Induction Heating Blankets with Curie Susceptors
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Solution Overview
Problem
Current methods for curing complex, three-dimensional composite parts using induction heating are limited by the need for constant, evenly distributed heat and often require expensive or complicated tooling, making them unsuitable for large-scale or prototype production.
Innovation Solution
An enclosure with susceptor-based heating blankets that utilize inflatable bladders to maintain pressure and provide uniform temperature, combined with a method of using susceptor wires with different Curie temperatures to achieve efficient and controlled heating, allowing for the curing of complex three-dimensional structures without the need for an autoclave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional oven or autoclave heating is used to cure composite parts, then uniform temperature distribution is achieved, but equipment cost and complexity increase significantly
Solution Approach 1:
The patent replaces traditional mechanical heating systems (ovens, autoclaves) with an electromagnetic induction heating system. The induction heating blankets generate heat through electromagnetic fields interacting with susceptor materials, eliminating the need for complex mechanical heating equipment while achieving uniform temperature distribution across the composite part surface.
Solution Approach 2:
The patent introduces heating blankets containing susceptor materials as intermediaries between the electromagnetic field source and the composite part. These blankets absorb electromagnetic energy and convert it to heat, which is then transferred to the composite part, providing controlled and uniform heating without direct contact with complex heating equipment.
2Productivity
If induction heating with susceptors is used to cure small composite parts, then heating efficiency improves, but temperature uniformity deteriorates on three-dimensional structures
Solution Approach 1:
The patent divides the heating system into multiple segmented heating blankets that can be individually positioned and controlled. Each blanket segment contains susceptor materials distributed throughout its structure, allowing independent optimization of heating zones to achieve uniform temperature distribution across complex three-dimensional surfaces while maintaining high heating efficiency.
Solution Approach 2:
The patent implements local quality by varying the susceptor material composition, distribution, and properties within different regions of the heating blankets. This allows tailored heating characteristics for different areas of the composite part, ensuring optimal temperature uniformity across three-dimensional surfaces while preserving the high efficiency of induction heating.
3Temperature
If complex tooling is used to achieve even heat distribution, then temperature uniformity improves, but manufacturing cost increases
Solution Approach 1:
The patent employs disposable or reusable heating blankets as simple, low-cost alternatives to expensive custom tooling. These blankets can be easily manufactured, stored, and reused across multiple production runs, providing consistent temperature uniformity without the high upfront costs and complexity of custom-made heating fixtures or autoclave tooling.
Solution Approach 2:
The heating blankets are designed to be universal tools that can accommodate various composite part geometries and sizes. By adjusting blanket configuration, susceptor distribution, and heating parameters, the same basic heating system can cure different three-dimensional structures, eliminating the need for expensive application-specific tooling while maintaining temperature uniformity.
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 enables uniform temperature distribution and efficient curing of complex three-dimensional structures, reducing the need for expensive tooling and external air circulation, thus facilitating cost-effective and efficient production processes.
Implementation Method 1
at least one of the plurality of heating blankets comprises a conductor for receiving current and generating a magnetic field in response thereto
Implementation Method 2
a first susceptor wire comprising an alloy having a first Curie temperature point, and a second susceptor wire. The second susceptor wire comprising a second Curie temperature point that is different than the first Curie temperature point of the first susceptor wire
Data Source
AI summary
An enclosure for heating a three dimensional structure. The enclosure comprising a body defining a cavity therein. The cavity sized to receive a three dimensional structure. A plurality of heating blankets configured to heat the three dimensional structure to a substantially uniform temperature. At least one of the plurality of heating blankets comprises a conductor for receiving current and generating a magnetic field in response thereto, a first susceptor wire comprising an alloy having a first Curie temperature point and a second susceptor wire. The second susceptor wire comprising a second Curie temperature point that is different than the first Curie temperature point of the first susceptor wire.