Heated Tooling for Rapid Composite Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing composite aircraft components are resource-intensive and time-consuming, requiring long cure cycles and reliance on autoclaves, vacuum bags, and caul plates, which limits production efficiency and increases costs.
Innovation Solution
A system and method utilizing a tool with a heating element to rapidly cure composite preforms using quick cure resins, where a mandrel with an inner mold line is placed within a tool with an outer mold line surface, and a bladder assembly provides compression and support, allowing for rapid gelling and removal of composite structures without the need for extensive autoclave processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional autoclave curing process is used, then composite structures are properly cured, but production time is long (4 to 24 hours)
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and curing characteristics of the resin system. Quick-cure resins with modified chemistry enable significantly faster gel times and cure cycles compared to traditional resins, allowing production times to be reduced from 4-24 hours to much shorter durations while maintaining adequate curing quality
Solution Approach 2:
The patent implements preliminary action through pre-heating the tool and preparing the resin system in advance. By pre-heating the tool to the required curing temperature before placing the composite layup, and using pre-gelled or pre-impregnated materials, the actual cure cycle time is dramatically reduced while ensuring proper curing occurs immediately upon closure
2Manufacturing precision
If manual vacuum bagging and caul plate assembly is used, then composite layup is consolidated, but resource consumption and process complexity increase
Solution Approach 1:
The patent merges multiple separate consolidation functions into a single integrated tool design. The tool combines heating elements, compression mechanisms, and sealing features into one unified system that performs layup consolidation without requiring separate vacuum bags, manual assembly of caul plates, and multiple handling steps
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components from the traditional process. By removing the need for vacuum bags, separate caul plates, and complex sealing systems, the invention simplifies the consolidation process to use only the essential tool components that directly perform the consolidation function
3Manufacturing precision
If fixed tooling is used, then composite structures are manufactured, but production flexibility and efficiency are limited
Solution Approach 1:
The patent applies dynamics by making the tooling system adaptable and reconfigurable rather than fixed. The tool design allows for quick changes between different composite structures through removable mandrels, adjustable heating zones, and modular components, enabling the same tool to produce various parts with different geometries and sizes, thereby increasing production flexibility and rate
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 significantly reduces production time and resource usage, enabling faster cycle times and cost savings by using quick cure resins that gel in under 30 minutes, allowing for more efficient manufacturing of composite aircraft components.
Implementation Method 1
heating an outer mold line surface at a processing temperature
Implementation Method 2
gelling a first composite preform inside the outer mold line surface
Data Source
AI summary
A system and method for manufacturing a composite structure includes a tool having an outer mold line surface, a mandrel removably disposed within the tool and having an inner mold line surface, and a heating element connected to the tool. The heating element is configured to set a process temperature of the outer mold line surface when the mandrel is placed within the tool.