Susceptor Coil Assembly Fabrication via Segmented Winding
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Solution Overview
Problem
Existing heating blanket technologies using susceptor wire configurations are inefficient for large-scale applications due to high material costs, complexity, and difficulty in maintaining desired heating profiles, especially for curing large composite structures.
Innovation Solution
A method and apparatus for fabricating a susceptor coil assembly by winding smart susceptor wire around a conductor wire using programmable drive systems to achieve precise tension and wrap density, allowing for customizable heating profiles and efficient heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If susceptor wire is threaded onto conductor wire in spring configuration, then susceptor can be oriented perpendicular to current flow to maximize induced magnetic fields, but large amount of Litz wire is required and cost increases
Solution Approach 1:
The susceptor wire is divided into multiple discrete coils spaced along the conductor wire, rather than using continuous spring configuration. This segmentation reduces the total amount of Litz wire needed while maintaining effective heating zones at each coil location.
Solution Approach 2:
Heating capability is concentrated at specific locations where susceptor coils are placed along the conductor wire, rather than distributed uniformly. This allows optimized heating profiles for different regions of the heating blanket, placing susceptor coils only where heating is needed.
2Temperature
If susceptor springs are used to maintain high density per unit length, then susceptor wire remains in region of highest magnetic field strength, but susceptor springs tend to tangle with one another
Solution Approach 1:
The continuous susceptor spring is segmented into discrete coils that are individually positioned and secured along the conductor wire. This prevents the tangling issue inherent in continuous spring configurations while maintaining the beneficial perpendicular orientation to magnetic fields at each coil location.
Solution Approach 2:
Susceptor coils are pre-formed and pre-positioned in their final orientations before being attached to the conductor wire. This preliminary arrangement eliminates the need for complex spring threading operations and prevents tangling during assembly and operation.
3Quantity of substance
If spring configuration is used for heating blanket, then susceptor density per unit length is maximized, but device complexity and cost increase for large-sized applications
Solution Approach 1:
The heating blanket structure uses discrete susceptor coils distributed along conductor wire segments, rather than continuous spring assemblies. This modular approach simplifies the overall structure, reduces material requirements for large-area blankets, and allows flexible configuration to match specific heating zone requirements.
Solution Approach 2:
Instead of distributing susceptor wire continuously in three-dimensional spring structures, the invention transitions to a two-dimensional arrangement where discrete coils are positioned in planes perpendicular to the conductor wire, simplifying the structural organization and reducing complexity.
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 solution enables cost-effective and efficient fabrication of susceptor coil assemblies for large-scale heating applications, providing customizable heating profiles and reducing material costs while maintaining consistent heat distribution.
Implementation Method 1
orient the susceptor wire as near to perpendicular as possible to the direction of current flow in the Litz wire. A near perpendicular orientation is desired so as to maximize the induced magnetic fields into the susceptor wire which creates heat by virtue of eddy currents created by the wire
Implementation Method 2
maximize the induced magnetic fields into the susceptor wire which creates heat
Data Source
AI summary
A method and system for fabricating a susceptor coil assembly. An apparatus comprising a tensioning section; a feeding section for feeding a conductor wire toward the tensioning section, the tensioning section maintaining a desired tension of the conductor wire; and a coiling section for winding a susceptor wire around an outer surface of the conductor wire so as to fabricate a susceptor coil assembly. The coiling section winds the susceptor wire around the conductor wire as the conductor wire moves from the feeding section towards the tensioning section. A first programmable drive is programmable to achieve a desired feedrate of the conductor wire from the feeding section to the coiling section.