Carbon Fiber Self-Heating Curing for Polymer Manufacturing

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Solution Overview

Problem

Conventional methods for manufacturing fiber reinforced polymer materials require high-energy thermal curing processes, often necessitating large ovens and expensive equipment, limiting flexibility and increasing costs, especially for large-scale productions.

Innovation Solution

A method involving carbon fibers that act as both structural reinforcement and heating elements by conducting electrical current to heat the thermosetting resin to its cure temperature, eliminating the need for conventional ovens and allowing in-situ curing, with optional use of thermally insulating molds to reduce energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal curing in large ovens is used, then the thermosetting resin can be cured to form polymer matrix, but the energy consumption is high and manufacturing costs increase

Engineering Contradiction:

Improvecuring process reliabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent merges the structural reinforcement function of carbon fibers with the heating function by utilizing the electrical conductivity of carbon fibers. The carbon fibers serve dual purposes: providing mechanical strength as reinforcement and generating heat through electrical resistance to cure the thermosetting resin, thereby eliminating the need for separate heating systems and large ovens.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The carbon fiber reinforced polymer structure performs self-heating and self-curing by conducting electrical current through its own carbon fiber reinforcement. The structure uses its inherent electrical conductivity to generate the necessary heat for curing the resin matrix, making the system self-sufficient without external heating equipment.

Inventive Principle:

Principle #25Self-service

2Reliability

If conventional thermal curing equipment is used, then the resin can be cured, but the equipment cost and manufacturing complexity increase

Engineering Contradiction:

Improvecuring process reliabilityVSAvoidmanufacturing equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex external heating equipment (large ovens, heating elements, temperature control systems) from the manufacturing process. By utilizing the inherent electrical conductivity of carbon fibers, the curing process is simplified to only requiring an electrical power source, dramatically reducing equipment complexity and manufacturing costs.

Inventive Principle:

Principle #2Taking out (Extraction)

3Manufacturing precision

If large ovens are used for curing, then the resin can be heated uniformly, but the flexibility in production location is reduced

Engineering Contradiction:

Improvetemperature uniformityVSAvoidproduction location flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the mechanical/thermal heating system (large ovens with heating elements) with an electrical heating system utilizing electrical resistance in carbon fibers. This substitution enables the curing process to be performed in-situ at the production location without requiring large, immobile oven equipment, thereby increasing production flexibility and location adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If carbon fibers are used as reinforcement, then the product achieves high strength and stiffness, but the electrical conductivity enables energy loss through heating

Engineering Contradiction:

Improvemechanical strengthVSAvoidenergy loss

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The patent converts what was previously considered energy loss (heat generation due to electrical resistance in carbon fibers) into a beneficial effect. The electrical resistance that causes energy dissipation is harnessed to generate the necessary heat for curing the thermosetting resin, transforming a potential disadvantage into the core mechanism enabling the invention.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces manufacturing costs, increases flexibility in production location, and maintains the lightweight and mechanical properties of carbon fiber reinforced polymers, enabling efficient and energy-saving production of large composite structures.

Implementation Method 1

heating up the thermosetting resin to its cure temperature by a current flowing through at least a part of the carbon fibers

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The mold is made from a thermally insulating material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11377527B2Fiber reinforced polymer manufacturing

Publication Date: 2022.07.05 BEYOND GRAVITY SCHWEIZ AG

AI summary

Method of manufacturing a product comprising fiber reinforced polymer material, the method comprising the steps of:providing 10 carbon fibers being embedded in a thermosetting resin,heating 20 the thermosetting resin up to its cure temperature by a current flowing through at least a part of said carbon fibers,letting convert 30 the thermosetting resin to a thermoset polymer.The invention is further directed to a device for performing the method and to a composite sandwich panel structure manufactured according to the method.