Local Composite Curing With Expandable Pressure Enclosure

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Solution Overview

Problem

Existing composite manufacturing processes require autoclaves for curing, which lead to bottlenecks due to throughput limitations and the inability to perform spot or remote curing, and are costly in terms of equipment and energy consumption.

Innovation Solution

A system utilizing a constraining container with an expandable medium that applies positive pressure to uncured or partially cured composite structures, allowing for localized curing without the need for autoclaves, using expandable materials and controlled heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If autoclave curing is used for composite materials, then the composite structure can be cured under controlled temperature and pressure conditions, but the manufacturing process experiences bottlenecks due to throughput limitations and requires transport of materials to and from the autoclave

Engineering Contradiction:

Improvecuring qualityVSAvoidmanufacturing throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent divides the curing process into localized segments using multiple portable curing devices that can independently cure different portions of composite structures. Each device contains its own heating and pressurization systems, allowing parallel curing operations across multiple locations simultaneously, thereby eliminating the single-bottleneck autoclave and improving overall manufacturing throughput while maintaining controlled curing conditions.

Inventive Principle:

Principle #1Segmentation

2Reliability

If autoclave curing is used, then composite materials can be cured under pressure, but the equipment and energy consumption are high

Engineering Contradiction:

Improvecuring qualityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The patent implements local quality by applying pressure and heat only to the specific portions of composite structures that require curing, rather than pressurizing entire large autoclave chambers. Each portable curing device concentrates energy delivery to its local treatment zone, significantly reducing overall energy consumption while maintaining the necessary temperature and pressure conditions for high-quality curing.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If autoclave curing is used, then composite materials can be cured uniformly, but spot curing, repair, and remote curing needs cannot be met

Engineering Contradiction:

Improvecuring uniformityVSAvoidcuring flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent creates universal portable curing devices that can perform multiple functions: initial curing of new composite portions, spot curing of specific areas, repair of damaged sections, and remote curing in field conditions. Each device is self-contained with heating, pressurization, and control systems, allowing it to adapt to various curing scenarios while maintaining uniform curing quality through controlled temperature and pressure application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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, cheaper, and more flexible curing with a smaller footprint, eliminating the need for large autoclaves and allowing for repair of composite parts outside a factory environment.

Implementation Method 1

An expandable medium is disposed within the interior volume between the cover and the composite structure and is configured to expand to a predetermined volume when a predetermined change is produced in an attribute of the expandable medium such that the expandable medium applies positive pressure to the composite structure and the walls of the cover

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the expandable medium applies positive pressure to the composite structure and the walls of the cover

Methodology Applied

Scientific EffectPressure application: Pressure Increase

Implementation Method 3

For many composite materials, the manufacturing process includes curing the composite structure, typically under elevated temperatures and pressures

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS20250340026A1Systems and methods for locally curing composite structures

Publication Date: 2025.11.06 THE BOEING CO

AI summary

A system for locally curing a composite structure includes a constraining container including a cover and having an interior volume. The cover is configured to enclose a portion of a composite structure. The system includes a retainer configured to hold the cover against the composite structure. The system included an expandable medium configured to be disposed within the interior volume of the cover between the walls and the composite structure.