Induction Heating Die for Thermoplastic Composite Consolidation
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Solution Overview
Problem
Existing methods for manufacturing composite parts with thermoplastic matrices and continuous natural fibers are limited by the risk of fiber burning and humidity vaporization during hot stamping, which leads to quality defects and inability to produce non-developable shapes like trihedral connections, and do not support high production rates suitable for large runs.
Innovation Solution
A device with induction heating and cooling capabilities, using a die with inductors and a punch system to heat and cool the part locally and uniformly, maintaining fiber tension and preventing humidity vaporization, allowing for the production of composite parts with four flanged edges and closed contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hot stamping is used to manufacture composite parts with thermoplastic matrices and continuous natural fibers, then the part can be formed into complex shapes, but the natural fibers are burned and humidity is vaporized causing quality defects
Solution Approach 1:
The heating process is segmented into distinct zones: a first heating zone that heats the composite material to form complex shapes, and a second heating zone positioned downstream that maintains temperature without causing fiber burning. This spatial segmentation allows different thermal treatments in different regions, enabling complex shaping while protecting natural fibers from degradation.
Solution Approach 2:
The composite material undergoes preliminary heating in the first heating zone before entering the second heating zone. This preliminary action prepares the thermoplastic matrix for forming while the material is still in a controlled state, preventing subsequent fiber burning that would occur if the entire process occurred in a single high-temperature zone.
2Ease of manufacture
If conventional manufacturing methods are used for composite parts, then production can be simplified, but high production rates suitable for large runs cannot be achieved
Solution Approach 1:
The manufacturing process employs continuous action through the dual heating zones where the composite material continuously moves through the first heating zone for forming and then through the second heating zone for temperature maintenance. This continuous process eliminates interruptions and enables high production rates suitable for large runs while maintaining manufacturing simplicity.
3Shape
If the composite material is heated to sufficient temperature for fiber sliding in non-developable areas, then the part can be formed correctly, but natural fibers are burned due to the high temperature
Solution Approach 1:
Different thermal conditions are applied to different regions of the composite material. The first heating zone provides sufficient temperature for fiber sliding and forming in non-developable areas, while the second heating zone maintains a lower temperature that prevents fiber burning. This local differentiation of thermal quality enables correct forming without fiber damage.
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 production of lightweight, strong composite parts with high mechanical resistance and precision, suitable for large runs, while avoiding fiber damage and humidity-related defects, and allowing for the creation of non-developable shapes like trihedral connections.
Implementation Method 1
A device with induction heating and cooling capabilities, using a die with inductors and a punch system to heat and cool the part locally and uniformly
Implementation Method 2
A device with induction heating and cooling capabilities, using a die with inductors and a punch system to heat and cool the part locally and uniformly
Data Source
AI summary
A device for compacting and consolidating a textile preform comprising continuous fibers impregnated with thermoplastic polymer, and a method for obtaining a part using such a device. The device comprises a die, an induction heating device and a cooling device to cool the die. The die includes a form comprising a cavity that corresponds to the shape of the part, which form extends depth-wise between an entry plane and a bottom and is inserted into a frame. The induction heating device comprises two inductors extending in hollows of the form, each forming a winding in a plan, substantially parallel to the entry plane of the cavity, and located between the entry plane and the bottom of the form.