Induction Heated Composite Tooling with Segmented Cooling
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Solution Overview
Problem
Current composite fabrication techniques face limitations in achieving controlled cooling and maintaining dimensional accuracy and full consolidation of composite components, which affects the performance and weight savings in production processes.
Innovation Solution
A composite fabrication apparatus comprising a stacked tooling apparatus with hydraulically-actuated tooling dies, induction coils for heating, thermally-conductive die susceptors, and a cooling system to rapidly heat, consolidate, and cool composite materials, ensuring precise shaping and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heated dies are used for composite fabrication, then heating capability is improved, but controlled cool-down capability deteriorates
Solution Approach 1:
The tooling system is segmented into separate heating and cooling functional zones. Heating is achieved through induction coils coupled with die susceptors in specific regions, while independent cooling channels provide controlled cool-down in other regions. This segmentation allows simultaneous or sequential operation of heating and cooling functions without interference.
Solution Approach 2:
Die susceptors are introduced as intermediary elements between the induction coils and the composite workpiece. These susceptors efficiently transfer electromagnetic energy to thermal energy locally, enabling precise heating control. The cooling medium serves as an intermediary heat sink, absorbing excess heat and enabling controlled cool-down rates independent of the heating system.
2Productivity
If rapid heating and consolidation is achieved, then production rate is improved, but dimensional accuracy deteriorates
Solution Approach 1:
The system incorporates feedback control through thermocouples positioned at multiple locations within the tooling and composite stack. These sensors continuously monitor temperature and provide real-time feedback to the control system, which adjusts induction coil power and cooling flow rates to maintain target temperature profiles. This closed-loop control enables rapid heating while preventing thermal runaway that would compromise dimensional accuracy.
Solution Approach 2:
The tooling system employs dynamic control of heating and cooling rates based on real-time process conditions. Induction heating power and cooling medium flow rates are continuously adjusted during the consolidation process to optimize both production speed and dimensional control. The system transitions from rapid heating to controlled cool-down at optimal moments in the process cycle.
3Strength
If full consolidation of composite is achieved, then structural integrity is improved, but production time increases
Solution Approach 1:
The tooling is pre-heated to target consolidation temperatures before the composite material is introduced. Die susceptors are pre-positioned and electrically connected to induction coils that are already energized or can be rapidly energized. This preliminary preparation eliminates warm-up time during production cycles, enabling rapid achievement of consolidation temperatures without compromising structural integrity.
Solution Approach 2:
Traditional convective or conductive heating methods are replaced with electromagnetic induction heating. This substitution enables much faster and more uniform heating of the composite and tooling, reducing the time required to reach consolidation temperatures. The induction system provides direct volumetric heating that penetrates through the composite stack, achieving full consolidation faster than surface-based heating methods.
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 apparatus enables efficient production of composite components with improved dimensional accuracy and performance by optimizing the heating and cooling processes, allowing for rapid and controlled consolidation and cooling, thus enhancing the structural integrity and weight savings in composite materials.
Implementation Method 1
a thermal control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die
Implementation Method 2
heating the first tooling die and the second tooling die
Implementation Method 3
a cooling system disposed in thermal contact with the first tooling die and the second tooling die
Data Source
AI summary
A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a thermal control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A composite fabrication method is also disclosed.