetting composite part to a predetermined temperature; applying a consolidation pressure to the uncured thermosetting composite part; and distributing the consolidation pressure applied to the uncured thermosetting composite part disposed on the processing mold via the pressure medium bag.

[0023] The method may further include placing a compactor on top of the pressure medium bag, and wherein the compactor also distributes the consolidation pressure applied to the pressure medium bag and the uncured thermosetting composite part disposed on the processing mold.

[0024] At least one of the processing mold and the pressure medium bag may include a heating surface, and the uncured thermosetting composite part may be heated to a predetermined temperature by at least one of the heating surface on the processing mold and the heating surface on the pressure medium bag.

[0025] At least one of the heating surface on the processing mold and the heating surface on the pressure medium bag may include a smart sensor, and wherein the smart sensor may have a Curie temperature corresponding to the predetermined temperature.

[0026] The pressure medium may include an average particle size of about 0.5 mm to about 5 mm, and wherein the pressure medium includes a thermal insulation material.

[0027] From the detailed description provided below, further application areas will become apparent. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for illustrative purposes only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The drawings, which are incorporated in and constitute a part of this specification, illustrate implementations of the teachings herein and, together with the description, serve to explain the principles of the invention. In the drawings:

[0029] Figures 1 to 2 A system for curing thermosetting composites according to an implementation of the present disclosure is shown.

[0030] Figure 3 Induction heating using intelligent sensors according to an implementation is shown.

[0031] Figure 4 A system for curing thermosetting composites according to an implementation is shown.

[0032] Figure 5 A system for curing thermosetting composites according to an implementation is shown.

[0033] Figure 6 A method for curing thermosetting composites according to an implementation is shown

[0034] Figure 7 A flowchart of a method for aircraft production and maintenance is shown.

[0035] Figure 8 A block diagram of an aircraft is shown.

[0036] It should be noted that some details of the drawings have been simplified and drawn to facilitate understanding of the teachings herein rather than to maintain strict structural accuracy, details, and scale. DETAILED DESCRIPTION

[0037] Reference will now be made in detail to illustrative implementations of the teachings herein, examples of which are shown in the drawings. Generally, the same reference numerals are used throughout the drawings to refer to the same or like parts.

[0038] Uncured thermosetting composite parts, also referred to as "preforms", are typically cured by subjecting them to a combination of heat and pressure according to a predetermined curing schedule of applied pressure, temperature, and the duration for which the pressure and temperature are maintained. These programmed temperatures and pressures are sometimes referred to as the cure temperature profile and consolidation pressure profile.

[0039] As used herein, the term "uncured thermoset composite part" or "preform" refers to one or more plies of a composite material impregnated with a resin. For example, an uncured thermoset composite part can be a fiber-reinforced uncured thermoset polymer composite part.

[0040] For a fiber-reinforced thermoset polymer composite part, curing generally refers to applying heat and / or pressure to crosslink and consolidate the fibers of the fiber-reinforced thermoset polymer composite part. Although a thermoset resin can be partially cured (i.e., crosslinked) without applying pressure, it generally results in a poorly consolidated part. Thus, as used herein, the term "curing" includes applying heat (to cure / crosslink) and applying pressure (to consolidate) a fiber-reinforced thermoset polymer composite part, such as the thermoset composite parts of the present disclosure.

[0041] In other instances, an uncured thermoset composite part can be a prepreg. As used herein, the term "prepreg" refers to a pre-impregnated stack of composite plies, such as an epoxy-impregnated unidirectional composite tape. A prepreg can be flexible until it is cured, typically cured by heat and pressure or cured in an autoclave.

[0042] Aspects of systems and methods for curing thermoset composites that require the application of heat and pressure are described below. Although the following description of the systems and methods is with respect to uncured thermoset composite parts, note that the present disclosure is not limited thereto. The systems and methods described below can be applied to other materials that require the application of heat and pressure for curing, e.g., curing adhesives for structural bonding and consolidating thermoplastic fiber-reinforced composites.

[0043] Figures 1 to 2 A system for curing a thermoset composite according to an implementation of the present disclosure is shown. As Figures 1 to 2 shown, a system 10 for curing an uncured thermoset composite part 100 is shown to include a processing mold 200, a pressure medium bag 300, and a mechanical press 400. System 10 is shown to further include a controller 260, a sensor 262, and a power supply 264, although these components are not required for all implementations. Other implementations can include additional components. For example, Figure 4 A system for curing a thermoset composite according to another implementation is shown. As Figure 4 shown and as discussed in more detail below, in some implementations, system 10 further includes a compactor 500.

[0044] The uncured thermoset composite part 100 can be a preform. The uncured thermoset composite part 100 can include an uncured fiber-reinforced thermoset polymer composite material. For example, the uncured thermoset composite part 100 can include a laminated sheet layer of fiber-reinforced polymer resin, such as carbon fiber epoxy resin, or other thermoset materials that must be heated to a preselected temperature to achieve curing.

[0045] In other implementations, the uncured thermoset composite part 100 includes an interwoven wire fabric (IWWF), a fiber metal laminate, and / or a honeycomb or foam core surrounded by a composite material.

[0046] The processing mold 200 is configured to receive the uncured thermoset composite part 100. For example, the processing mold 200 can be configured to receive and support the uncured thermoset composite part 100 during the curing process. The processing mold 200 can include a receiving surface 211, and the shape of the receiving surface substantially matches the shape of the uncured thermoset composite part 100. For example, the processing mold 200 includes a receiving surface 211 having a shape that substantially matches the lower side 102 of the uncured thermoset composite part 100 to be cured.

[0047] In some implementations, the processing mold 200 is configured to receive and support a pressure medium bag 300. For example, the processing mold 200 can include a wall 220 configured to hold the pressure medium bag 300 in a restricted position above the uncured thermoset composite part 100 to limit the movement of the pressure medium bag 300. In other implementations, the processing mold 200 is configured to seal against the pressure medium bag 300, and the pressure medium bag 300 is configured to act as a vacuum bag.

