Fiber-Reinforced Composite Structures With Pulsed Induction Curing
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Solution Overview
Problem
Existing resin curing methods for fiber reinforced polymeric structures, particularly those involving high temperature resins, pose a risk to heat-sensitive materials like rocket propellants due to excessive thermal energy, leading to potential decomposition or ignition.
Innovation Solution
Employing electromagnetic induction processes that are pulsed and optionally coupled with cooling steps between pulses to control thermal energy application, allowing precise curing of resin systems with a broad range of temperatures without damaging heat-sensitive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high temperature resin systems are employed to achieve high temperature strength, then the mechanical properties at elevated temperatures are improved, but excessive thermal energy is imparted to heat sensitive materials causing decomposition or ignition
Solution Approach 1:
The patent applies periodic pulsed electromagnetic induction heating instead of continuous heating. The process uses a series of controlled heating pulses with intermediate cooling periods, allowing the resin to cure through cumulative thermal exposure while preventing excessive temperature buildup that would damage heat-sensitive materials like rocket propellant.
Solution Approach 2:
The patent changes the heating parameters by using electromagnetic induction heating with controllable pulse duration, frequency, and power levels. This allows precise control of thermal energy input to match the resin's curing requirements without exceeding the thermal tolerance of sensitive materials, enabling the use of high-temperature resin systems safely.
2Reliability
If conventional oven curing methods are used, then resin curing is achieved, but thermal control is insufficient leading to excessive energy imparted to the structure
Solution Approach 1:
The patent replaces conventional thermal convection oven heating with electromagnetic induction heating. This substitution enables direct, controlled, and rapid heating of the resin through electromagnetic fields, providing superior thermal control and reducing wasted thermal energy while ensuring reliable resin curing.
Solution Approach 2:
The patent implements precise control of heating parameters including pulse width, duty cycle, and power level through the electromagnetic induction system. This allows the curing process to be optimized for minimum energy input while achieving complete resin cure, eliminating the excessive energy waste associated with conventional oven methods.
3Object-affected harmful factors
If pulsed electromagnetic induction processes are used to control thermal energy, then heat sensitive materials are protected, but process complexity increases
Solution Approach 1:
The patent incorporates feedback control mechanisms that monitor temperature and adjust the electromagnetic induction heating pulses in real-time. This feedback system automatically optimizes the pulse parameters to achieve complete resin curing while preventing overheating of sensitive materials, simplifying the operational complexity despite the pulsed process design.
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 safe and efficient curing of fiber reinforced polymer structures, maintaining mechanical properties at elevated temperatures while protecting heat-sensitive components from thermal damage.
Implementation Method 1
electromagnetic induction processes that are pulsed processes that can be optionally coupled with cooling steps between pulses
Implementation Method 2
electromagnetic induction processes that are pulsed processes that can be optionally coupled with cooling steps between pulses to control thermal energy application
Implementation Method 3
pulsed processes that can be optionally coupled with cooling steps between pulses to control thermal energy application
Data Source
AI summary
The present invention relates to resin compositions, fiber reinforced polymeric structures and electromagnetic induction processes for making same. Such magnetic induction processes are pulsed processes that can be optionally coupled with cooling steps between pulses. The aforementioned fiber reinforced polymeric structures can take forms that include, but are not limited to, pipes; pressure vessels, including rocket motor cases and fire extinguishers; golf club shafts; tennis and badminton racquets; skis; snowboards; hockey sticks; fishing rods; bicycle frames; boat masts; oars; paddles; baseball bats; and softball bats. In addition, such fiber reinforced polymeric structures can be supplemented with other materials, such as a rocket propellant, to form articles, for example, a rocket motor.