US20130233476A1 - Out-of-autoclave and alternative oven curing using a self heating tool - Google Patents
Out-of-autoclave and alternative oven curing using a self heating tool Download PDFInfo
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- US20130233476A1 US20130233476A1 US13/651,814 US201213651814A US2013233476A1 US 20130233476 A1 US20130233476 A1 US 20130233476A1 US 201213651814 A US201213651814 A US 201213651814A US 2013233476 A1 US2013233476 A1 US 2013233476A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/3807—Resin-bonded materials, e.g. inorganic particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
- B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
- B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/10—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor
- H05B3/12—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
- H05B3/14—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
- H05B3/145—Carbon only, e.g. carbon black, graphite
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/70—Completely encapsulating inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
- B29K2105/165—Hollow fillers, e.g. microballoons or expanded particles
- B29K2105/167—Nanotubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/757—Moulds, cores, dies
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
- H05B2203/005—Heaters using a particular layout for the resistive material or resistive elements using multiple resistive elements or resistive zones isolated from each other
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/011—Heaters using laterally extending conductive material as connecting means
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/013—Heaters using resistive films or coatings
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/017—Manufacturing methods or apparatus for heaters
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2214/00—Aspects relating to resistive heating, induction heating and heating using microwaves, covered by groups H05B3/00, H05B6/00
- H05B2214/04—Heating means manufactured by using nanotechnology
Definitions
- Pre-preg material is made of composite fibers such as carbon, glass, aramid and the like, that are bonded together with a resin that is activated with heat to cure.
- the pre-preg material is typically supplied in sheets or plies.
- the manufacturer then forms stacks of plies of pre-preg material on a forming surface of a tool having a desired shape. Once the pre-preg material is formed on the tool, the tool is placed in an autoclave or conventional oven to cure the resin.
- the aerospace industry's desire for increasingly larger structures has resulted in larger autoclaves and conventional ovens needed to cure the pre-preg material. The larger the autoclaves and conventional ovens, the more costs associated with building and operating them.
- Embodiments of the present invention include both apparatuses and methods.
- the following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
- a method of curing composite material to form a composite structure including, laying up and forming pre-preg material on a forming surface of cured pre-preg material of a composite structure forming tool and passing current through nano tube impregnated resin within the forming tool to heat the tool internally to cure the pre-preg material.
- a curing tool in another embodiment, includes cured nano tube impregnated resin. At least two conductors are formed in the nano tube impregnated resin.
- the curing tool also includes a forming surface portion. The forming surface portion includes cured composite material of pre-preg material.
- the curing tool further includes at least a first insulation layer that separates the cured composite material from the nano tube impregnated resin.
- FIG. 1 is a tool formation flow diagram of one embodiment of the present invention
- FIG. 2 is a partial side perspective view illustration of the formation of a support base portion of a tool of one embodiment of the present invention
- FIGS. 3A-3I are partial side perspective views illustrating the further formation of a heating tool of one embodiment of the present invention.
- FIG. 3J is a bottom perspective view of the tool with formed passages of one embodiment of the present invention.
- FIG. 3K is a cross-sectional end view of a heating tool of one embodiment of the present invention.
- FIG. 3L is a cross section end view of the heating tool of FIG. 3H coupled to a controller and power source of one embodiment of the present invention
- FIG. 3M is a side perspective view of the forming of conductors in a heating tool of another embodiment of the present invention.
- FIG. 4 is a composite structure forming flow diagram of one embodiment of the present invention.
- FIG. 7 is a tool formation flow diagram of the formation of the tool of FIG. 6 .
- Embodiments of the present invention provide methods and apparatuses for fabricating molds, forms, or mandrels (that can be generally referred to as a tool) that are self heating.
- a tool is provided that includes an internal heating source.
- Embodiments allow composite structures to be cured on the same tool as they were fabricated on without the need for an autoclave or an oven. Hence, large out-of-autoclave structures are cured while sitting on a production floor thereby eliminating size constraints on autoclaves and ovens.
- embodiments of the self heating tools allow for the mass production of smaller composite parts. Rather than stacking hundreds of uncured parts into an autoclave in a time-consuming process, each part could have its own self heating tool. Each self heating tool can be heated on the production floor thereby providing an efficient part flow through the manufacturing plant.
- a tool is formed with resin impregnated with nano tubes.
- the nano tubes in embodiments are electrically conductive.
- the nano tubes used to impregnate the resin are carbon nanofibers (nano tubes). Passing current through the resin results in heat being generated due to electrical resistance in the nano tube impregnated resin.
- the amount of heat created by the tool is varied.
- conductive strips such as, but not limited to, copper strips are embedded in the cured nano tube impregnated resin. An electrical potential is created between adjacent conductive strips (conductive strips that are near each other) which cause a current to pass through the nano tube impregnated resin.
- an alternating current (AC) is applied to the adjacent conductive strips to produce the current through the nano tube impregnated resin.
- a formation flow diagram 100 of one embodiment is illustrated.
- the formation flow diagram 100 is described below in concert with illustrations in FIGS. 2 through 3I .
- a first step is determining what resin is compatible with a heat range needed to cure pre-preg material (out of autoclave material) used to form a composite structure ( 102 ).
- the nano tube percentage should be in relation to the resin ( 104 ).