[0048] The processing mold 200 can be configured to heat the uncured thermoset composite part 100. The processing mold 200 can employ any of a variety of heating techniques to generate the heat required to heat the uncured thermoset composite part 100 to a predetermined temperature, such as a curing temperature or a temperature profile. For example, the processing mold 200 can include a heating surface 214 configured to heat the uncured thermoset composite part 100 to a predetermined temperature. The heating surface 214 can be disposed on the receiving surface 211 and can cover at least a portion of the receiving surface 211. In other implementations, the receiving surface 211 includes the heating surface 214. The heating surface 214 can be configured to contact at least a portion of the uncured thermoset composite part 100 supported by the processing mold 200.

[0049] The processing mold 200 can generate heat by electromagnetic induction, and the generated heat can be transferred to at least a portion of the uncured thermoset composite part 100. For example, as Figures 1 to 3As shown, the magnetic properties of the magnetic material are combined with the application of high-frequency alternating current power to generate heat. As described in more detail below, the processing die 200 can include induction heating and intelligent sensors to heat the uncured thermosetting composite part 100. For example, the heating surface 214 includes one or more induction heating elements 252, which include an electrical conductor 254 and a surrounding intelligent sensor sleeve 256 having a preselected Curie temperature, and the electrical conductor and the intelligent sensor sleeve are coaxially arranged. The heating surface 214 is configured to heat at least a portion of the uncured thermosetting composite part 100 to a predetermined temperature, such as a curing temperature or a temperature profile.

[0050] Thus, in one implementation, the processing die 200 includes a heating surface 214 that is configured to contact the uncured thermosetting composite part 100 and heat at least a portion of the uncured thermosetting composite part 100 to a predetermined temperature. The heating surface 214 can include intelligent sensors, and the intelligent sensors can have a Curie temperature corresponding to the predetermined temperature.

[0051] In one implementation, the predetermined temperature or temperature profile ranges from just above room temperature (80°F) to about 820°F. The predetermined temperature or temperature profile can vary according to the composition of the uncured thermosetting composite part 100 and / or the curing requirements of the resin or composite ply forming the uncured thermosetting composite part 100. For example, the predetermined temperature or temperature profile can range from just above room temperature (80°F) to about 350°F.

[0052] As Figure 3 shown, the heating surface 214 includes an upper panel 246 and a lower panel 248 having an interior filled with a heat-conductive material 250.

[0053] The upper panel 246 and the lower panel 248 can include a rigid layer of a suitable resin, such as epoxy resin or bismaleimide (BMI), that surrounds one or more induction heating elements 252. The rigid layer of resin can form the upper panel 246 of the heating surface 214 and can be configured to match the lower side 102 of the uncured thermosetting composite part 100 disposed on the processing die 200. In other implementations, other resins are used to fabricate the upper panel 246 and the lower panel 248, including but not limited to polybenzoxazine (BXA). In some implementations, the heating surface 214 forms a permanent, non-flexible shape suitable for a particular application or the uncured thermosetting composite part 100. For example, the heating surface 214 and / or the upper panel 246 and the lower panel 248 can include metal.

[0054] As described above, the induction heating element 252 can be embedded within the material 250. The induction heating element 252 can include a coaxial arrangement of an electrical conductor 254 and a surrounding susceptor sleeve 256. The electrical conductor 254 can include, for example but not limited to, a litz wire, with a helical susceptor sleeved over the litz wire. The susceptor sleeve 256 can extend substantially the entire length of the electrical conductor 254. The axial spacing between the electrical conductor 254 and the susceptor sleeve 256 electrically insulates the susceptor sleeve 256 from the electrical conductor 254. The susceptor sleeve 256 is inductively heated by an alternating current flowing through the electrical conductor 254. The inductively heated susceptor sleeve 256 conducts heat to the material 250, which in turn conducts heat through the heating surface 214 to the uncured thermoset composite component 100.

[0055] The material 250 can include ferromagnetic or superparamagnetic particles (not shown) to assist in heating the material 250. In the case of using ferromagnetic particles, the material 250 is heated to a temperature substantially below the Curie temperature of the particles by hysteresis heating of the ferromagnetic particles. In the case where superparamagnetic particles are incorporated into the material 250, heat conducted through the material 250 gives rise to relaxation heating of the superparamagnetic particles, which corresponds to a range of Curie temperatures related to the size or diameter of the superparamagnetic particles.

[0056] As Figure 1 shown, suitable wiring 258 connects one or more of the heating elements 252 in the heating surface 214 to an alternating current power supply 264, which can be a portable or fixed power supply. The power supply 264 is connected to a power source, such as but not limited to a conventional 60 Hz, 110 volt or 220 volt electrical outlet (not shown). The power supply 264 supplies alternating current to the electrical conductor 254, preferably in a range from about 1,000 Hz to about 300,000 Hz, although higher frequencies are possible. One or more thermal sensors 262 can be provided on the heating surface 214 to monitor the temperature of the heating surface 214 in order to assist in regulating the amplitude or frequency of the alternating current supplied to the electrical conductor 254. The power supply 264 can be regulated by a suitable controller 260 based on the temperature monitored by the thermal sensors 262.

[0057] As Figures 1 to 3 shown, the susceptor sleeve 256 is formed of a magnetic material having a Curie temperature. The susceptor sleeve 256 can be formed as a solid or integral component in a cylindrical arrangement. The susceptor sleeve 256 can be implemented as an intelligent susceptor sleeve 256.

