Thermal Transfer Blanket With Phase-Change Media for Uniform Composite Curing

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Solution Overview

Problem

Existing methods for repairing composite materials, such as those used in aircraft, suffer from inadequate temperature control during curing, leading to non-uniform heating or cooling, which can weaken the structure and compromise repair quality.

Innovation Solution

A thermal transfer blanket system utilizing a thermal energy storage media within a flexible container, equipped with thermocouples for temperature monitoring, allows for controlled heating or cooling of composite materials without external power sources, ensuring uniform temperature profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional electrical heater blankets are used for curing composite materials, then heating capability is provided, but temperature uniformity deteriorates due to hot spots and cold spots

Engineering Contradiction:

Improvetemperature uniformityVSAvoidcuring quality

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The thermal energy storage media is pre-heated to a high temperature before application to the repair site. This preliminary heating action allows the media to serve as a portable heat source that maintains uniform temperature during curing, eliminating the need for continuous electrical power and avoiding temperature non-uniformity issues.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The thermal energy storage media acts as an intermediary between the heat source and the composite material. It absorbs and stores thermal energy, then releases it uniformly to the resin during curing, mediating the heat transfer process to prevent hot and cold spots.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Duration of action of stationary object

If electrical heater blankets are used to maintain temperature, then curing capability is provided, but energy consumption increases continuously

Engineering Contradiction:

Improvecuring durationVSAvoidenergy consumption

Core Design Contradiction:

Duration of action of stationary objectVSUse of energy by moving object

Solution Approach 1:

The thermal energy storage media serves itself as a portable power source by storing thermal energy during charging and autonomously releasing it during the curing process. This self-service capability eliminates the need for continuous external electrical power supply, making the system suitable for field repairs.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The thermal energy storage media utilizes phase transition (melting and solidification) to store and release thermal energy. During charging, the media absorbs heat and undergoes phase transition; during curing, it releases stored energy as it transitions back, providing sustained heating without continuous energy input.

Inventive Principle:

Principle #36Phase transitions

3Temperature

If heating power is increased to prevent cold spots, then temperature maintenance improves, but hot spots and thermal damage increase

Engineering Contradiction:

Improvetemperature controlVSAvoidthermal damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The system changes the temperature parameter profile by using pre-heated thermal energy storage media with a controlled initial temperature. This allows gentle, uniform heating that prevents thermal shock and damage to the composite structure while maintaining adequate curing temperature.

Inventive Principle:

Principle #35Parameter changes

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 system provides efficient and uniform thermal treatment of composite materials, enabling effective curing of resins in complex structures, even in austere environments, while maintaining structural integrity and avoiding hot or cold spots.

Implementation Method 1

Thermal energy is transferred between the thermal transfer blanket and the material, thereby modifying the temperature of the material

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 2

The thermal transfer blanket comprises a thermal energy storage media having a first temperature

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS12631403B2Method of making and a method of using a thermal transfer blanket system

Publication Date: 2026.05.19 THE BOEING CO

AI summary

A method of thermally treating a material includes applying a thermal transfer blanket to a surface of the material. The thermal transfer blanket comprises a thermal energy storage media having a first temperature, the material having a second temperature that is different than the first temperature. Thermal energy is transferred between the thermal transfer blanket and the material, thereby modifying the temperature of the material.