Localized 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 not suitable for repair needs.

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, then composite structures can be cured under controlled temperature and pressure, but throughput is limited and spot/remote curing is not available

Engineering Contradiction:

Improvecuring qualityVSAvoidthroughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent divides the curing process into localized segments using multiple portable curing units that can independently cure different portions of composite structures. Each unit contains its own heating and pressurization systems, allowing parallel curing of multiple sections simultaneously, thereby increasing throughput while maintaining curing quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces portability and mobility as a new dimension by using portable curing units with wheels or other mobility features. This allows the curing system to move to different locations (spot curing, remote curing) rather than requiring the workpiece to be transported to a fixed autoclave, enabling curing in previously inaccessible locations and improving productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If autoclave curing is used, then composite structures can be cured under controlled conditions, but transport of raw materials and cured components is required

Engineering Contradiction:

Improvecuring qualityVSAvoidtransport requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Instead of transporting the composite workpiece to a fixed autoclave for curing, the patent inverts the process by bringing the curing system to the workpiece location. The portable curing units can be positioned directly at the curing site, eliminating the need for transporting raw materials or cured components and simplifying operation.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If traditional curing equipment is used, then composite structures can be cured, but equipment costs and energy costs are high

Engineering Contradiction:

Improvecuring capabilityVSAvoidenergy cost

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The patent applies local quality by using portable curing units that concentrate heating and pressurization resources only where and when needed, rather than maintaining a large autoclave system that consumes energy continuously. Each portable unit has controlled heating elements and insulation that minimize energy waste, reducing overall energy costs while maintaining curing capability.

Inventive Principle:

Principle #3Local quality

4Reliability

If autoclave curing is used, then composite structures can be cured, but the process is not suitable for repair needs

Engineering Contradiction:

Improvecuring capabilityVSAvoidrepair suitability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamics by making the curing system portable and adaptable rather than fixed and static. The portable curing units can be quickly deployed and repositioned to accommodate repair work at various locations, and can be used on partially cured or fully cured structures, making the system versatile for both manufacturing and repair applications.

Inventive Principle:

Principle #15Dynamics

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 reduced equipment and energy costs, facilitating repair of composite parts outside a factory environment, and eliminating the need for secondary autoclave curing.

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

curing the composite structure

Methodology Applied

Scientific EffectThermal curing: Heating

Data Source

PatentUS20260070292A1Systems and methods for locally curing composite structures

Publication Date: 2026.03.12 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.