[0058] The flow of an alternating current through the electrical conductor 254 causes a magnetic field 268 to be generated around the susceptor sleeve 256. Due to the electrical conductor 254 being exposed to the magnetic field 268, eddy currents 270 are generated within the electrical conductor, and these eddy currents 270 cause inductive heating of the susceptor sleeve 256. Then, the heat from the susceptor sleeve 256 is conducted through the material 250 and the heating surface 214 to the uncured thermoset composite part 100. The magnetic material forming the susceptor sleeve 256 preferably has a high magnetic permeability and a Curie temperature corresponding to the desired temperature to which the uncured thermoset composite part 100 is to be heated by the processing mold 200, i.e., the curing temperature of the uncured thermoset composite part 100. Preferably, the size and configuration of the susceptor sleeve 256 and the electrical conductor 254 are set such that at temperatures below the Curie temperature of the susceptor sleeve 256, the magnetic field 268 is concentrated within the susceptor sleeve 256 due to the magnetic permeability of the susceptor sleeve.

[0059] The susceptor sleeve 256 is continuously heated during the application of the alternating current until the magnetic material forming the susceptor sleeve 256 reaches the Curie temperature. After reaching the Curie temperature, the susceptor sleeve 256 becomes non-magnetic, at which point the magnetic field 268 is no longer concentrated within the susceptor sleeve 256. The induced eddy currents 270 and the associated resistive heating are reduced to a level sufficient to maintain the temperature of the susceptor sleeve 256 at the Curie temperature, and thus the uncured thermoset composite part 100 and / or the processing mold 200 remain heated to the desired curing temperature for the duration of the curing cycle, at which point the alternating current is removed from the conductor 254.

[0060] Although some implementations use inductive heating in the processing mold 200, the present disclosure is not limited thereto, and other heating methods may be used to heat the processing mold 200, such as resistive heating, forced ventilation, heating oil, etc.

[0061] The pressure medium bag 300 is configured to be placed over the uncured thermoset composite part 100 disposed on the processing mold 200 and includes a pressure medium 320. The pressure medium bag 300 includes a receiving surface 311, and the pressure medium bag is configured to substantially conform to the shape of the uncured thermoset composite part 100. For example, the pressure medium bag 300 may substantially conform to the upper side surface 103 of the uncured thermoset composite part 100 to be cured.

[0062] The pressure medium bag 300 is configured to distribute the consolidation pressure from the mechanical press 400 to the uncured thermoset composite part 100 disposed on the processing mold 200. As used herein, the distribution of the consolidation pressure means ensuring that the consolidation pressure is substantially similar at all points of the uncured thermoset composite part 100. That is, as Figure 2 and Figure 4As shown, the consolidation pressure applied by the mechanical press 400 is evenly distributed by the pressure medium bag 300 such that substantially similar amounts of consolidation pressure are applied to all surfaces of the uncured thermosetting composite part 100 that are in contact with the pressure medium bag 300.

[0063] In contrast, in conventional methods where a mechanical press is used to apply the consolidation pressure without a pressure medium bag 300, the geometry of the processing die or the mechanical press can result in non-uniform application of the consolidation pressure. This is especially the case when the thermosetting composite part has a complex shape or profile. For example, as Figure 2 and Figure 4 shown, the pressure medium bag 300 enhances the distribution of the pressure applied by the mechanical press 400 to surfaces perpendicular to or at an angle to the mechanical press 400, as shown by arrow 388. Similarly, in view of the variability in the thickness of the uncured thermosetting composite part 100 or the mismatch between the geometry of the uncured thermosetting composite part 100 and the mechanical press 400, the pressure medium bag 300 allows substantially similar amounts of consolidation pressure to be applied to the uncured thermosetting composite part 100, which mismatch could otherwise create pressure hot spots or regions in the absence of pressure.

[0064] The pressure medium bag 300 is configured to contain a pressure medium 320.

[0065] The pressure medium bag 300 can include a flexible material that is configured to withstand the consolidation pressure from the mechanical press 400 and distribute the consolidation pressure to the uncured thermosetting composite part 100. The flexible material of the pressure medium bag 300 can be compatible with the uncured thermosetting composite part 100. For example, the pressure medium bag 300 can include silicone, toughened rubber, polyurethane, or other suitable elastomers that provide dimensional stability to the pressure medium bag 300 while maintaining sufficient flexibility to allow the distribution of the consolidation pressure through the pressure medium 320.

[0066] The pressure medium bag 300 can be implemented as one or more pressure medium bags 300. The pressure medium bag 300 can have an internal volume that is divided or partitioned. For example, in some implementations, the pressure medium bag 300 includes one or more dividers 335 that define one or more compartments 340, and the one or more compartments 340 are configured to restrict the movement of at least one of the pressure medium 320 to maintain and / or distribute the consolidation pressure within the one or more compartments 340. In some implementations, the one or more dividers 335 that define the one or more compartments 340 are configured to maintain the shape of the pressure medium bag 300.

[0067] In some implementations, the pressure medium bag 300 includes one or more backing plates 333. The backing plates can be implemented as metal strips bonded to the surface of the pressure medium bag 300 and are configured to increase or remove a texture effect on the uncured thermoset composite part 100 during the curing process. In other implementations, one or more backing plates 333 are placed between the pressure medium bag 300 and the uncured thermoset composite part 100. One or more backing plates 333 can be thermally conductive to easily transfer heat from the processing mold 200 and / or the pressure medium bag 300.

[0068] The pressure medium 320 can include a plurality of pressure mediums 320. For example, the pressure medium 320 can include at least one of solid particles, a gel-like material, and a liquid.

[0069] The pressure medium 320 can include a gel-like medium, such as silicone gel. The pressure medium 320 can include a liquid. The pressure medium 320 can include a plurality of solid particles. For example, the pressure medium 320 can include one or more of sand, glass, polystyrene foam, silica aerogel, rubber, metal, and ceramic particles. The pressure medium 320 can have an average particle size of about 0.5 mm to about 5 mm. For example, the pressure medium 320 can have an average particle size of about 4 mm or less, 3 mm or less, 2 mm or less, or 1 mm or less.

