Thermoset Composite Curing via Real-Time Temperature Feedback

Solution Overview

Problem

Existing methods for curing thermoset composites are resource-intensive and inefficient, particularly for large parts, as they rely on heating to a threshold temperature for a threshold time, disregarding the actual temperature trajectory and peak exotherm, leading to suboptimal utilization of factory equipment and capacity.

Innovation Solution

A method and system for curing thermoset composites to a target state of cure by monitoring the actual temperature and elapsed time, ceasing heating based on the maximum temperature achieved and the time spent above the threshold, using a heating assembly, support mandrel, temperature detector, and controller to regulate the curing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heating is continued to ensure complete curing, then the state of cure is improved, but resource consumption and production time increase

Engineering Contradiction:

Improvestate of cureVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system continuously monitors the actual temperature of the thermoset composite during curing and uses this feedback to determine when to cease heating. The controller tracks both the maximum temperature achieved and the elapsed time above threshold, automatically stopping the heating process when the target state of cure is reached, thereby optimizing both curing quality and production time.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention changes the curing approach from using fixed threshold parameters to dynamically adjusting heating based on actual temperature measurements and elapsed time. By monitoring real-time temperature data and comparing it against target parameters, the system adapts the heating process to achieve optimal cure state efficiently.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If heating is continued to ensure complete curing, then the state of cure is improved, but energy consumption increases

Engineering Contradiction:

Improvestate of cureVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system continuously monitors the actual temperature of the thermoset composite during curing and uses this feedback to determine when to cease heating. The controller tracks both the maximum temperature achieved and the elapsed time above threshold, automatically stopping the heating process when the target state of cure is reached, thereby optimizing both curing quality and production time.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention applies partial action by heating the thermoset composite only to the extent necessary to achieve the target state of cure, rather than continuing heating beyond what is needed. This prevents excessive energy consumption while ensuring adequate curing through precise control based on actual temperature and time measurements.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If large heating assemblies are used to cure large parts, then complete curing is achieved, but factory space and equipment cost increase

Engineering Contradiction:

Improvecuring completenessVSAvoidfactory space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The system continuously monitors the actual temperature of the thermoset composite during curing and uses this feedback to determine when to cease heating. The controller tracks both the maximum temperature achieved and the elapsed time above threshold, automatically stopping the heating process when the target state of cure is reached, thereby optimizing both curing quality and production time.

Inventive Principle:

Principle #23Feedback

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 allows for efficient and reproducible curing of thermoset composites to a specific state of cure, reducing resource consumption and improving process efficiency, while also enabling partial curing which can enhance characteristics such as reduced moisture absorption compared to fully cured materials.

Implementation Method 1

heating the thermoset composite to greater than a threshold temperature

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

monitoring an actual temperature of the thermoset composite

Methodology Applied

Scientific EffectTemperature detection: Thermocouple

Implementation Method 3

considering a peak exotherm temperature that may be achieved by the thermoset composite during the heating

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS11331833B2Systems and methods of curing a thermoset composite to a desired state of cure

Publication Date: 2022.05.17 TORAY INDUSTRIES INC

AI summary

Systems and methods of curing a thermoset composite (TSC) to a target state of cure (SOC) are disclosed herein. The methods include heating the thermoset composite to greater than a threshold temperature. During the heating, the methods further include monitoring an actual temperature of the thermoset composite, determining a maximum temperature achieved by the thermoset composite, and determining an elapsed time that the actual temperature of the thermoset composite is greater than the threshold temperature. The methods further include ceasing the heating based, at least in part, on the maximum temperature of the TSC and the elapsed time. The systems include a heating assembly, a support mandrel, a thermoset composite, a temperature detector, and a controller programmed to perform the methods.