Composite Consolidation Chamber for Faster Pressurized Curing
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Solution Overview
Problem
Existing methods for manufacturing composite components, particularly fiber-reinforced composites, are costly and time-consuming, especially for large and complex shapes, and struggle to achieve aesthetically pleasing surfaces with high production capacity and reduced cycle times.
Innovation Solution
A thermal processing and consolidation system that includes an upper and lower chamber assembly forming an enclosed plenum, with an automatic coupling system and controller, enabling rapid and controlled thermal processing and consolidation of composite components under pressure and vacuum, using a programmable logic controller to manage temperature and pressure profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional autoclave molding methods are used, then material integrity and structural quality are ensured, but production capacity is low and cycle times are long (1-8 hours)
Solution Approach 1:
The patent replaces traditional hot air heating and conventional autoclave mechanical systems with induction heating technology and a modern press system featuring rapid heating/cooling plates. This substitution enables significantly faster thermal processing cycles while maintaining material integrity through precise temperature control and uniform heat distribution across the composite workpiece.
Solution Approach 2:
The invention implements rapid heating and cooling capabilities with controllable rates, allowing the system to quickly transition through different temperature zones during the curing process. The heating and cooling rates can be independently controlled to optimize both production speed and material quality, reducing cycle times from 1-8 hours to much shorter durations while maintaining structural integrity.
2Stability of the object's composition
If conventional heating methods are used, then uniform heating is achieved, but heating and cooling speeds are slow
Solution Approach 1:
The patent replaces conventional slow hot air heating with induction heating technology that generates heat directly within the heating plates through electromagnetic induction. This provides rapid heating capability while maintaining uniform temperature distribution across the workpiece surface, and enables equally rapid cooling through the cooling plate system.
Solution Approach 2:
The system employs periodic control of heating and cooling rates, allowing rapid temperature changes when material properties permit, while maintaining uniform temperature distribution throughout the composite structure. The controller manages the periodic activation of heating zones and cooling channels to achieve both speed and uniformity.
3Adaptability or versatility
If hand layup methods are used, then complex contoured parts can be formed, but production time increases and labor costs rise
Solution Approach 1:
The system employs automated material placement mechanisms that can automatically lay up composite materials onto complex contoured molds, reducing or eliminating manual labor. The automated system maintains the adaptability to form complex shapes while significantly increasing production speed and reducing labor costs associated with hand layup methods.
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
The system significantly reduces manufacturing time and cost while ensuring high-quality, aesthetically pleasing composite components by providing efficient thermal processing and consolidation, minimizing voids, and enhancing production capacity.
Implementation Method 1
The heating is accomplished by hot air or heated molds that are slow to heat and slow to cool
Implementation Method 2
Parts can be laid up by hand or by automated means into the mold profile and optionally bagged for vacuum forming
Implementation Method 3
the laminate is heated, formed to the profile of the mold by vacuum and/or pressure, and thermally processed and consolidated
Data Source
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AI summary
A thermal processing and consolidation system is provided that includes an upper chamber assembly lower chamber assembly, and layup and demolding station, transfer assembly, automatic or permanent coupling system, and controller. The upper chamber assembly couples to the lower chamber assembly to form an enclosed plenum, the enclosed plenum operable to maintain a pressurized environment about a tool. The layup and demolding station receives the tool and facilitates the layup, bagging and sealing of unprocessed components at the tool. A transfer assembly accurately positions the tool on the lower chamber assembly in alignment with the upper chamber assembly. An automatic or permanent coupling system provides services to the tool and the enclosed plenum. A controller directs services to be supplied to the enclosed plenum and tool in accordance with a set of process parameters. This set of process parameters allows an individual set of unprocessed components to be thermally processed and consolidated.