Composite Curing via Segmented Bond Tool and Heated Base
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of composite laminates is incompatible with small manufacturers due to the large and expensive equipment required, such as autoclaves, which are not feasible for small-scale operations.
Innovation Solution
An internally heated and pressurized system that uses a heated base, bond tool, pressure seal, and pressure sealed cover to apply heat and pressure evenly, allowing for the curing of prepreg fiber reinforced composite layers without the need for large autoclaves, utilizing a generic heated base that can accommodate multiple bond tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional autoclaves or ovens under vacuum are used to cure composite laminates, then the curing process can be completed, but the equipment becomes large and expensive, making it incompatible with small manufacturers
Solution Approach 1:
The system divides the curing process into two independent functions: a portable bond tool for laminate construction and a separate heated base for curing. This segmentation allows the bond tool to remain small and maneuverable while the heating function is provided by a separate base unit, eliminating the need for large autoclave equipment.
Solution Approach 2:
The heated base serves multiple functions: it provides thermal energy for curing, acts as a support surface for the bond tool, and functions as a portable workstation. This multi-functionality consolidates equipment needs, allowing small manufacturers to replace large autoclaves with a compact, versatile base unit.
2Reliability
If traditional large equipment like autoclaves is used, then curing can be achieved, but power requirements and energy consumption increase significantly
Solution Approach 1:
The heated base concentrates thermal energy directly at the curing location through the bond tool, rather than heating a large chamber. This localized heating approach maintains reliable curing capability while significantly reducing overall power requirements by eliminating the need to heat large volumes of air or equipment.
Solution Approach 2:
The system replaces the mechanical compression and heating system of traditional autoclaves with a simpler direct-heating approach using the heated base. This substitution maintains curing reliability while reducing energy consumption by eliminating the need for large-scale thermal chambers and complex pressure systems.
3Adaptability or versatility
If traditional equipment is used, then curing can be performed, but the equipment occupies large space and reduces manufacturing flexibility
Solution Approach 1:
By separating the bond tool from the heated base, the system creates two independent components that can be configured flexibly. The bond tool can be adapted for different laminate types and applications, while the heated base provides consistent curing capability, enabling small manufacturers to adapt to various production needs without requiring different large equipment.
Solution Approach 2:
The heated base serves as a universal platform that can accommodate different bond tools and curing requirements. This universality allows small manufacturers to use the same base unit for various composite manufacturing tasks, increasing adaptability while minimizing the total equipment volume required.
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 system enables the rapid and energy-efficient fabrication of composite structures in a small space, reducing power requirements and eliminating the need for additional ovens, while allowing for the production of various parts using the same heated base, thus increasing flexibility and efficiency.
Implementation Method 1
Heat from the heated base and pressure in the pressurized region facilitate curing of the prepreg fiber reinforced composite layers
Implementation Method 2
Pressure is applied through the portal onto the pressure seal, which forces the prepreg fiber reinforced composite layer(s) to conform to the interior portion of the bond tool
Data Source
AI summary
An internally heated and pressurized system for fabricating a composite laminate structure and method for use thereof is disclosed. One of a plurality of thin, thermally conductive bond tools, prepreg fiber reinforced composite layers, and a pressure applying membrane are nested within a heated base, and then covered by a pressure sealed cover. The system is pressurized through the pressure sealed cover. The pressure causes the pressure applying membrane to force the prepreg fiber reinforced composite layers onto the upper surface of the bond tool. The heated base transfers heat to the composite layers via the bond tool, which heats and cures the composite layers together and to a shape determined by the upper surface of the bond tool. Each bond tool is formed with a generic lower surface for nesting within the heated base and an upper surface for forming composite layers into the shape of a specific part.