[0070] In some implementations, the pressure medium 320 includes a thermal insulation material. For example, the pressure medium 320 can be configured to insulate the uncured thermoset composite part 100 to reduce the amount of heat loss. The pressure medium 320 can have a thermal conductivity of 1 W / mK or less.

[0071] The pressure medium bag 300 can be configured to heat the uncured thermoset composite part 100. The pressure medium bag 300 can employ any of a variety of heating techniques to generate the heat required to heat the uncured thermoset composite part 100 to a predetermined temperature, such as a curing temperature or a temperature profile. For example, the pressure medium bag 300 can include a heating surface 314 that is configured to heat the uncured thermoset composite part 100 to a predetermined temperature. In some implementations, the heating surface 314 includes the same elements as the heating surface 214 for the processing mold 200 described above and operates on the same principle.

[0072] The heating surface 314 can be disposed on the receiving surface 311 and can cover at least a portion of the receiving surface 311. In other implementations, the receiving surface 311 includes the heating surface 314. The heating surface 314 can be configured to contact at least a portion of the uncured thermosetting composite component 100 supported by the processing die 200, such as the upper side 103. Thus, the pressure medium bag 300 can include a heating surface 314 that is configured to contact at least a portion of the uncured thermosetting composite component 100 and heat at least said portion of the uncured thermosetting composite component 100 to a predetermined temperature.

[0073] The pressure medium bag 300 can generate heat by electromagnetic induction, and the generated heat can be transferred to at least a portion of the uncured thermosetting composite component 100. For example, the heating surface 314 can include a smart sensor, and the smart sensor can have a Curie temperature corresponding to the predetermined temperature.

[0074] As Figures 1 to 3 shown, the pressure medium bag 300 includes electromagnetic induction heating and a smart sensor to heat the uncured thermosetting composite component 100. For example, the heating surface 314 includes one or more electromagnetic induction heating elements 352, the one or more electromagnetic induction heating elements including an electrical conductor 354 and a surrounding smart sensor sleeve 356 having a preselected Curie temperature, the electrical conductor 354 and the surrounding smart sensor sleeve 356 being coaxially arranged. The heating surface 314 includes an upper panel 346 and a lower panel 348 having an interior filled with a heat-conductive material 350.

[0075] The heating surface 314 can be configured to heat at least a portion of the uncured thermosetting composite component 100 to a predetermined temperature, such as a curing temperature or a temperature profile.

[0076] The upper panel 346 and the lower panel 348 can be formed of a flexible elastomeric material having a relatively high thermal conductivity and a relatively low electrical conductivity. For example, the upper panel 346 and the lower panel 348 can include silicone, rubber, polyurethane, or other suitable elastomers, which provide dimensional stability to the heating surface 314 while maintaining sufficient flexibility to allow the pressure medium bag 300 to conform to at least a portion of the surface of the uncured thermosetting composite component 100, including surfaces having irregular or wavy profiles. In one implementation, the material 350 includes an elastomer cast around the electromagnetic induction heating element 352. The smart sensor sleeve 356 can include a braided material in a sleeve configuration around the conductor 354 to enhance the flexibility of the heating surface 314 and / or the pressure medium bag 300.

[0077] As Figure 1As shown, suitable wiring 258 connects one or more heating elements 352 in the heating surface 314 to the power supply device 264. One or more thermal sensors 262 may be disposed on the heating surface 314 to monitor the temperature of the heating surface 314 to assist in regulating the amplitude or frequency of the alternating current supplied to the conductor 354. The power supply device 264 may be adjusted by a suitable controller 260 based on the temperature monitored by the thermal sensor 262.

[0078] In some implementations, the system 10 heats the uncured thermosetting composite part 100 disposed on the processing die 200 from both sides. For example, the system 10 may include a heating surface 214 on the processing die 200 and a heating surface 314 on the pressure medium bag 300, and both the heating surfaces 214 and 314 apply heat to the uncured thermosetting composite part 100. In other implementations, the system 10 heats the uncured thermosetting composite part 100 disposed on the processing die 200 from one side. For example, the system 10 includes only the heating surface 214 on the processing die 200 or the heating surface 314 on the pressure medium bag 300, and only one of the heating surfaces 214 and 314 applies heat to the uncured thermosetting composite part. In another example, the system 10 may include both the heating surface 214 on the processing die 200 and the heating surface 314 on the pressure medium bag 300, but only one of the heating surfaces 214 and 314 applies heat to the uncured thermosetting composite part 100.

[0079] Generally, consolidation pressure is applied during the curing of the uncured thermosetting composite part 100 to remove the entrapped air or volatiles generated by the crosslinking reaction of the thermosetting resin. The consolidation pressure also helps to ensure the close contact between the reinforcing fibers and the resin in the finally cured thermosetting composite part.

[0080] Thus, in some implementations, the mechanical press 400 applies a predetermined pressure to the uncured thermosetting composite part 100. For example, the mechanical press 400 is configured to apply consolidation pressure to the pressure medium bag 300 and the uncured thermosetting composite part 100 disposed on the processing die 200.

[0081] The mechanical press 400 is configured to apply consolidation pressure to the uncured thermosetting composite part 100 for a predetermined period of time. The predetermined period of time for applying the consolidation pressure may start only after the uncured thermosetting composite part 100 is heated to a predetermined temperature, such as the curing temperature. In other implementations, the predetermined period of time for applying the consolidation pressure starts before the uncured thermosetting composite part 100 is heated to the predetermined temperature. In some implementations, the consolidation pressure increases or decreases as a function of time and temperature according to the temperature and pressure distribution.

