Dimensional Control Structure for Induction-Cured Composite Panels

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Solution Overview

Problem

Existing methods for curing composite parts out-of-autoclave are limited to small parts and require complex and expensive tooling, necessitating a need for simpler and cost-effective solutions suitable for large-scale composite part curing.

Innovation Solution

A dimensional control structure comprising a lattice of spar and rib stiffener proxies within an open casing, combined with a rigid curing tool and vacuum bagging material, allows for double vacuum debulking and curing of composite panels using induction heating, maintaining dimensional accuracy and reducing manufacturing time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional autoclave curing is used for composite parts, then curing quality and dimensional control are improved, but manufacturing cost and equipment complexity increase significantly

Engineering Contradiction:

Improvedimensional controlVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The curing system is segmented into modular components: a rigid curing tool for support, a flexible vacuum bagging material for sealing and vacuum application, and a dimensional control structure with lattice for precision. This segmentation allows each component to perform its specific function efficiently while reducing overall system complexity compared to traditional autoclaves.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The vacuum bagging material acts as an intermediary between the atmospheric pressure and the composite part, transmitting pressure uniformly during curing. The dimensional control structure serves as an intermediary that maintains precise dimensional control without requiring the complex mechanical restraint systems of traditional autoclaves.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If out-of-autoclave curing methods are used to reduce equipment complexity, then manufacturing cost and equipment simplicity are improved, but curing quality and dimensional control deteriorate

Engineering Contradiction:

Improveequipment simplicityVSAvoidcuring quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The dimensional control structure includes a lattice that replicates the desired final dimensions and geometry of the composite part. This lattice template guides the curing process to achieve precise dimensional control without requiring complex autoclave equipment, effectively copying the target geometry into the tooling design.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system utilizes changes in vacuum pressure parameters and thermal parameters through induction heating to achieve high-quality curing. By carefully controlling the vacuum level and heating rate, the process maintains curing quality comparable to autoclave methods while using simpler equipment.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If induction heating is used for localized heating, then energy efficiency and manufacturing time are improved, but heating uniformity may deteriorate

Engineering Contradiction:

Improvemanufacturing timeVSAvoidheating uniformity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The induction heating system applies heating locally to specific regions of the composite part that require it most, rather than heating the entire workpiece uniformly. This localized approach reduces overall manufacturing time and energy consumption while the vacuum bagging material helps distribute thermal energy to maintain adequate uniformity in critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The induction heating system provides continuous heating throughout the curing process without interruption, maintaining the thermal energy input needed for complete resin cure. This continuous useful action ensures thorough curing while minimizing total process time compared to intermittent heating methods.

Inventive Principle:

Principle #20Continuity of useful action

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 solution enables efficient curing of large composite parts with reduced manufacturing time and costs, while ensuring precise dimensional control and energy savings through localized heating, minimizing out-of-tolerance components.

Implementation Method 1

induction heating and smart susceptors

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

A vacuum is pulled in a first vacuum zone between a vacuum bagging material and a rigid curing tool while a composite material is on the rigid curing tool

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentEP4331819B1Dimensional control structure for curing a composite panel, unduction curing system and method of curing a composite panel

Publication Date: 2025.10.01 THE BOEING CO

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AI summary

Methods and an induction curing system for curing a composite panel. The induction curing system comprises; a rigid curing tool (302) configured to hold a composite material (306); a vacuum bagging material (312) sealed to the rigid curing tool (302); and a dimensional control structure (314) having a lattice (316) and an open casing (318) formed of a rigid material, the lattice positioned (316) within a concavity of the open casing (318), the dimensional control structure (314) sealed to at least one of the vacuum bagging material (312) or the rigid curing tool (302).