Composite Curing via Induction Heating and Fibre Alignment
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Solution Overview
Problem
Current methods for repairing composite components, such as Carbon Fibre Reinforced Plastic, face challenges with impact resistance, durability, and aerodynamic performance, and existing repair techniques often result in reduced structural strength and inconsistent curing, particularly in on-platform scenarios where thermal damage and fire risks are concerns.
Innovation Solution
A method involving a fibre composite component with electrically conductive fibres suspended in a resin matrix, where an energy field aligns these fibres to create an electrically conductive path for uniform heating and curing, allowing for rapid and even curing without excessive surface temperature elevation, reducing thermal damage and fire risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heater mats are used for on-platform curing, then the resin matrix can be cured, but thermal damage occurs to adjacent cured areas and fire risk increases
Solution Approach 1:
The patent replaces thermal conduction heating (heater mats) with electromagnetic induction heating. The curing process uses an induction heating apparatus that generates an alternating magnetic field to induce eddy currents in conductive fibres within the resin matrix, converting electromagnetic energy directly into heat within the material itself rather than heating from the surface outward. This eliminates the thermal gradient problems and fire risks associated with conventional heater mats.
Solution Approach 2:
The patent utilizes the phase transition properties of the resin matrix during curing. The induction heating rapidly raises the temperature of the resin matrix through eddy current heating, causing the thermoset resin to undergo its curing phase transition. The conductive fibres facilitate uniform energy distribution throughout the matrix, ensuring homogeneous curing without localized thermal damage.
2Manufacturing precision
If autoclave curing is used, then uniform curing can be achieved, but the component must be removed from the platform and production time increases
Solution Approach 1:
The patent enables the resin matrix to heat itself through induction heating. The alternating magnetic field induces eddy currents within the conductive fibres embedded in the matrix, generating heat internally throughout the material volume simultaneously. This self-heating mechanism achieves uniform curing without requiring removal from the platform or complex autoclave equipment, significantly reducing production downtime while maintaining curing quality.
3Productivity
If conductive fibres are added to resin matrix, then uniform heating and rapid curing are achieved, but the fibres need alignment to create effective conductive paths
Solution Approach 1:
The patent employs ultrasonic vibration to align the conductive fibres within the resin matrix. An ultrasonic alignment apparatus generates high-frequency vibrations that cause the fibres to orient themselves in specific directions, creating effective conductive networks for eddy current flow. This mechanical vibration method achieves fibre alignment without complex mechanical constraints or manual positioning, enabling rapid and uniform induction heating throughout the matrix.
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 method ensures high-quality, uniform curing with minimal thermal damage to surrounding areas, maintaining structural integrity and aerodynamic performance, and can be performed on-platform with reduced downtime, addressing the limitations of traditional repair methods.
Implementation Method 1
applying an energy field to the resin matrix to thereby align the second fibres such that they provide an electrically conductive path between adjacent layers of first fibres
Implementation Method 2
applying an electric current through the electrically conductive fibre network to thereby heat and cure the resin matrix
Data Source
AI summary
A method of forming a fibre composite component (10), the method comprising: providing a plurality of first fibres (102), the first fibres (102) being arranged in a plurality of layers (104a-e) with an uncured thermoset resin matrix (106) being provided therebetween. The resin matrix (106) comprises a plurality of second electrically conductive fibres (108) suspended therein having a shorter length than the first fibres (102). The method comprises then applying an energy field to the resin matrix (106) to thereby align the second fibres (108) such that they provide an electrically conductive path between adjacent layers (104a-e) of first fibres (102) to form an electrically conductive fibre network comprising the first and second fibres (102, 108). The method comprises then inducing an electric current through the electrically conductive fibre network to thereby heat and cure the resin matrix (106).