Laser Heating System for Aircraft Composite Patch Curing
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Solution Overview
Problem
Current heating systems for composite structures in aircraft rework, such as heat blankets, fail to provide uniform heating, leading to inconsistencies and potential damage to surrounding components during the curing process of composite patches.
Innovation Solution
A rework system comprising a laser unit and a controller, which generates laser beams to achieve a desired level of heating for curing composite patches on composite structures, while a sensor system monitors temperature and a mask system protects adjacent components from excessive heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat blankets are used for heating composite patches, then the heating process can be performed, but uniform heating is not achieved
Solution Approach 1:
The patent replaces the mechanical contact-based heat blanket system with a non-contact laser heating system. The laser unit directs energy precisely onto the composite patch without physical contact, eliminating the uneven thermal distribution caused by heat blanket contact issues and achieving uniform heating across the patch surface.
Solution Approach 2:
The laser heating system applies heat locally and selectively to specific areas of the composite patch through controlled laser beam positioning. This allows precise temperature control at different locations on the patch, ensuring uniform heating across the entire surface while avoiding overheating of surrounding components.
2Temperature
If heat blankets are used for heating, then heating can be applied, but surrounding components may be damaged by excessive heat
Solution Approach 1:
The laser heating system provides highly localized heating by directing the laser beam only onto the composite patch area that requires curing. This concentrated energy delivery heats only the intended target without significantly affecting surrounding components, thus preventing heat damage while maintaining effective curing temperatures.
Solution Approach 2:
The heating process is segmented into controlled zones using the laser system, which can be precisely positioned and moved to treat only the specific patch area. This segmentation isolates the heat application to the necessary region, preventing thermal spread to adjacent components that are not part of the curing process.
3Device complexity
If conventional heating systems are used, then the process is simple, but heating uniformity and control are insufficient
Solution Approach 1:
The patent replaces complex mechanical contact-based heating systems with a laser-based optical system. While the laser system introduces new technological elements, it eliminates the need for physical contact mechanisms, insulation layers, and complex thermal management hardware, achieving precise temperature control through optical energy delivery.
Solution Approach 2:
The laser heating system allows precise control of heating parameters including power output, beam duration, spot size, and movement speed. These parameters can be adjusted and programmed to achieve exact temperature profiles required for different composite materials and patch sizes, providing superior temperature control precision compared to conventional systems.
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 system ensures uniform and controlled heating of composite patches, preventing damage to surrounding components and enhancing the curing process's efficiency and effectiveness.
Implementation Method 1
The laser unit is configured to generate a number of laser beams
Data Source
AI summary
A method and apparatus comprising a laser unit and a controller. The laser unit is configured to generate a number of laser beams. The controller is configured to operate the laser unit to generate the number of laser beams resulting in a desired level of heating of a composite patch that cures the composite patch on a composite structure.