Composite manufacturing method and apparatus
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Solution Overview
Problem
The fusion joining of composite materials is hindered by slow cooling cycles, inconsistent weld quality, and thermal conductivity issues, particularly with induction welding, where the cooling of composite parts is the rate-limiting step and can lead to variations in weld quality due to differing thicknesses and geometries.
Innovation Solution
The use of magnetocaloric materials to manage heat through a magnetic phase change, where a magnetic field is applied to induce a phase change in the magnetocaloric material, exhausting heat during the field application and allowing heat to flow from the composite part to the material for cooling, thereby regulating the temperature and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If induction welding is used to join composite parts, then heating efficiency and welding speed are improved, but cooling cycle time increases and weld quality consistency deteriorates
Solution Approach 1:
The patent applies magnetic phase transition of magnetocaloric material to achieve rapid cooling. When a magnetic field is applied to the magnetocaloric material, it undergoes a phase transition that absorbs heat from the composite part, enabling fast cooling without extending the cooling cycle time
Solution Approach 2:
The patent introduces magnetocaloric material as an intermediary between the induction coil and the composite part. This intermediary material facilitates heat transfer from the composite part during the cooling phase, improving cooling efficiency while maintaining welding speed
2Productivity
If induction welding is used to join composite parts, then welding speed is improved, but weld quality consistency deteriorates due to variable thickness and geometry
Solution Approach 1:
The magnetic phase transition of the magnetocaloric material provides controlled and uniform heat absorption during cooling, ensuring consistent thermal conditions across different part geometries and thicknesses, thereby improving weld quality consistency
Solution Approach 2:
The patent changes the thermal properties of the cooling system by using magnetocaloric material with specific magnetic and thermal characteristics. This allows precise control of the cooling rate and temperature distribution, maintaining weld quality consistency across variable geometries
3Speed
If magnetocaloric material is used for cooling, then cooling speed is improved, but device complexity increases
Solution Approach 1:
The magnetocaloric material serves multiple functions: it acts as a cooling medium during the cooling phase and can potentially serve as a heating element during the heating phase when exposed to magnetic fields. This multi-functionality reduces the need for separate heating and cooling systems, thereby reducing overall device complexity
Solution Approach 2:
The patent combines the heating induction coil and the cooling magnetocaloric material into a single integrated apparatus. The same magnetic field generation system is used for both heating (via eddy currents in the part) and cooling (via phase transition in the magnetocaloric material), simplifying the device structure
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
This method enables rapid and consistent heat removal from composite parts, addressing the slow cooling and inconsistency issues by utilizing the magnetocaloric effect to efficiently cool composite assemblies, ensuring uniform cooling across varying thicknesses and geometries.
Implementation Method 1
providing a magnetocaloric material; applying a magnetic field to the magnetocaloric material to induce a magnetic phase change of the magnetocaloric material; exhausting heat from the magnetocaloric material while the magnetic field is applied
Implementation Method 2
flowing heat from the composite part to the magnetocaloric material, to at least partially reverse the magnetic phase change and to cool the composite article or assembly
Implementation Method 3
A magnetic field is then applied by passing current through the induction coil. In many cases, a magnetic susceptor (typically a metallic mesh) is positioned between the faying surfaces, and eddy currents are induced in the magnetic susceptor causing the susceptor to heat up
Implementation Method 4
eddy currents are induced in the magnetic susceptor causing the susceptor to heat up and melt the matrix material in the region of the faying surfaces
Data Source
Figure 1(a)~1(d)
Figure 1(e)
Figure 2(a)~2(d)
AI summary
Disclosed are methods and apparatus for use in composite manufacturing, to facilitate cooling of composite parts. The methods and apparatus disclosed are of particular use in thermal joining methods. A magnetic field is applied to a magnetocaloric material to induce a magnetic phase change. Heat is exhausting heat from the magnetocaloric material while the magnetic field is applied and, when the magnetic field is disapplied, heat is flowed from the composite assembly to the magnetocaloric material, reversing the magnetic phase change and cooling the composite part. An induction coil for inductively heating the composite part may be used to apply the magnetic field.