Thermoset Composite Curing With Pressure Media Bag Consolidation
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Solution Overview
Problem
Existing methods for curing thermoset composites, such as autoclave curing, oven curing, and matched-die curing, are inefficient in terms of cure cycle time, require significant energy consumption, and often result in non-uniform pressure application, especially on complex shapes, leading to incomplete curing and increased production costs.
Innovation Solution
A system comprising a tooling die, pressure media bag, and mechanical press is used to apply heat and pressure uniformly to uncured thermoset composites, utilizing smart susceptors and flexible pressure media to ensure consistent pressure distribution and rapid heat-up without the need for an autoclave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If autoclave curing is used to cure thermoset composites, then complete curing and consolidation can be achieved, but the cure cycle time increases significantly due to the time required to heat up the autoclave and the composite part
Solution Approach 1:
The composite part is pre-heated in an oven before being placed in the compression mold, so that when consolidation pressure is applied, the part is already at or near curing temperature. This eliminates the time required to heat up the part during autoclave curing, significantly reducing the overall cure cycle time while still achieving complete curing
Solution Approach 2:
The heating function is extracted from the compression molding process and performed separately in an oven beforehand. This separation allows the compression mold to focus solely on applying consolidation pressure, while the oven handles the heating, thereby eliminating the time penalty associated with heating large autoclave chambers
2Reliability
If autoclave curing is used, then uniform pressure and heat can be applied, but additional space, infrastructure, and energy consumption are required
Solution Approach 1:
The heating function is extracted from the compression molding system and performed separately in a smaller oven, reducing the energy required to heat up the system. The compression mold focuses solely on applying pressure, while the pre-heating in the smaller oven consumes less energy than heating a large autoclave chamber
Solution Approach 2:
The invention uses a simpler, less expensive compression molding system without requiring a large autoclave infrastructure. The process uses conventional oven heating and a compression mold, eliminating the need for expensive autoclave equipment, specialized infrastructure, and associated operational costs
3Device complexity
If oven curing or matched-die curing is used instead of autoclave, then infrastructure costs are reduced, but pressure application becomes non-uniform especially on complex shapes
Solution Approach 1:
The composite part is pre-heated and partially consolidated in an oven before being placed in the compression mold for final consolidation. This preliminary action allows the part to become more pliable and easier to consolidate uniformly under pressure, improving pressure distribution on complex shapes while using simpler equipment
Solution Approach 2:
The process uses a two-stage approach where temperature and pressure parameters are applied in sequence rather than simultaneously. First, temperature is increased in the oven to make the resin more fluid, then pressure is applied in the compression mold to achieve uniform consolidation, with the part shape itself helping to distribute pressure evenly
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 system reduces cure cycle time, ensures uniform pressure application, and eliminates the need for autoclaves, thereby reducing energy consumption and infrastructure costs while achieving complete curing of complex shapes.
Implementation Method 1
a tooling die configured to receive and support an uncured thermoset composite part and to heat the uncured thermoset composite part
Implementation Method 2
a pressure media bag configured to be placed over the uncured thermoset composite part disposed on the tooling die and containing a pressure media; and a mechanical press configured to apply a consolidation pressure to the uncured thermoset composite part disposed on the tooling die, wherein the pressure media bag is configured to distribute the consolidation pressure
Data Source
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AI summary
A system (10) for curing a thermoset composite may include a tooling die (200) configured to receive and support an uncured thermoset composite part (100) and to heat the uncured thermoset composite part (100); a pressure media bag (300) configured to be placed over the uncured thermoset composite part (100) disposed on the tooling die (200) and including a pressure media (320); and a mechanical press (400) configured to apply a consolidation pressure to the uncured thermoset composite part (100) disposed on the tooling die (200), the pressure media bag (300) may be configured to distribute the consolidation pressure applied by the mechanical press (400) to the uncured thermoset composite part (100) disposed on the tooling die (200).