Resistor Wire Embedded in Composite Curing for Antenna Integration
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Solution Overview
Problem
Current methods for curing composite materials and embedding antennas in parts, such as those used in high-speed vehicles, face challenges with temperature gradients leading to uneven curing and added complexity without improving other manufacturing steps.
Innovation Solution
A method involving a resistor wire embedded within the composite material that serves dual purposes of curing the material and forming an embedded antenna, where the resistor wire is heated internally to reduce temperature gradients and uniformly cure the composite, while being severed to create antennas capable of detecting specific radio wave frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external heat is applied to cure composite materials, then the composite material can be cured, but temperature gradients and uneven curing occur within the part
Solution Approach 1:
The patent combines the heating function and antenna function into a single resistor wire element. The resistor wire serves dual purposes: generating heat for uniform curing and forming an embedded antenna structure. This merging eliminates the need for separate heating devices and antenna components, while ensuring uniform temperature distribution throughout the composite material during curing.
Solution Approach 2:
The composite material contains embedded resistor wires that generate their own heat when electrical current is applied. This self-heating mechanism eliminates the need for external heating equipment and ensures uniform heat generation from within the material itself, preventing temperature gradients and achieving even curing throughout the part.
2Object-affected harmful factors
If antennas are embedded in composite parts, then drag reduction is achieved, but manufacturing complexity increases
Solution Approach 1:
The resistor wire performs multiple functions simultaneously: it acts as a heating element for curing the composite material, serves as an embedded antenna for radar cross-section reduction, and provides structural reinforcement within the composite. This multi-functionality eliminates the need for separate antenna components and simplifies the manufacturing process while achieving drag reduction.
Solution Approach 2:
The patent merges the antenna structure with the curing heating element into a single resistor wire component. This integration means that the same element used for uniform curing also provides the embedded antenna functionality needed for drag reduction, thereby reducing manufacturing complexity rather than increasing it.
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 approach ensures uniform curing of composite materials and integrates antennas seamlessly, reducing manufacturing complexity and improving the structural integrity of parts like aircraft components.
Implementation Method 1
heat generated internally by the resistor wire
Implementation Method 2
antennas capable of detecting specific radio wave frequencies
Data Source
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AI summary
A method of making a part comprising stacking a plurality of uncured composite sheets to form an uncured composite stack. The method also comprises interposing a resistor wire between an adjacent two of the uncured composite sheets of the uncured composite stack. The method further comprises applying heat to the uncured composite stack externally of the uncured composite stack to at least partially cure the plurality of uncured composite sheets. The method additionally comprises transmitting an electric current through the resistor wire to generate heat, from the resistor wire, internally within the uncured composite stack to at least partially cure the plurality of uncured composite sheets. Applying heat to the uncured composite stack externally and generating heat internally converts the plurality of uncured composite sheets into a plurality of cured composite sheets and converts the uncured composite stack into a cured composite stack.