[0082] In one implementation, the mechanical press 400 applies a consolidation pressure (or load) of about 1 bar to about 8 bar. For example, the mechanical press 400 can apply a consolidation pressure of up to about 8 bar, up to about 7 bar, up to about 6 bar, up to about 5 bar, up to about 4 bar, up to about 3 bar, up to about 2 bar, or up to about 1 bar.

[0083] As Figure 3 shown, in some implementations, the system 10 further includes a compactor 500. The compactor 500 can have a shape corresponding to the shape of the processing mold 200 and / or the uncured thermosetting composite part 100. The compactor 500 is configured to further distribute the consolidation pressure applied by the mechanical press 400 to the pressure medium bag 300 and the uncured thermosetting composite part 100.

[0084] The compactor 500 can be heat-insulating. That is, the compactor 500 can be configured to prevent heat loss of the uncured thermosetting composite part 100 during the curing operation. The compactor 500 can include typical processing materials such as steel, invar, and fiber-reinforced composite materials.

[0085] The system 10 can include a vacuum bag assembly 600 (not shown). In some implementations, the vacuum bag assembly 600 is installed on top of the uncured thermosetting composite part 100 disposed on the processing mold 200. For example, the vacuum bag assembly 600 can include a bagging film covering the uncured thermosetting composite part 100, and the bagging film can be sealed to the processing mold 200 and / or the upper surface of the uncured thermosetting composite part 100 by means of a sealant. In some implementations, a vacuum is drawn from the vacuum bag assembly 600 to apply a negative pressure and extract volatiles and other gases that may be generated due to the curing process of the uncured thermosetting composite part 100. In other implementations, the vacuum bag assembly 600 is placed and sealed on top of the uncured thermosetting composite part 100 to press the uncured thermosetting composite part 100 against the processing mold 200 during the curing process.

[0086] In other implementations, the pressure medium bag 300 is configured to function as a vacuum bag. Figure 5 A system for curing thermosetting composites according to an implementation is shown. As Figure 5 shown, the system 10 includes one or more seals 380 that are configured to seal the pressure medium bag 300 to the processing mold 200. The one or more seals 380 can be integrated into the processing mold 200 on at least one of the pressure medium bags 300. For example, when the pressure medium bag is disposed on top of the uncured thermosetting composite part 100 and the processing mold 200, the one or more seals 380 can create an airtight seal. In some implementations, the pressure applied by the mechanical press 400 further enhances the airtight seal created by the one or more seals 380.

[0087] As Figure 5 shown, the pressure medium bag includes one or more vacuum ports 390. The one or more vacuum ports 390 are configured to evacuate air when the pressure medium bag is disposed over the uncured thermoset composite part 100 and the processing mold 200, and to draw a negative pressure through the one or more vacuum ports 390. Thus, the pressure medium bag 300 may include one or more vacuum ports 390, and the pressure medium bag 300 may be configured to function as a vacuum bag when placed over the uncured thermoset composite part 100 and the processing mold 200.

[0088] Figure 6 A method for curing a thermoset composite according to an implementation is shown. Figure 6 Examples of methods that may be used with the system 10 shown above and Figures 1 to 5 are shown. Thus, the following discussion will refer to Figures 1 to 5 the various components shown.

[0089] As Figure 6 shown, a method 800 for curing an uncured thermoset composite part 100 begins at operation 810 by placing the uncured thermoset composite part 100 on the processing mold 200. In some implementations, the processing mold 200 includes a heating surface 214, and at least a portion of the uncured thermoset composite part 100 is disposed over the heating surface 214 of the processing mold 200.

[0090] Operation 820 includes placing the pressure medium bag 300 over the uncured thermoset composite part 100 disposed on the processing mold 200. In some implementations, the pressure medium bag 300 includes a heating surface 314, and at least a portion of the uncured thermoset composite part 100 is in contact with the heating surface 314 of the pressure medium bag 300. In some implementations, the vacuum bag assembly 600 is placed over the uncured thermoset composite part 100 disposed on the processing mold 200, and the pressure medium bag 300 is placed over the vacuum bag assembly 600. Operation 820 may also include subjecting the uncured thermoset composite part 100 to a vacuum. For example, the pressure medium bag 300 may include one or more vacuum ports 390, and the pressure medium bag 300 may be configured to function as a vacuum bag when placed over the uncured thermoset composite part 100 and the processing mold 200, and to draw a negative pressure through the one or more vacuum ports 390.

[0091] Operation 830 includes heating the uncured thermoset composite part 100 to a predetermined temperature. The predetermined temperature can be the curing temperature corresponding to the composition of the uncured thermoset composite part 100. In other implementations, the predetermined temperature corresponds to the temperature along the curing temperature profile of the uncured thermoset composite part 100. The processing mold 200 may include a heating surface 214, the pressure medium bag 300 may include a heating surface 314, and the uncured thermoset composite part 100 may be heated to the predetermined temperature by one or both of the heating surfaces 214 and 314. For example, at least one of the processing mold 200 and the pressure medium bag 300 may include a heating surface (214 or 314), and the uncured thermoset composite part 100 may be heated to the predetermined temperature by at least one of the heating surface 214 on the processing mold 200 and the heating surface 314 on the pressure medium bag 300.

[0092] In some implementations, at least one of the heating surface 214 on the processing mold 200 and the heating surface 314 on the pressure medium bag 300 includes a smart sensor, and the smart sensor may have a Curie temperature corresponding to the predetermined temperature.

[0093] Operation 840 includes applying a consolidation pressure to the uncured thermoset composite part 100. The mechanical consolidation pressure can be applied by a mechanical press 400. In some implementations, the consolidation pressure is applied once the uncured thermoset composite part 100 reaches the predetermined temperature. In other implementations, the consolidation pressure is applied before the uncured thermoset composite part 100 reaches the predetermined temperature.

