Laminate Heating Layout for Uniform Pressure and Deformation Control
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Solution Overview
Problem
Existing methods for fusing composite materials with thermoplastic resin struggle with proper pressurization during heating, leading to potential deformation due to uneven temperature distribution and lack of pressure, which can result in molding defects.
Innovation Solution
A heating device and method that uses a combination of a heating unit, cooling unit, and pressurizing unit to control temperature and apply pressure simultaneously, ensuring the thermoplastic resin is heated above its softening point while being cooled below it, with the cooling unit surrounding the heating unit to maintain uniform pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is injected into the space between the induction coil and the composite material surface to protect from heat damage, then the surface temperature is lowered, but the composite material cannot be pressurized toward the fusion position
Solution Approach 1:
The device divides the processing area into two distinct zones: a heating zone with the induction coil where air injection cools the surface, and a pressurizing zone with rollers that apply pressure. This segmentation allows independent control of temperature and pressure in different spatial regions, resolving the contradiction between surface cooling and pressurization.
Solution Approach 2:
Air is introduced as an intermediary cooling medium between the induction coil and composite material surface to prevent excessive heating. Simultaneously, rollers act as mechanical intermediaries to transfer pressurizing force to the composite material at the fusion position, enabling both cooling and pressurization functions to coexist without interference.
2Stress or pressure
If the composite material is pressurized by a roller at a position conveyed from the heating position, then pressurization is achieved, but the thermoplastic resin temperature becomes lower than at the heating position
Solution Approach 1:
The composite material is pressurized by rollers at the heating position before being conveyed to the fusion position. This preliminary pressurization ensures the thermoplastic resin remains at elevated temperature during the pressurization process, maintaining optimal conditions for fusion while achieving the necessary mechanical pressure.
3Use of energy by stationary object
If a heating device contacts the composite material to heat while pressurizing, then heating and pressurization are achieved simultaneously, but the non-pressurized portion may be heated causing deformation
Solution Approach 1:
The heating device is designed with selective contact regions: contact portions that apply both heating and pressurization, and non-contact portions that avoid heating. This local differentiation ensures that only the intended areas receive thermal energy, preventing unwanted deformation in non-pressurized regions while maintaining efficient heating where needed.
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
Prevents deformation by maintaining uniform temperature and pressure across the laminate, ensuring effective fusion of composite materials without expansion or molding defects.
Implementation Method 1
a heating unit that heats, through a first contact surface that is in contact with the laminate, the thermoplastic resin included in the laminate that comes into contact with the first contact surface to a temperature equal to or higher than a softening temperature
Implementation Method 2
a cooling unit that cools, through a second contact surface that is in contact with the laminate, the thermoplastic resin included in the laminate located outside the second contact surface to a temperature lower than the softening temperature
Data Source
Figure 1~2
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AI summary
Provided is a heating device (100) comprising: a heating unit (10) that heats a laminate (200) which includes a plurality of sheet-like composite materials (201-206) including reinforced fiber and thermoplastic resin, and heats, via a first contact surface (11a) disposed in contact with the laminate (200), the thermoplastic resin included in the laminate (200) in contact with the first contact surface (11a) to a softening temperature or higher; a cooling unit (20) that cools, via a second contact surface (21a) disposed in contact with the laminate (200), the thermoplastic resin included in the laminate (200) located outside of the second contact surface (21a) to a temperature lower than the softening temperature; and a pressing unit (30) that applies a predetermined pressure to the laminate (200) via the first contact surface (11a) and the second contact surface (21a), the second contact surface (21a) being disposed so as to surround the first contact surface (11a).