Plasma Torch Heating Composite Roving Deposition
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Solution Overview
Problem
Current heating technologies for composite material deposition, such as laser and convective heating, face limitations in productivity, energy efficiency, and cost due to high investment costs, limited power, and quality issues related to heat distribution and safety concerns.
Innovation Solution
A plasma torch system is used to heat composite wicks, operating in a laminar flow regime to achieve higher temperatures and improved heat transfer efficiency, with a plasma jet directed towards the compaction line between the wick and substrate, and a cooling and protection jet system to maintain stability and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser heating is used, then heating precision is improved, but investment cost and energy consumption increase significantly
Solution Approach 1:
The patent changes the fundamental heating parameter from laser (optical energy) to plasma (thermal energy), operating at different temperature ranges and energy efficiencies. The plasma torch operates at atmospheric pressure with temperatures up to 20,000K, achieving effective heating with lower energy consumption and no need for complex cooling systems required by lasers.
Solution Approach 2:
The plasma torch system uses consumable electrodes and replaceable nozzles that can be easily replaced, avoiding the high investment cost and maintenance expenses of laser systems. The plasma generator uses simple electromagnetic components rather than expensive laser optics and cooling infrastructure.
2Productivity
If laser power is increased to improve productivity, then deposition rate increases, but cost and cooling requirements increase
Solution Approach 1:
The patent replaces the laser optical system with an electromagnetic plasma generation system. The plasma torch uses electromagnetic fields to ionize gas and generate thermal energy, eliminating the need for optical components and associated cooling systems. This substitution enables higher productivity through direct thermal heating without the energy losses and cooling requirements of laser systems.
3Area of stationary object
If convective heating with hot gas is used, then heating coverage is improved, but temperature limit and energy efficiency worsen
Solution Approach 1:
The patent segments the heating function into multiple plasma jets that can be independently controlled and positioned. Each jet provides focused high-temperature heating, while the collective arrangement of multiple jets achieves broad heating coverage. This segmentation allows the system to overcome the temperature limits of single hot gas streams while maintaining extensive heating area through coordinated multiple plasma sources.
4Power
If turbulent plasma jet is used, then heating intensity is improved, but spatial coherence and stability worsen
Solution Approach 1:
The patent employs periodic stabilization techniques where the plasma jet parameters are modulated and controlled in a periodic manner to maintain laminar flow stability. By carefully controlling the gas flow rate, electrode positioning, and power supply frequency, the system achieves stable laminar plasma jets that maintain spatial coherence while delivering consistent heating intensity over time.
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 plasma torch system significantly increases productivity while reducing costs, achieving higher heat transfer efficiency and maintaining stable heating, thus overcoming the limitations of existing technologies.
Implementation Method 1
a plasma torch (1) mounted on said wick dispensing head (4), said plasma torch (1) being powered by an electric generator (G) and supplied by at least one plasma-generating fluid to generate a plasma jet (2) suitable for heating the wick(s) (3) to be deposited on the substrate (5)
Implementation Method 2
said plasma torch (1) being powered by an electric generator (G) and supplied by at least one plasma-generating fluid to generate a plasma jet (2)
Implementation Method 3
The plasma jet (2) is directed towards a compaction line between the wick(s) (3) and the substrate (5) to heat surfaces of the wick(s) (3) and the substrate (5) proximal to this compaction line
Implementation Method 4
plasma jet (2) suitable for heating the wick(s) (3) to be deposited on the substrate (5)
Implementation Method 5
a cooling and protection jet system to maintain stability and prevent overheating
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention concerns a system (100) for placing one or more rovings (3) made from composite material on a substrate (5), characterised in that the system comprises at least: - a roving-laying head (4) suitable for laying at least one roving (3), - an electricity generator (G), and - at least one plasma torch (1) mounted on the roving-laying head (4) and powered by the electricity generator (G), - the plasma torch (1) being further supplied with at least one plasma-forming fluid for generating at least one plasma jet (2) suitable for heating the roving or rovings (3) to be laid on the substrate.