In-line Composite Consolidation via UV Curing

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Solution Overview

Problem

Current methods for fabricating composite parts are inefficient, particularly due to slow batch processes that require manual placement of plies and thermal curing, limiting the production of non-prismatic parts.

Innovation Solution

A system for in-line consolidation of composite materials using pre-impregnated (prepreg) sheets, where the prepreg is cut and cured using ultraviolet light, with rollers maintaining tension and a mold assembly for shaping, allowing for efficient production of composite parts with arbitrary cross-sections and curvature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If thermal curing in a mold assembly is used, then composite parts can be cured, but the process is slow and requires manual placement of plies

Engineering Contradiction:

Improveproduction speedVSAvoidcycle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces thermal curing with ultraviolet light curing. Instead of using heat (thermal energy) to cure the composite material, the invention uses ultraviolet light (electromagnetic radiation) to initiate and accelerate the curing process. This substitution of the curing mechanism dramatically reduces cycle time and eliminates the need for manual operations, enabling continuous automated production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses pre-impregnated (prepreg) composite material that is prepared in advance with resin already impregnated into the fibers. This preliminary preparation allows the material to be ready for immediate curing without requiring manual resin application or placement operations during the manufacturing process, thereby increasing productivity and reducing cycle time.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If manual placement of plies is used, then composite parts can be formed, but the process is slow and labor-intensive

Engineering Contradiction:

Improveease of forming composite partsVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent employs a self-adhering prepreg material that automatically bonds to itself and to the substrate when exposed to ultraviolet light. The material's own adhesive properties and the light-curing mechanism work together to eliminate the need for manual placement operations. The prepreg lays itself down and cures in place, making the process easier to manufacture while dramatically improving productivity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces manual mechanical placement operations with an automated ultraviolet light curing system. Instead of workers manually positioning and pressing plies into place, the system uses UV light to trigger self-adhering bonding, eliminating labor-intensive operations and significantly increasing production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If traditional batch processes are used, then composite parts can be produced, but the process is slow and limits production to prismatic parts

Engineering Contradiction:

Improveability to produce complex geometriesVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent transitions from static batch processing to a dynamic continuous flow process. The prepreg material moves continuously through the system on a conveyor belt, and ultraviolet light sources are positioned to cure the material as it passes. This dynamic approach allows for the production of complex three-dimensional geometries while maintaining high production speeds, as the process can be continuously adjusted and optimized during operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention replaces traditional thermal curing mechanisms with ultraviolet light curing, enabling continuous automated processing. The UV light system can be precisely positioned and controlled to cure complex geometries as the material moves through the system, eliminating the limitations of batch processing and enabling both high productivity and geometric versatility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method significantly reduces cycle time and enables the production of composite parts with complex geometries by automating the cutting, molding, and curing process, improving efficiency compared to traditional methods.

Implementation Method 1

The prepreg is cured with ultraviolet light from an ultraviolet source

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11167455B1Device for in-line consolidation of composite materials

Publication Date: 2021.11.09 HRL LAB

AI summary

A system for fabricating composite parts efficiently. Pre-impregnated (prepreg) composite material is drawn as a sheet from a roll and fed by advancement rollers into a stamping and molding station in which a piece of the prepreg material is cut, on a mold, from the sheet. Pressure is applied to cause the prepreg material to conform to a surface of the mold, and the prepreg is cured with ultraviolet light. Additional layers of prepreg may be cut and cured on any layers that have already been cured on the mold. The complete part may be removed from the mold with ejector pins. Scrap prepreg may be recycled in a recycling station that separates reinforcing fiber from uncured resin.