Composite Curing Tool with Integrated Heating and Vacuum
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Solution Overview
Problem
The existing process for manufacturing aircraft seat shells using composite materials is lengthy, expensive, and inefficient due to difficulties in lay-up, curing, and machining, as well as the need for multiple equipment setups and high energy consumption.
Innovation Solution
A tool with an integrated heating element and vacuum system for curing composite components, which allows for quicker lay-up and curing on a warm surface, reducing the need for separate heating equipment and vacuum supplies, and enabling more efficient use of space and resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional oven or autoclave is used for curing, then curing can be achieved, but the process is expensive, time-consuming, and requires large space
Solution Approach 1:
The patent combines the curing chamber, heating elements, and vacuum system into a single integrated tool that replaces the traditional oven or autoclave. The curing chamber is directly integrated with heating elements that can be activated during the curing process, eliminating the need for separate heating equipment and reducing overall process time.
Solution Approach 2:
The tool allows for preliminary heating of the curing chamber before the actual curing process begins. The heating elements can pre-heat the chamber to the required temperature, and the vacuum system can be activated in advance to remove moisture and air, ensuring optimal conditions are established before the curing cycle starts.
2Reliability
If separate heating equipment and vacuum supplies are used, then curing can be achieved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single tool: the curing chamber combines the heating and vacuum functions, eliminating the need for separate heating equipment and vacuum supplies. The heating elements are embedded within the curing chamber structure, and the vacuum system is directly connected to the same chamber, creating a unified system that reduces complexity.
Solution Approach 2:
The tool is designed as a multi-functional device that performs lay-up, heating, vacuuming, and curing operations within a single integrated system. The same curing chamber serves all these purposes, making the tool universally applicable for different stages of the composite manufacturing process without requiring multiple specialized equipment.
3Manufacturing precision
If nylon bagging is used for vacuum sealing, then vacuum can be applied, but the bagging is not reusable and creates waste
Solution Approach 1:
The patent employs a reusable flexible membrane or film that replaces the traditional nylon bagging. This membrane can be repeatedly used across multiple curing cycles without degradation, eliminating the waste associated with disposable nylon bags while maintaining the vacuum sealing function.
Solution Approach 2:
The tool incorporates a vacuum system that can be activated and deactivated multiple times without consuming consumable materials. The flexible membrane or film used for sealing is designed to be reused and recovered across different curing operations, eliminating the need to discard and replace nylon bagging material after each use.
4Ease of operation
If lay-up is performed at room temperature, then process is simple, but curing time increases
Solution Approach 1:
The tool allows for preliminary heating of the curing chamber before the actual curing process begins. The heating elements can pre-heat the chamber to the required temperature, and the vacuum system can be activated in advance to remove moisture and air, ensuring optimal conditions are established before the curing cycle starts.
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 solution significantly reduces the time and cost associated with the manufacturing process, allows for more efficient use of equipment and space, and improves the uniformity of the composite structure through even heating and vacuum management.
Implementation Method 1
at least one heating element within the sealed zone for heating the uncured composite component
Implementation Method 2
a vacuum port for providing a vacuum to the sealed zone
Data Source
AI summary
The present invention provides a tool 1 for curing a composite component, the tool comprising a lay-up surface 8 for laying-up layers of an uncured composite component, a cover assembly 9 for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port 25 for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating element 15, 53 within the sealed zone for heating the uncured composite component. The invention also provides a method of manufacturing a composite component and a composite component. The composite component may form at least part of a piece of aircraft furniture, such as an aircraft seat shell.