Contoured Shroud for Uniform Composite Curing
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Solution Overview
Problem
Conventional industrial ovens are inadequate for curing large composite material structures like aircraft parts due to non-uniform heating, leading to structural warping, and lack the pressure required for high-performance resin systems, making them unsuitable for large-scale aerospace manufacturing.
Innovation Solution
An industrial oven system with a contoured shroud that directs heated airflow through annular channels to achieve uniform temperature distribution along the length of the composite material structure, using computational fluid dynamics to optimize heat transfer and airflow velocity, ensuring consistent heating rates and preventing warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional industrial ovens are used to cure large composite material structures, then the cost of operation is reduced compared to autoclaves, but the temperature distribution becomes non-uniform causing structural warping
Solution Approach 1:
The shroud is contoured with varying cross-sectional shapes along its length to create different airflow characteristics at different locations. This local variation in shroud geometry directs heated airflow preferentially to thicker portions of the composite structure, achieving non-uniform heat distribution that compensates for the thermal mass differences and results in uniform temperature across the entire structure.
Solution Approach 2:
The shroud employs curved and contoured surfaces rather than straight cylindrical geometry. The contoured shroud includes varying radial distances from the central axis, creating annular channels with non-uniform cross-sections that optimize airflow distribution and heat transfer to different regions of the composite material structure.
2Device complexity
If conventional industrial ovens are used to cure large composite material structures, then the equipment complexity is reduced compared to autoclaves, but the heating rate becomes insufficient causing prolonged curing time
Solution Approach 1:
The contoured shroud acts as an intermediary component between the heated airflow source and the composite material structure. It modifies and conditions the heated airflow before it reaches the structure, concentrating thermal energy where needed and directing flow patterns that enhance heat transfer efficiency, thereby achieving faster curing rates without requiring autoclave-level pressure systems.
Solution Approach 2:
The system utilizes controlled airflow through the contoured shroud to deliver thermal energy to the composite structure. By manipulating air flow velocity, temperature, and distribution patterns through the annular channels, the system achieves efficient heat transfer and accelerated curing while maintaining atmospheric pressure operation.
3Ease of operation
If heated airflow is directed uniformly across the composite material structure, then the simplicity of heating is maintained, but temperature gradients cause warping of the structure
Solution Approach 1:
The contoured shroud creates locally optimized heat distribution by varying its cross-sectional geometry along the length of the structure. Thicker portions receive concentrated heated airflow through corresponding sections of the shroud, while thinner portions receive reduced airflow, achieving uniform temperature distribution that prevents warping without requiring complex external control systems.
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 provides uniform temperature control and desired heating rates, effectively preventing structural warping and enabling the curing of large composite material structures, such as aircraft parts, while maintaining cost-effectiveness compared to aerospace autoclaves.
Implementation Method 1
The shroud is contoured to direct a heated airflow along the annular channels and over the composite material structure to cure the composite material structure
Implementation Method 2
using computational fluid dynamics to optimize heat transfer and airflow velocity
Data Source
AI summary
An industrial oven system for curing composite material parts can include an oven compartment configured to receive a composite material structure therein that extends along a majority of the length and/or width of the compartment, the compartment having an inner wall that defines a cavity between proximal and distal ends of the compartment. A shroud can be disposed circumferentially between the inner wall of the compartment and an outer wall of the composite material structure. The shroud defines a first longitudinal annular channel between the inner wall and an outer surface of the shroud, and defines a second longitudinal annular channel between the outer wall of the composite material structure and an inner surface of the shroud. The shroud is contoured to direct a heated airflow longitudinally along the annular channels and over the composite material structure to cure the composite material structure, the heated airflow generally being at a higher temperature than a surface of the composite material part. One or more contour elements of the shroud can direct more heat to a corresponding thicker portion of the composite material structure generally aligned with the contour element relative to an amount of heat directed to adjacent relatively thinner portions of the composite material structure so as to effect a desired heating rate of the composite material structure to achieve a substantially uniform temperature along substantially the entire length of the composite material structure, thereby inhibiting warping of the composite material structure during a curing process.