Self-Heating Composite Tool Using Carbon Nanotube Resin
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Solution Overview
Problem
The aerospace industry faces challenges in forming large composite structures without the need for expensive and size-constrained autoclaves or conventional ovens, which are required for curing pre-preg materials.
Innovation Solution
A self-heating tool is developed using carbon nanotube impregnated resin with embedded conductive strips and insulation layers, allowing for internal heating of composite structures without external ovens, enabling efficient curing of composite materials on the production floor and facilitating mass production of smaller parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional autoclaves or conventional ovens are used to cure pre-preg material, then the composite structure can be cured, but the equipment size and operating costs increase significantly
Solution Approach 1:
The tool itself is equipped with heating elements that enable it to cure the pre-preg material directly, making the tool self-sufficient for the curing process. This eliminates the need for external autoclaves or ovens, allowing the tool to serve both forming and curing functions.
Solution Approach 2:
The heating elements are integrated directly into the tool structure, merging the curing function with the forming tool. This combination eliminates the need for separate curing equipment and reduces overall system complexity.
2Reliability
If traditional autoclaves or conventional ovens are used to cure pre-preg material, then the composite structure can be cured, but the building and operating costs increase
Solution Approach 1:
The tool generates its own heat through integrated heating elements, eliminating the need for expensive external autoclave or oven facilities. This self-powered approach significantly reduces both capital expenditure on equipment and operational costs.
Solution Approach 2:
The patent replaces the mechanical/thermal system of external autoclaves or ovens with an electrical heating system integrated into the tool. This substitution uses electricity directly at the point of need, eliminating the need for large thermal processing equipment and reducing operating costs.
3Reliability
If external ovens are used for curing, then curing can be achieved, but the production flow speed decreases and part throughput is limited
Solution Approach 1:
Each tool is equipped with its own heating elements, enabling immediate curing of pre-preg material directly on the tool after forming. This eliminates the need to wait for external oven cycles, significantly increasing part flow speed and productivity.
Solution Approach 2:
The heating elements are pre-installed in the tool during manufacturing, so that curing capability is ready before the tool is used. This preliminary preparation allows for immediate curing action without requiring additional equipment setup or waiting 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
This solution eliminates the need for large autoclaves and ovens, allowing for efficient curing of composite structures on-site, reducing costs and enabling faster part flow through manufacturing plants while allowing for the production of larger composite parts without size constraints.
Implementation Method 1
heating the tool internally to cure the pre-preg material
Implementation Method 2
carbon nanotube impregnated resin with embedded conductive strips
Data Source
Figure 1
Figure 2~3A
Figure 3B~3C
AI summary
Method and apparatus for curing composite material to form composite structures are provided. A curing tool (350) in one embodiment includes cured nano tube impregnated resin (302a,302b), at least two conductors (306) formed in the nano tube impregnated resin, at least one layer of cured composite material (204) and at least one insulation layer (300,310) separating the cured composite material from the nano tube impregnated resin (302a,302b).