Fast Curing Process for Composite Laminate Components
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Solution Overview
Problem
Current composite laminate curing processes are time-consuming and costly, requiring lengthy cure cycles and inconsistent heating, which impairs material properties and necessitates fully curing individual components before bonding, leading to inefficiencies in manufacturing composite structures.
Innovation Solution
A fast curing method using a Dynamic Mechanical Analyzer to rapidly heat composite structures to 15-20 degrees F/min, achieving 80-90% cure and stiffness within 20-30 minutes, allowing for partial curing to maintain shape and stiffness, enabling subsequent bonding and final curing, thus reducing overall cycle time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cure cycles are used with slow heating rates (1-8 degrees F./per minute), then consistent heating and complete curing are achieved, but manufacturing time increases significantly (minimum of 120 minutes at cure temperature)
Solution Approach 1:
The patent changes the heating rate parameter from traditional slow rates (1-8 degrees F./per minute) to fast rates (15-20 degrees F./per minute), and introduces intermediate curing stages at different temperatures (first cure at lower temperature, second cure at higher temperature). This parameter transformation enables faster production while maintaining curing quality through controlled multi-stage heating.
Solution Approach 2:
The curing process is segmented into multiple stages: a first cure cycle at a lower temperature to achieve initial set and dimensional stability, followed by a second cure cycle at a higher temperature to complete the curing. This segmentation allows the material to be handled and bonded during the first stage without requiring complete curing, thereby reducing total cycle time while ensuring final material properties.
2Strength
If individual components are fully cured before bonding, then complete material properties are achieved, but manufacturing cost and time increase due to multiple separate cure cycles
Solution Approach 1:
The first cure cycle performs preliminary curing to achieve sufficient dimensional stability and handling strength, allowing components to be bonded together before final curing. This preliminary action eliminates the need for separate full curing operations after bonding, improving manufacturing efficiency while ensuring final material strength is achieved through the second cure cycle.
Solution Approach 2:
The patent merges the bonding operation with the curing process by performing bonding during the first cure cycle when components have sufficient strength, and then completing both bonding and curing in a single integrated operation. This consolidation eliminates multiple separate cure cycles and improves manufacturing efficiency.
3Loss of time
If fast heating rates (15-20 degrees F./per minute) are applied, then cure time is reduced to 20-30 minutes, but heating consistency may be compromised
Solution Approach 1:
The patent incorporates monitoring of the curing process and uses feedback to adjust heating parameters. The system tracks temperature, pressure, and material response during curing, allowing real-time adjustments to maintain heating consistency even at fast rates. This feedback mechanism ensures reliable curing while achieving reduced cycle times.
Solution Approach 2:
The curing process uses dynamic heating rates that can be adjusted during different stages. The system transitions from fast heating during the first cure cycle to controlled heating during the second cure cycle, allowing optimization of both speed and consistency at different phases of the process.
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 fast curing process significantly reduces manufacturing time and cost by allowing partial curing of composite structures, enabling them to be bonded and fully cured later, while maintaining dimensional stability and mechanical properties equivalent to fully cured materials, facilitating complex structure construction and quality assurance.
Implementation Method 1
The temperature of the component is rapidly raised by applying heat at an accelerated temperature for a ramp time
Implementation Method 2
heat is removed from the component to slow the curing process
Data Source
AI summary
A method for fast curing a component made from composite laminate. The method rapidly raising the temperature of the component by applying heat at an accelerated temperature for a ramp time, holding the temperature of the component at a set temperature for a set dwell time, and removing heat from the component to slow curing process. The method may additionally include inspecting the component after removing the component from heat, and curing the component a final time to equivalent or better strength.