[0094] Operation 850 includes distributing, via the pressure medium bag 300, the consolidation pressure applied to the uncured thermoset composite part 100 disposed on the processing mold 200. For example, the pressure medium bag 300 may distribute the consolidation pressure applied to the uncured thermoset composite part 100 disposed on the processing mold 200. In one implementation, the pressure medium bag 300 distributes the consolidation pressure applied by the mechanical press 400 to the uncured thermoset composite part 100 disposed on the processing mold 200.

[0095] The pressure medium bag 300 is configured to hold a pressure medium 320. The pressure medium 320 may include an average particle size of about 1 mm or less, and the pressure medium 320 may include a thermal insulation material.

[0096] In other implementations, system 10 further includes a compactor 500. Method 800 further includes placing the compactor 500 on top of the pressure medium bag 300, and the compactor 500 also distributes the consolidation pressure to the pressure medium bag 300 and the uncured thermoset composite part 100 disposed on the processing mold 200. For example, the compactor 500 is configured to distribute the consolidation pressure applied by the mechanical press 400 to the pressure medium bag 300 and the uncured thermoset composite part 100 disposed on the processing mold 200.

[0097] Implementations of the present disclosure can find use in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace, marine, automotive applications, and other applications where thermoset composite materials are thermally cured. Accordingly, reference is now made Figure 7 and Figure 8 , implementations of the present disclosure can be used in Figure 7 the aircraft manufacturing and maintenance method 1000 shown in Figure 8 and the environment of the aircraft 2000 shown in

[0098] Each process of method 1000 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator can include, but is not limited to, any number of aircraft manufacturers and prime system subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator can be an airline, a leasing company, a military entity, a maintenance organization, etc.

[0099] As Figure 8 shown, the aircraft 2000 produced by the illustrative method 1000 can include a fuselage 2115 and an interior 2120 having a plurality of systems 2118. Examples of systems 2118 include one or more of a propulsion system 2122, an electrical system 2124, a hydraulic system 2126, and an environmental system 2128. Any number of other systems can be included. Although an aerospace example is shown, the principles of the present disclosure can be applied to other industries, such as the marine and automotive industries.

[0100] During any one or more stages of the aircraft manufacturing and repair method 1000, the systems and methods exemplified herein may be employed. For example, components or sub-assemblies corresponding to the production process 1106 may be manufactured or produced in a manner similar to components or sub-assemblies produced when the aircraft 2000 is in service. Moreover, during the production stages 1106 and 1108, one or more exemplary devices, exemplary methods, or combinations thereof may be utilized, such as by sufficiently accelerating the assembly of the aircraft 2000 or reducing its cost. Similarly, when the aircraft 2000 is in service, one or more exemplary devices, exemplary methods, or combinations thereof may be utilized, for example but not limited to, maintenance and repair 1114.

[0101] Although Figure 7 and Figure 8 the disclosure has been described with respect to aircraft and aircraft manufacturing and repair, the present disclosure is not limited thereto. The systems and methods of the present disclosure for curing thermosetting composites may also be used for spacecraft, satellites, submarines, surface ships, automobiles, tanks, trucks, power plants, and any other suitable type of object.

[0102] Throughout the specification and claims, unless the context clearly dictates otherwise, the following terms are employed with the meanings expressly associated herein. As used herein, phrases such as "in an implementation," "in certain implementations," and "in some implementations" do not necessarily refer to the same (one or more) implementation, although they may. Additionally, as used herein, phrases such as "in another implementation" and "in some other implementations" do not necessarily refer to different implementations, although they may. As described below, various implementations may be readily combined without departing from the scope or spirit of the present disclosure.

[0103] As used herein, the term "or" is an inclusive operator and is equivalent to the term "and / or" unless the context clearly dictates otherwise. The term "based on" is not exclusive and allows for additional factors not described, unless the context clearly dictates otherwise. In the specification, a recitation of "at least one of A, B, and C" includes implementations that include A, B, or C, multiple instances of A, B, or C, or combinations such as A / B, A / C, B / C, A / B / B / B / B / C, A / B / C, etc. Moreover, throughout the specification, the meanings of "a," "an," and "the" include plural references. The meaning of "in" includes "in" and "on." Similarly, implementations of the present disclosure may suitably include elements A, B, C, etc., consist of elements A, B, C, etc., or consist essentially of elements A, B, C, etc.

[0104] It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the present invention, a first object, component or step may be referred to as a second object, component or step, and similarly, a second object, component or step may be referred to as a first object, component or step. The first object, component or step and the second object, component or step are each an object, component or step, but they are not considered to be the same object, component or step. It will also be understood that the terms "comprising", "having", "including" and / or "containing", when used in this specification, specify the presence of the stated features, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components and / or groups thereof. In addition, as used herein, the term "if" may be interpreted to mean "when" or "in" or "in response to determining" or "in response to detecting", depending on the context.

[0105] Unless otherwise specified, all physical properties defined below are measured at 20 °C to 25 °C.

[0106] When any numerical range is mentioned herein, such a range is understood to include every and all numbers and / or fractions between the minimum and maximum values of the stated range, as well as the endpoints. For example, a range of 0.5% to 6% will explicitly include all intermediate values such as 0.6%, 0.7% and 0.9%, all the way up to and including 5.95%, 5.97% and 5.99%, and many other values. The same applies to every other numerical property and / or range of elements described herein, unless the context clearly indicates otherwise.

[0107] In addition, all numerical values are "about" or "approximate" the values shown, and take into account the experimental errors and variations expected by a person of ordinary skill in the art. It should be understood that all numerical values and ranges disclosed herein are approximate values and ranges. The terms "about" or "substantially" and "substantially" or "approximate" with respect to a quantity or measured value mean that the stated characteristic, parameter or value need not be precisely achieved. Instead, deviations or variations, including for example tolerances, measurement errors, measurement precision limitations and other factors known to a person skilled in the art, may occur in amounts that do not preclude the effect that the characteristic is intended to provide.

