DBD-Assisted Joule Heating for Carbon Fiber Composite Curing

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Solution Overview

Problem

Conventional methods for producing thermosetting carbon fiber reinforced composites (CFRCs) require large thermal ovens and molds, limiting the ability to create complex shapes and being time-consuming, while current out-of-oven 3D printing techniques are restricted to UV-curable or rapid-curing resins, which are not applicable to most commercially relevant thermosetting resins.

Innovation Solution

The use of dielectric barrier discharge (DBD)-assisted Joule heating and Radio Frequency (RF) applicators to generate electric fields that locally heat and cure carbon fiber/resin composites during 3D printing, allowing for the creation of heat-cured CFRCs without the need for thermal ovens or molds, using conductive carbon fibers to induce heating and cure a wide range of thermosetting resins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional thermal ovens and molds are used to cure CFRCs, then the composites can be cured, but the process becomes time-consuming and limited in creating complex shapes

Engineering Contradiction:

Improvecuring speedVSAvoidcuring time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the conventional thermal oven system with a dielectric barrier discharge (DBD) plasma system. Instead of using thermal energy from large ovens to cure the composites, the invention uses plasma-generated localized heating through dielectric barrier discharge, enabling rapid in-situ curing without time-consuming oven treatments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The DBD applicator provides localized heating directly at the point where the carbon fiber/resin tow is extruded. The plasma energy is concentrated and applied only where needed during the extrusion process, allowing rapid curing of the specific area being printed without requiring heating of the entire composite structure in a large oven.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If UV-curable or rapid-curing resins are used for out-of-oven AM, then the resin can be cured quickly, but most commercially relevant thermosetting resins cannot be used

Engineering Contradiction:

Improveresin compatibilityVSAvoidcuring speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent changes the curing mechanism from UV-induced or chemically rapid-curing to plasma-induced thermal curing. By using dielectric barrier discharge to generate localized thermal energy, the system can cure a wide range of commercially available thermosetting resins (such as epoxies, polyesters, and vinyl esters) that would otherwise be incompatible with out-of-oven printing, while maintaining rapid curing speeds.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If large thermal ovens are used for heat-cured resin, then the resin can be cured, but the equipment becomes cumbersome and complex

Engineering Contradiction:

Improveprocess simplicityVSAvoidoven size

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention extracts the curing function from the large thermal oven system and concentrates it into a compact DBD applicator. Instead of using a large oven to heat and cure the entire composite, the plasma system performs the curing function in a localized, compact manner directly during the printing process, eliminating the need for large, cumbersome oven equipment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical thermal oven system with an electromagnetic plasma system. The DBD applicator uses dielectric barrier discharge to generate plasma, which provides localized thermal energy for curing. This substitution eliminates the need for large mechanical heating chambers and simplifies the overall manufacturing equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables the rapid curing of CFRCs in desired shapes, achieving properties similar to those produced in conventional ovens, with the ability to print complex 3D structures and multilayered structures without direct contact with the applicator, and allows for the use of most commercially available thermosetting resins, enhancing the efficiency and versatility of 3D printing processes.

Implementation Method 1

DBD-assisted Joule heating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

dielectric barrier discharge (DBD)-assisted Joule heating

Methodology Applied

Scientific EffectDielectric barrier discharge: Dielectric Heating

Implementation Method 3

electric fields to locally heat resin as it is extruded

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20240140020A1Free-form fabrication of continuous carbon fiber composites using electric fields

Publication Date: 2024.05.02 ESSENTIUM INC

AI summary

An out-of-oven system for free-form fabrication of continuous carbon fiber composites includes a dielectric barrier discharge (DBD) applicator configured to create an electric field proximal to the continuous carbon fiber composite. The DBD applicator includes a first electrode disposed within a dielectric barrier, and a second electrode spaced apart from the first electrode. The first and second electrodes are configured to allow the continuous carbon fiber composite to pass therebetween to cure the continuous carbon fiber composite. The system uses Joule heating to cure the continuous carbon fiber composite.