Infrared Thermography for Real-Time Composite Defect Detection
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Solution Overview
Problem
Current methods for detecting defects in composite laminates, such as disbonds and inclusions, are inefficient as they require curing and subsequent inspection, leading to costly and time-consuming repair processes.
Innovation Solution
A system that applies thermal energy to uncured composite layers and uses digital thermographic imaging to identify defects by analyzing heat characteristics, allowing for real-time detection and correction before the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal energy is applied to uncured composite layers for real-time defect detection, then detection speed and correction efficiency are improved, but equipment complexity increases
Solution Approach 1:
The patent replaces mechanical/curing-based inspection methods with thermal energy application and infrared thermography. A heat source applies thermal energy to the composite laminate, and an infrared camera detects temperature variations caused by defects, enabling real-time inspection without curing the material first.
Solution Approach 2:
The patent introduces thermal energy as an intermediary to reveal defects. The heat source and infrared camera act as mediators that transfer thermal energy through the material and detect anomalies, allowing indirect observation of internal defects like disbonds and inclusions that are not visible on the surface.
2Ease of manufacture
If defects are detected after curing, then manufacturing process simplicity is maintained, but repair costs and time increase
Solution Approach 1:
The patent performs defect detection during the manufacturing process itself, before curing and before final assembly. By inspecting uncured or partially cured laminates, defects can be identified and corrected while the material is still accessible and modifiable, preventing rework later in the production cycle.
3Device complexity
If traditional inspection methods are used, then equipment cost is reduced, but detection accuracy and capability improve less
Solution Approach 1:
The patent uses thermal radiation detection where defects manifest as variations in temperature distribution. The infrared camera captures thermal images showing different temperatures as visual patterns, allowing defects to be identified through thermal contrast rather than physical appearance.
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 faster and cheaper detection and correction of defects in composite laminates, reducing the need for extensive repair procedures and improving the efficiency of the manufacturing process.
Implementation Method 1
a heat source arranged relative to the surface and operable to provide thermal energy to a surface of a first ply of material on the work surface
Implementation Method 2
a thermographic digital camera arranged relative to the surface and operable to capture at least one digital thermographic image of the surface of the first ply of material
Implementation Method 3
analyzing at least one heat characteristic of regions of the first ply of material in the at least one digital thermographic image to identify defect regions
Data Source
AI summary
Method and apparatus for detecting defects in a composite is provided. After a ply of material for a workpiece is positioned, thermal energy is applied to a top surface of the ply of material, and a digital thermographic camera captures images of the top surface. A computer processor determines heat characteristics of the top surface to identify regions of the top surface with different heat characteristics. Such different areas are identified as regions that include a defect. The defect regions can be repaired prior to disposing additional plies of material over previously-applied plies.