Induction Cure Tool with Segmented Susceptors
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Solution Overview
Problem
The challenge in curing composite parts lies in managing temperature variations caused by exothermic reactions during the curing process, particularly in parts with both thin and thick areas, where conventional cure tools with large thermal mass struggle to quickly and evenly remove excess heat, leading to suboptimal curing results.
Innovation Solution
The method employs induction heating of matched laminated tools with smart susceptors and tailored cooling systems that apply coolant directly to selected areas of the susceptors to maintain uniform temperature, using sensors and a programmed controller to manage temperature and cooling based on real-time data from multiple locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cure tools with large thermal mass are used, then the tools can maintain structural stability, but the heat from exothermic reactions cannot be quickly removed, resulting in suboptimal curing
Solution Approach 1:
The cure tool is divided into multiple independently controllable zones with separate heating and cooling elements. This segmentation allows different regions of the tool to be managed independently, enabling rapid heat removal from specific areas where exothermic reactions occur while maintaining structural integrity of the overall tool.
Solution Approach 2:
The cure tool incorporates dynamically controllable heating and cooling elements that can be activated or deactivated based on real-time temperature feedback. This dynamic control system allows the tool to adapt its thermal characteristics during the curing process, quickly removing heat from problematic areas while maintaining stability where needed.
2Reliability
If slow temperature ramp-up profiles are used to control exothermic reactions, then temperature variations can be managed, but production throughput is reduced
Solution Approach 1:
The tool is divided into multiple zones with independent temperature control, allowing different regions to be heated at different rates. This enables rapid overall heating while controlling local exothermic reactions through targeted cooling in specific zones, thereby maintaining both temperature control quality and production speed.
Solution Approach 2:
Temperature sensors are positioned throughout the cure tool to provide real-time feedback on temperature distribution. This feedback system enables the control system to detect and respond to exothermic reactions as they occur, allowing for rapid temperature adjustments without slowing down the overall curing process, thus maintaining high throughput while ensuring proper temperature control.
3Temperature
If cooling is applied to remove excess heat from thick areas, then temperature control in thick regions is improved, but the temperature in thinner areas drops below the desired cure temperature
Solution Approach 1:
The cure tool is segmented into multiple independently controllable zones with separate heating and cooling elements positioned at different locations. This allows selective cooling of thick areas where exothermic reactions occur while simultaneously maintaining or applying heat to thinner areas, ensuring uniform temperature distribution across the entire part and complete curing throughout.
Solution Approach 2:
Different regions of the cure tool are given different thermal characteristics tailored to their specific requirements. Thick areas receive enhanced cooling capability to manage exothermic heat, while thinner areas receive enhanced heating capability to ensure adequate cure temperature, creating locally optimized thermal environments for reliable curing throughout the entire part.
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 allows for precise and rapid temperature control, ensuring consistent heating across the composite part layup without the need for slow thermal cycles, thereby improving curing efficiency and maintaining optimal temperature conditions.
Implementation Method 1
The susceptors are heated by an induction heating system in order to cure and consolidate the layup
Implementation Method 2
A cooling system cools those sections of the susceptors that have overheated
Implementation Method 3
binder resins that may generate exothermic reactions during curing
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A composite part layup is cured using a set of tools adapted to hold the layup and which include at least one tool face contacting the layup. Means are provided for heating the tool face to cure the part layup, and for selectively cooling sections of the tool face.