Susceptor Wire Array for Uniform Composite Heating
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Solution Overview
Problem
Conventional heating equipment for composite structures fails to provide uniform heat distribution, particularly when heat sinks are present, leading to overheating or underheating during the rework process, and lacks effective temperature regulation across a broad range of temperatures.
Innovation Solution
A susceptor wire array with multiple wires of different Curie temperatures is integrated into a heating blanket, using a conductor to generate a magnetic field and induce eddy currents in the susceptor wires, allowing for uniform heat application and compensation for heat sinks, thereby maintaining temperature uniformity from 100° F to 375° F.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional resistive heating blankets are used, then heating function is provided, but uniform temperature distribution cannot be achieved across the rework area
Solution Approach 1:
The heating blanket is divided into multiple independent heating zones, each controlled by separate susceptor wires with different Curie temperatures. This segmentation allows different regions to be heated to different temperatures simultaneously, achieving uniform overall temperature distribution across the rework area while accommodating heat sinks.
Solution Approach 2:
Different susceptor wires are assigned different Curie temperatures to create local temperature variations. Wires with lower Curie temperatures are placed in regions requiring lower heat input, while wires with higher Curie temperatures are placed in regions requiring more heat, such as areas with heat sinks. This local quality differentiation enables precise temperature control across the entire rework area.
2Adaptability or versatility
If multi-zone blanket systems are added to compensate for heat sinks, then temperature regulation capability is improved, but device complexity increases substantially
Solution Approach 1:
The susceptor wires automatically regulate temperature through their inherent Curie temperature characteristics. When a susceptor wire reaches its Curie temperature, its magnetic properties change, causing it to stop generating heat without requiring external control. This self-service mechanism eliminates the need for complex feedback loops, sensors, and control systems while maintaining excellent temperature regulation capability.
Solution Approach 2:
The invention utilizes the Curie temperature parameter of magnetic materials to achieve temperature control. By selecting susceptor wires with different Curie temperatures, the system can regulate temperature across a broad range (100°F to 375°F) simply by changing which susceptor wires are activated, without requiring complex control mechanisms.
3Reliability
If conventional heating equipment is used, then heating function is provided, but overheating or underheating occurs during the rework process
Solution Approach 1:
The susceptor wires provide inherent feedback through their Curie temperature effect. As each susceptor wire heats up and reaches its Curie temperature, its magnetic permeability drops, automatically reducing the eddy currents and heat generation. This negative feedback mechanism prevents overheating without requiring external temperature sensors or control systems.
Solution Approach 2:
The magnetic properties of the susceptor wires act as an intermediary between the electromagnetic field and thermal energy. The Curie temperature transition of the magnetic material serves as a natural mediator that regulates heat generation, preventing both overheating and underheating by automatically adjusting heat output based on temperature conditions.
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 ensures uniform heat distribution across composite structures, preventing overheating or underheating by adjusting heat input based on the Curie temperature of the susceptor wires, effectively accommodating heat sinks and maintaining temperature control over a wide range.
Implementation Method 1
a conductor for receiving current and generating a magnetic field in response thereto
Implementation Method 2
induce eddy currents in the susceptor wires, allowing for uniform heat application
Implementation Method 3
using a conductor to generate a magnetic field and induce eddy currents in the susceptor wires
Implementation Method 4
a first susceptor wire comprising an alloy having a first Curie temperature point and a second susceptor wire comprising an alloy having a second Curie temperature point
Data Source
AI summary
A susceptor wire array. The array includes a first susceptor wire comprising an alloy having a first Curie temperature point and a second susceptor wire comprising an alloy having a second Curie temperature point, the second Curie temperature point is different than the first Curie temperature point of the first susceptor wire. In one susceptor wire arrangement, the second Curie temperature point of the second susceptor wire is lower than the first Curie temperature point of the first susceptor wire. In another susceptor wire arrangement, the array further comprises a third susceptor wire, the third susceptor wire comprising an alloy having a third Curie temperature point. The third Curie temperature point of the third susceptor wire may be different than the first Curie temperature point of the first susceptor wire.