Composite Induction Consolidation Apparatus
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Solution Overview
Problem
Current autoclave designs for processing high-performance thermoplastic composite structures face challenges due to extended cycles and equipment wear from high processing temperatures, limiting production rates and increasing costs.
Innovation Solution
A composite induction consolidation apparatus utilizing magnetic induction coils and ferromagnetic facesheets within an autoclave for rapid heating and cooling of thermoplastic composite parts, allowing for ambient air pressure consolidation and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resistive (radiant and convective) heating is used in autoclave designs, then the composite part can be heated and consolidated, but the processing cycles are extended and equipment wear increases due to higher processing temperatures
Solution Approach 1:
The patent replaces resistive heating (radiant and convective) with induction heating technology. Induction heating uses electromagnetic fields to directly heat the composite part and tooling through ferromagnetic materials, eliminating the need for prolonged resistive heating cycles and reducing overall processing time while maintaining consolidation quality
Solution Approach 2:
The patent utilizes the Curie temperature phase transition of ferromagnetic materials in the tooling. When the ferromagnetic tooling reaches its Curie temperature, it loses its magnetic properties, which signals the optimal heating point and allows for precise control of the heating cycle, preventing overheating and reducing cycle time
2Productivity
If higher processing temperatures are used to speed up consolidation, then processing time is reduced, but equipment wear and tear increases
Solution Approach 1:
The patent replaces conventional resistive heating with induction heating, which provides more precise temperature control and faster heating rates. This substitution allows reaching consolidation temperatures quicker and maintaining them more precisely, reducing the duration of high-temperature exposure and thereby decreasing equipment wear while maintaining high processing speeds
Solution Approach 2:
The patent changes the heating method parameter from resistive to induction heating, and utilizes the Curie temperature parameter of ferromagnetic materials to control the heating process. This parameter change enables precise temperature control at the Curie point, preventing excessive temperatures that would cause equipment wear while maintaining efficient processing speeds
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 enables rapid and controlled processing of thermoplastic composites, reducing cycle times to under 50 minutes, enhancing production throughput and enabling the use of higher-performing materials while minimizing equipment wear and capital investments.
Implementation Method 1
at least one magnetic induction coil in the base mandrel
Implementation Method 2
rapid heating and cooling of thermoplastic composite parts
Implementation Method 3
a ferromagnetic base mandrel facesheet having a specific Curie temperature
Data Source
AI summary
A composite induction consolidation apparatus includes a base mandrel and a ferromagnetic base mandrel facesheet having a specific Curie temperature carried by the base mandrel. The base mandrel facesheet is adapted to support a composite part and allow ambient air pressure to compact the composite part against the base mandrel facesheet. At least one magnetic induction coil is provided in the base mandrel.