Heated Tool Assembly for Composite Splice Uniformity
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Solution Overview
Problem
There is a need for an apparatus and method to join composite components of relatively long length without the need for an autoclave, while maintaining a substantially uniform temperature across the splice joint without significant temperature variation.
Innovation Solution
A bonding machine apparatus with a tool platform and pressure platform that are movable relative to each other, featuring a heating system and pressure bladder to apply uniform heat and pressure, along with a thermally conductive tool liner and heat sinks to ensure uniform temperature distribution across the mandrel and composite sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an autoclave is used to apply heat and pressure to composite components, then uniform temperature and pressure can be achieved, but the components must fit within the autoclave's length limitations
Solution Approach 1:
The heating system is divided into multiple independent heating zones along the mandrel, each capable of being controlled separately. This segmentation allows the system to handle longer components by dividing the heating function into manageable sections that can be independently adjusted to maintain uniform temperature across the entire length of the component.
Solution Approach 2:
A thermally conductive liner is introduced as an intermediary between the heating elements and the composite component. This liner acts as a heat distribution medium that conducts heat uniformly along the mandrel, ensuring temperature uniformity across long components without requiring the entire length to fit within a traditional autoclave chamber.
2Use of energy by moving object
If heating elements are placed directly on the mandrel, then heat can be applied efficiently, but temperature variation occurs across the length of the splice joint
Solution Approach 1:
A thermally conductive liner is placed between the heating elements and the mandrel to act as a heat distribution intermediary. This liner conducts heat uniformly along the mandrel surface, preventing localized overheating and ensuring even temperature distribution across the entire splice joint area while maintaining heating efficiency.
Solution Approach 2:
The heating system employs different heating element configurations and power levels for different zones along the mandrel. By adjusting the local heating characteristics in different regions, the system compensates for heat loss variations and maintains uniform temperature across the entire length of the splice joint.
3Strength
If pressure is applied uniformly across the composite components, then maximum mechanical properties are achieved, but the components must be contained within a fixed space
Solution Approach 1:
A flexible bladder is used to apply pressure to the composite components. The bladder can be inflated with gas or liquid to generate uniform pressure across the entire length of the components without requiring a rigid containment structure like an autoclave. This pneumatic/hydraulic approach simplifies the apparatus while maintaining the ability to apply uniform pressure for achieving maximum mechanical properties.
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 curing of composite structural members with uniform temperature across the splice joint, overcoming the limitations of traditional autoclave usage for long composite components.
Implementation Method 1
a heating system for heating the tool and a tool liner in thermal contact with the inner surface for distributing heat thereto in a substantially uniform manner
Implementation Method 2
a pressure bladder for applying pressure to the member. The pressure bladder may be supported by the pressure platform for pressing the member against the tool
Data Source
AI summary
A heated tool assembly for forming a structural member may include a heated tool and a pressure bladder for mounting the structural member. The tool may have an inner surface, a liner in thermal contact with the inner surface of the tool, and a heating system for heating the tool. The heating system may include a heater for heating a heated medium, a blower for blowing the heated medium, and a plurality of nozzles for directing the heated medium over the tool liner.