Pulsed Radiation Heating for Composite Tackiness Control
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Solution Overview
Problem
Existing methods for manufacturing composite articles using prepreg layers face challenges in efficiently and controllably increasing the tackiness of the layers during the manufacturing process, often leading to inconsistent heating and potential overheating, which can damage the materials.
Innovation Solution
Employing a pulsed electromagnetic radiation source, such as a Xenon flashlamp, to heat the contact surfaces of composite materials, allowing for quick, consistent, and controlled temperature increases, thereby enhancing tackiness and reducing the need for supplemental heating and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a continuous heat source is used to heat composite materials, then the heating consistency is improved, but the risk of overheating and material damage increases
Solution Approach 1:
The patent employs pulsed radiation sources that deliver heat in periodic bursts rather than continuous exposure. Each pulse provides a controlled amount of energy, and the intervals between pulses allow heat dissipation, preventing cumulative overheating while maintaining consistent heating effects across the material surface.
Solution Approach 2:
The heating system dynamically adjusts the timing, duration, and intensity of radiation pulses based on real-time material response. This dynamic control enables the system to adapt to varying material properties and environmental conditions, optimizing heat input while preventing excessive temperature rise that could damage the composite material.
2Productivity
If the heating speed is increased to improve manufacturing efficiency, then the productivity is improved, but the temperature control precision deteriorates
Solution Approach 1:
By using periodic pulsed radiation, the system achieves rapid heating during each pulse while the intervals between pulses provide natural cooling periods. This periodic cycle enables fast overall heating rates without sacrificing temperature control precision, as each pulse's effect is transient and可控.
Solution Approach 2:
The system applies preliminary heating pulses to raise the material temperature quickly to near-target levels, then uses subsequent smaller or more spaced-out pulses to fine-tune the temperature. This preliminary action approach enables rapid initial heating followed by precise temperature control.
3Reliability
If supplemental heating and cooling systems are added to prevent overheating, then the temperature control reliability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the cooling function from a separate supplemental system and integrates it into the heating process itself by using pulse intervals. The periods between radiation pulses naturally serve as cooling phases, eliminating the need for dedicated active cooling systems while maintaining reliable temperature control.
Solution Approach 2:
The pulsed radiation system performs multiple functions: heating during pulse intervals and cooling during off intervals. This multi-functional approach consolidates what would traditionally require separate heating and cooling systems into a single integrated pulsed radiation source, reducing overall system complexity.
4Productivity
If the radiation intensity is increased to reduce heating time, then the productivity is improved, but the risk of harmful effects increases
Solution Approach 1:
The system uses high-intensity radiation delivered in periodic pulses rather than continuous exposure. Each pulse provides intense heating to reduce overall processing time, while the intervals between pulses allow the material to dissipate excess heat, preventing cumulative damage from sustained high-intensity exposure.
Solution Approach 2:
The pulsed radiation approach rushes through the heating process in brief intense bursts rather than maintaining prolonged exposure. This skipping approach delivers the necessary thermal energy quickly to improve productivity while minimizing the total time the material is exposed to potentially harmful radiation intensities.
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 pulsed radiation source enables faster and more controlled heating and cooling of composite materials, improving manufacturing efficiency and preventing overheating, while accommodating both thermoplastic and thermoset materials' temperature requirements, thus facilitating efficient composite article production and repair.
Implementation Method 1
increasing the surface tack of a contact surface by exposing the contact surface, which comes into contact with another surface during said manufacturing, to radiation pulses emitted by a pulsed radiation source
Implementation Method 2
the heat source typically needs to apply energy quickly, consistently and controllably, in order to facilitate efficient manufacture
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
Apparatus and methods are disclosed for manufacturing a composite article from a composite material. An exemplary method comprises exposing a contact surface (305), which comes into contact with another surface (310) during said manufacture, to radiation pulses emitted by a pulsed radiation source (315a).