Embedded Heaters for Composite Curing
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Solution Overview
Problem
Existing composite laminate formation processes are inefficient and detrimental to structural properties due to the embedding of wires, which cause discontinuities, contamination, and increased weight, and the convective heating methods used for curing are slow, expensive, and imprecise.
Innovation Solution
The integration of embedded heaters within the composite laminate structure to generate heat for curing, reducing the need for external heating chambers and allowing for direct conductive heat transfer, thereby improving efficiency and control over the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wires are embedded through the laminate structure to provide electrical current, then power distribution is enabled, but structural properties are degraded due to discontinuities and stress concentrations
Solution Approach 1:
The patent extracts the harmful wire embedding from the laminate structure and replaces it with a surface-mounted electrical interface. The electrical connection is established through a conductive adhesive pattern applied to the laminate surface, eliminating the need for wires penetrating through the structural plies and cellular core, thereby preserving structural integrity while maintaining electrical functionality
Solution Approach 2:
The patent introduces a conductive adhesive as an intermediary between the electrical connection point and the laminate structure. This conductive adhesive serves as a mediator that provides electrical current distribution without requiring physical wire penetration through the laminate, thus avoiding the discontinuities and stress concentrations that would compromise structural properties
2Adaptability or versatility
If insulated wires are routed through the laminate surface at multiple locations, then electrical current delivery is achieved, but discontinuities such as bumps and stress concentrations are introduced
Solution Approach 1:
The patent replaces the mechanical wire routing system with a conformal conductive adhesive pattern applied to the laminate surface. This substitution eliminates the need for physical wire routing through the laminate surface, thereby avoiding the introduction of bumps and stress concentrations while maintaining electrical current delivery capability
Solution Approach 2:
The patent uses a thin conductive adhesive film applied to the laminate surface to provide electrical connection. This thin film approach allows for smooth integration with the laminate surface without creating protruding wire structures, thereby maintaining structural uniformity and avoiding stress concentrations
3Ease of manufacture
If wire stripping and preparation tasks are performed, then wire embedding is enabled, but foreign object debris contamination risk increases
Solution Approach 1:
The patent extracts the wire preparation and embedding process entirely from the manufacturing sequence. Instead of performing wire stripping and embedding tasks, the process uses direct application of conductive adhesive to the laminate surface, eliminating the sources of foreign object debris contamination associated with wire preparation while maintaining electrical connection capability
4Ease of manufacture
If convective heating processes are used to cure composite parts, then curing is achieved, but energy efficiency is poor due to heating large volumes of air and tooling
Solution Approach 1:
The patent employs self-curing resin systems that cure through chemical reaction without requiring external convective heating. The resin contains curing agents and catalysts that enable the curing process to occur autonomously at lower temperatures, eliminating the energy-intensive heating of large volumes of air and tooling while maintaining effective curing capability
Solution Approach 2:
The patent changes the curing parameters from high-temperature convective heating to lower-temperature chemical self-curing. By modifying the resin composition to include self-curing agents and catalysts, the curing process occurs through chemical reaction rather than thermal convection, dramatically reducing energy consumption while achieving effective cure
5Ease of manufacture
If large heating chambers are used for curing composite parts, then curing capacity is provided, but manufacturing cost and time increase
Solution Approach 1:
The patent uses self-curing resin systems that eliminate the need for large heating chambers and associated autoclave equipment. The resin cures autonomously through chemical reaction, removing the bottleneck of heating chamber availability and cycle time while maintaining adequate curing capacity for composite part fabrication
Solution Approach 2:
The patent changes the curing parameters from prolonged high-temperature convective heating in large chambers to accelerated chemical self-curing at lower temperatures. This parameter change dramatically reduces curing cycle time and eliminates the need for large heating chambers, thereby improving manufacturing productivity while maintaining curing capability
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 approach enables faster and more precise curing of composite parts, reducing waste energy and improving structural integrity, while also eliminating the need for large heating chambers, thus lowering manufacturing costs and times.
Implementation Method 1
one or more electrically resistive heaters configured to generate heat as an integral portion of the composite laminate structure
Implementation Method 2
direct conductive heat transfer from the heaters to a matrix
Data Source
AI summary
A system for forming a component includes one or more heaters configured to generate heat to form the component, wherein the component, upon formation, includes the one or more heaters. A method for forming a component includes generating, by one or more heaters, heat to form the component; and forming the component, at least in part, by said generating, wherein the component, upon formation, includes the one or more heaters.