Smart Susceptor Heater Blankets for Composite Debulking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for debulking composite parts, especially large-scale components like aircraft components, are inefficient and costly due to the need for autoclave processing, which requires expensive equipment and high energy consumption, and existing out-of-autoclave methods are not suitable for large-scale parts without causing thermal and electromagnetic interference.
Innovation Solution
The use of interconnected smart susceptor heater blankets with opposing current flow directions and modular design to provide precise and uniform temperature control during the debulking process, allowing for out-of-autoclave processing of large composite parts without the need for autoclave equipment, while minimizing thermal and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclave processing is used for debulking large composite parts, then debulking effectiveness is improved, but equipment cost and energy consumption increase significantly
Solution Approach 1:
The patent replaces the mechanical compression system of autoclaves with an electromagnetic heating system using induction coils and susceptor materials. The induction heating system generates eddy currents in the susceptor blanket, which converts electromagnetic energy directly to thermal energy, eliminating the need for mechanical compression and high-energy autoclave environments while achieving effective debulking through localized heating and vacuum application.
Solution Approach 2:
The patent changes the physical parameters of the heating system by using induction heating at controlled frequencies and temperatures below the resin cure point. By controlling the electromagnetic field parameters and susceptor properties, the system achieves effective debulking at lower energy consumption compared to autoclave processing, while maintaining debulking effectiveness through precise temperature and vacuum control.
2Area of stationary object
If a single large heater blanket is used for large composite parts, then coverage area is improved, but thermal and electromagnetic interference increase
Solution Approach 1:
The patent divides the heater blanket into multiple modular sections, each with its own induction coils and susceptor segments. This segmentation allows independent control of each module's electromagnetic field and temperature, preventing thermal and electromagnetic interference that would occur with a single large continuous blanket. The modular design enables scalable coverage for large composite parts while maintaining controlled interference levels in each segment.
3Power
If adjacent wire assemblies carry current in the same direction, then electromagnetic field generation is improved, but electromagnetic interference between adjacent assemblies increases
Solution Approach 1:
The patent employs an asymmetric current distribution pattern where adjacent wire assemblies carry current in opposite directions. This asymmetric arrangement creates electromagnetic fields that cancel each other's interference effects while maintaining the overall power output. The alternating current directions generate complementary electromagnetic fields that reduce net interference between adjacent assemblies while preserving the heating effectiveness.
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 enables efficient and cost-effective debulking of large composite parts with precise temperature control, reducing energy consumption and equipment costs, and allowing for the processing of larger components outside of an autoclave, while maintaining uniform heating and safety.
Implementation Method 1
a susceptor wire wrapped around the litz wire to form a plurality of susceptor windings
Implementation Method 2
heating to a temperature below the cure temperature... using induction heating and smart susceptors
Implementation Method 3
each first wire assembly includes a litz wire... a current flow through each first wire assembly
Implementation Method 4
A vacuum is applied to the vacuum bag to remove air from between each adjacent ply
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A processing apparatus (1200) such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers (1400) to form an article (900) such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets (300, 300'). The plurality of smart susceptor heater blankets (300, 300') may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.