[0108] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification are to be understood as referring to weight percentages. The given percentages and amounts are based on the effective weight of the material. For example, for an active ingredient provided in solution form, the amount given is based on the amount of the active ingredient without the amount of solvent, or may be determined by weight loss after evaporation of the solvent.

[0109] Regarding programs, methods, techniques, and workflows according to some implementations, some operations in the programs, methods, techniques, and workflows disclosed herein may be combined and / or the order of some operations may be changed.

[0110] This disclosure includes illustrative embodiments and implementations according to the following clauses:

[0111] Clause 1. A system 10 for curing a thermosetting composite material, the system comprising:

[0112] A processing mold 200 configured to receive and support an uncured thermosetting composite part 100 and heat the uncured thermosetting composite part 100;

[0113] A pressure medium bag 300 configured to be placed on top of the uncured thermosetting composite part 100 disposed on the processing mold 200 and comprising a pressure medium 320; and

[0114] A mechanical press 400 configured to apply a consolidation pressure to the uncured thermosetting composite part 100 disposed on the processing mold 200,

[0115] wherein the pressure medium bag 300 is configured to distribute the consolidation pressure applied by the mechanical press 400 to the uncured thermosetting composite part 100 disposed on the processing mold 200.

[0116] Clause 2. The system of Clause 1, wherein the processing mold 200 includes a heating surface 214 configured to contact at least a portion of the uncured thermosetting composite part 100 supported by the processing mold 200 and heat at least the portion of the uncured thermosetting composite part 100 to a predetermined temperature.

[0117] Clause 3. The system of Clause 2, wherein the heating surface 214 of the processing mold 200 includes an intelligent sensor, and wherein the intelligent sensor has a Curie temperature corresponding to the predetermined temperature.

[0118] Clause 4. The system of any one of Clauses 1 to 3, wherein the pressure medium bag 300 includes a heating surface 314 configured to contact at least a portion of the uncured thermosetting composite part 100 and heat at least the portion of the uncured thermosetting composite part 100 to a predetermined temperature.

[0119] Clause 5. The system according to Clause 4, wherein the heating surface 314 of the pressure medium bag 300 includes an intelligent sensor, and wherein the intelligent sensor has a Curie temperature corresponding to the predetermined temperature.

[0120] Clause 6. The system according to any one of Clauses 1 to 5, wherein the pressure medium bag includes a medium bag 310 configured to hold the pressure medium 320, and

[0121] wherein the medium bag 310 includes a flexible material configured to withstand and distribute the consolidation pressure applied by the mechanical press 400.

[0122] Clause 7. The system according to Clause 6, wherein the pressure medium bag 300 includes one or more vacuum ports 390, and the pressure medium bag 300 is configured to be used as a vacuum bag when placed on the uncured thermosetting composite part 100 and the processing mold 200.

[0123] Clause 8. The system according to Clause 6 or 7, wherein the pressure medium 320 includes a plurality of pressure media 320.

[0124] Clause 9. The system according to Clause 8, wherein the pressure medium 320 has an average particle size of about 0.5 mm to about 5 mm or less.

[0125] Clause 10. The system according to Clause 8, wherein the pressure medium 320 includes a heat insulating material.

[0126] Clause 11. The system according to Clause 8, wherein the pressure medium 320 includes a gel-like medium.

[0127] Clause 12. The system according to Clause 8, wherein the pressure medium 320 includes one or more of sand, glass, and ceramic materials.

[0128] Clause 13. The system according to any one of Clauses 1 to 12, wherein the pressure medium bag 300 includes one or more pressure medium bags 300.

[0129] Clause 14. The system according to Clause 8, wherein the pressure medium bag 300 includes one or more partition portions 340, and

[0130] wherein the one or more partition portions 340 are configured to restrict the movement of at least one of the pressure media 320 to maintain the consolidation pressure within the one or more partition portions 340.

[0131] Clause 15. The system according to any one of Clauses 1 to 14, the system further comprising a compactor 500, wherein the compactor 500 has a shape corresponding to the shape of at least one of the processing die 200 and the uncured thermosetting composite part 100, and wherein the compactor 500 is configured to distribute the consolidation pressure applied by the mechanical press 400 to the pressure medium bag 300 and the uncured thermosetting composite part 100.

[0132] Clause 16. A method 900 for curing a thermosetting composite material, the method comprising:

[0133] Placing the uncured thermosetting composite part 100 on the processing die 200;

[0134] Placing the pressure medium bag 300 on top of the uncured thermosetting composite part 100 disposed on the processing die 200, the pressure medium bag 300 containing a pressure medium 320;

[0135] Heating the uncured thermosetting composite part 100 to a predetermined temperature;

[0136] Applying a consolidation pressure to the uncured thermosetting composite part 100; and

[0137] Distributing the consolidation pressure applied to the uncured thermosetting composite part 100 disposed on the processing die 200 via the pressure medium bag 300.

[0138] Clause 17. The method according to Clause 16, wherein the method further comprises placing the compactor 500 on top of the pressure medium bag 300, and wherein the compactor 500 also distributes the consolidation pressure applied to the pressure medium bag 300 and the uncured thermosetting composite part 100 disposed on the processing die 200.

[0139] Clause 18. The method according to Clause 17, wherein at least one of the processing die 200 and the pressure medium bag 300 includes a heating surface 214 / 314, and the uncured thermosetting composite part 100 is heated to the predetermined temperature by at least one of the heating surface 214 on the processing die 200 and the heating surface 314 on the pressure medium bag 300.

[0140] Clause 19. The method according to Clause 18, wherein at least one of the heating surface 214 on the processing die 200 and the heating surface 314 on the pressure medium bag 300 includes a smart sensor, and wherein the smart sensor has a Curie temperature corresponding to the predetermined temperature.

[0141] Clause 20. The method according to any one of Clauses 16 to 19, wherein the pressure medium 320 has an average particle size of from about 0.5 mm to about 5 mm, and wherein the pressure medium 320 comprises a heat insulating material.

[0142] The present disclosure has been described with reference to illustrative embodiments and implementations. Although some embodiments have been shown and described, those skilled in the art will understand that changes may be made to these embodiments without departing from the principles and spirit of the foregoing detailed description. The present disclosure is intended to be construed to include all such modifications and changes as long as they fall within the scope of the appended claims or their equivalents.

Claims

1. A system (10) for curing a thermosetting composite material, the system comprising: A processing mold (200) configured to receive and support an uncured thermosetting composite part (100) and including a heating surface (214) configured to heat the uncured thermosetting composite part (100); A pressure medium bag (300) configured to be placed over the uncured thermosetting composite part (100) disposed on the processing mold (200) and including a pressure medium (320); And A mechanical press (400) configured to apply a consolidation pressure to the uncured thermosetting composite part (100) disposed on the processing mold (200), Wherein the pressure medium bag (300) is configured to distribute the consolidation pressure applied by the mechanical press (400) to the uncured thermosetting composite part (100) disposed on the processing mold (200), Wherein the pressure medium bag (300) includes a heating surface (314) configured to contact at least a portion of the uncured thermosetting composite part (100) and heat at least the portion of the uncured thermosetting composite part (100) to a predetermined temperature, Wherein the heating surface (314) of the pressure medium bag (300) includes one or more induction heating elements (352), the one or more induction heating elements including an electrical conductor (354) and a surrounding intelligent receptor sleeve (356), and wherein the intelligent receptor sleeve has a Curie temperature corresponding to the predetermined temperature.

2. The system according to claim 1, wherein, The heating surface (214) of the processing mold (200) is configured to contact at least a portion of the uncured thermosetting composite part (100) supported by the processing mold (200) and heat at least a portion of the uncured thermosetting composite part (100) to a predetermined temperature.

3. The system according to claim 2, wherein The heating surface (214) of the processing mold (200) includes an intelligent receptor, and wherein the intelligent receptor has a Curie temperature corresponding to the predetermined temperature.

4. The system according to any one of claims 1 to 3, wherein The pressure medium bag includes a medium bag (310) configured to hold the pressure medium (320), and Wherein the medium bag (310) includes a flexible material configured to withstand and distribute the consolidation pressure applied by the mechanical press (400).

5. The system according to claim 4, wherein, The pressure medium bag (300) includes one or more vacuum ports (390), and the pressure medium bag (300) is configured to function as a vacuum bag when placed over the uncured thermosetting composite part (100) and the processing mold (200).

6. The system according to claim 4, wherein, The pressure medium (320) includes a plurality of pressure media (320).

7. The system according to claim 6, wherein, The pressure medium (320) has an average particle size of 0.5 mm to 5 mm.

8. The system according to claim 6, wherein The pressure medium (320) includes a heat insulating material.

9. The system according to claim 6, wherein The pressure medium (320) includes a gel-like medium.

10. The system according to claim 6, wherein, The pressure medium (320) includes one or more of sand, glass, and ceramic materials.

11. The system according to any one of claims 1 to 3, wherein, The pressure medium bag (300) includes one or more pressure medium bags (300).

12. The system according to claim 6, wherein The pressure medium bag (300) includes one or more partition portions (340), and wherein the one or more partition portions (340) are configured to restrict the movement of at least one of the pressure media (320) to maintain the consolidation pressure within the one or more partition portions (340).

13. The system according to any one of claims 1 to 3, the system further comprising a compactor (500), wherein, The compactor (500) includes a shape corresponding to at least one of the processing die (200) and the uncured thermosetting composite part (100), and wherein the compactor (500) is configured to distribute the consolidation pressure applied by the mechanical press (400) to the pressure medium bag (300) and the uncured thermosetting composite part (100).

14. A method (900) for curing a thermosetting composite material, the method comprising: placing an uncured thermosetting composite part (100) on a processing die (200), the processing die (200) including a heating surface (214); placing a pressure medium bag (300) on the uncured thermosetting composite part (100) disposed on the processing die (200), the pressure medium bag (300) containing a pressure medium (320), the pressure medium bag (300) including a heating surface (314), the heating surface (314) being configured to contact at least a portion of the uncured thermosetting composite part (100); the heating surface (214) on the processing die (200) and the heating surface (314) on the pressure medium bag (300) heat the uncured thermosetting composite part (100) to a predetermined temperature, the heating surface (314) on the pressure medium bag (300) includes one or more induction heating elements (352), the one or more induction heating elements include an electrical conductor (354) and a surrounding intelligent receptor sleeve (356), and wherein the intelligent receptor sleeve has a Curie temperature corresponding to the predetermined temperature; applying a consolidation pressure to the uncured thermosetting composite part (100); and distributing the consolidation pressure applied to the uncured thermosetting composite part (100) disposed on the processing die (200) via the pressure medium bag (300).

15. The method according to claim 14, wherein The method further includes placing a compactor (500) on the pressure medium bag (300), and wherein the compactor (500) also distributes the consolidation pressure applied to the pressure medium bag (300) and the uncured thermosetting composite part (100) disposed on the processing die (200).

16. The method according to claim 14, wherein, The heating surface (214) on the processing die (200) includes an intelligent receptor, and wherein the intelligent receptor has a Curie temperature corresponding to the predetermined temperature.

17. The method according to any one of claims 14 to 16, wherein The pressure medium (320) has an average particle size of from 0.5 mm to 5 mm, and wherein the pressure medium (320) comprises a heat insulating material.

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