- the percentage ratio is based on a desired outcome (desired heat to be generated by a tool).
- the nano tubes are then mixed with the resin to form carbon nano tube impregnated resin ( 106 ).
- a type of resin that can be used is K-factor resin provided by Boyce Components LLC.
- Example nano tubes used are carbon nano tubes provided by Polygraf Products which is a part of Applied Sciences Inc.
- a foundation for the nano tube impregnated resin has to be provided to form the self heating tool.
- plies of pre-preg material 204 a, 204 b, 204 c are laid up and formed on a mandrel 202 ( 108 ).
- the plies of pre-preg material form a support base portion 204 .
- six to eight layers (plies) of carbon pre-preg material are used to form the support base portion 204 which is approximately 0.180 to 0.250 inches thick.
- FIG. 2 illustrates ply layers 204 a, 204 b and 204 c being applied to the mandrel 202 .
- the ply layers of pre-preg material 204 a, 204 b and 204 c include carbon fibers.
- the plies that make up the support base portion 204 are then cured ( 110 ).
- a first insulation layer 300 is applied ( 112 ). This is illustrated in FIG. 3A .
- the first insulation layer 300 is a dry woven glass layer 300 that is laminated on the support base portion 204 .
- the insulation layer (dry woven glass layer 300 ) is then cured on the support base portion 204 ( 113 ).
- the thickness of the insulation layer 300 in one embodiment is in the range of 0.003 to 0.005 inches.
- a first coat of carbon nanotube impregnated resin 302 a is applied over the dry woven glass layer 300 ( 114 ). This is illustrated in FIGS. 3B and 3C .
- a sponge brush 304 is used to apply the first coat of carbon nano tube impregnated resin 302 a to the first dry woven glass layer 300 .
- the first coat of carbon nano tube impregnated resin 302 a is applied with a uniform thickness of approximately 10 to 11 mils.
- the desired spacing of the conductive strips 306 to be used in the tool is then determined ( 116 ).
- the conductive strips 306 are made of a metal such as copper.
- the conductive strips 306 are then placed on a surface of the first coat carbon nano tube impregnated resin 302 a ( 118 ) as illustrated in FIG. 3D .
- a second coat of carbon nano tube impregnated resin 302 b is then applied over the first coat of carbon nano tube impregnated resin 302 a and the conductive strips 306 ( 120 ).
- the first and second coats of carbon nano tube impregnated resin 302 a and 302 b are then cured ( 122 ).
- the tool in this state is illustrated in FIG. 3F .
- the conductive strips 306 are illustrated above as being substantially straight in the embodiment illustrated in FIGS.
- a second insulation layer 310 is laminated then laid up and laminated on the carbon nano tube impregnated resin 302 b ( 124 ). This layer of the insulation 310 is then cured ( 125 ).
- the second insulation layer 310 is a dry woven glass layer 310 having a thickness in the range of 0.003 to 0.005 inches.
- the addition of the second insulation layer 310 is illustrated in FIG. 3G .
- ply layers 312 a and 312 b of pre-preg material are laid up ( 126 ) and cured ( 126 ) to form a tool forming surface 312 of the tool 350 .
- the lying up of the ply layers 312 a and 312 b are illustrated in FIG.
- the tool can be straight along its length, it can be curved along its length and its cross-sectional geometry can vary along its length.
- any shaped tool is contemplated and tool 350 of FIG. 3I is merely an example of one shape of a tool used to form a C-shaped composite structure.
- the tool 350 is removed from the base mold 124 once the tool is formed. Bores 330 are then selectively formed through the base support portion 204 , the first insulation layer 300 and the first cured carbon nano tube impregnated resin 302 a to the conducting strips 306 ( 130 ). This is illustrated in FIG. 3J and FIG. 3K .
- a Dremel® power tool by the Robert Bosch Tool Corporation, or similar tool, is used to make the bores through the tool 350 to the respective conducting strips 306 .
- Conductive wires 340 are then coupled to the conductive strips 306 ( 132 ) as illustrated in FIG. 3L .
- FIG. 3L further illustrates, a power source 342 coupled to the conductive wires 340 and a controller 344 .
- FIG. 4 an illustration of a composite structure forming flow diagram 400 is illustrated.
- the flow diagram 400 is described in concert with FIGS. 5A and 5B .
- the process starts by laying up and forming pre-preg material on the tool ( 402 ). In one embodiment, this is done by applying one or more layers of pre-preg material on the tool forming surface portion 312 of the tool 350 and pressing the one or more layers of pre-preg material onto the tool forming surface portion 312 of the tool 350 to form the pre-preg material into the shape of the tool forming surface portion 312 .
- An example of laying up a layer of ply material 500 on a tool 350 is illustrated in FIG. 5A .
- the power source 342 provides power to the conductive strips 306 in the tool 350 ( 404 ).
- An example, of the power source 342 coupled to heat a tool 350 is illustrated in FIG. 5B .
- pre-preg material on the tool 350 is cured to form a composite structure 550 .
- the heat of the tool 350 as a result of the power being supplied to conductors (conductive strips) in the tool 350 , cures the pre-preg material ( 404 ) to form the composite structure 550 .
- a vacuum bag system known in the art is used to compact the pre-preg material during curing ( 403 ). Once the pre-preg material is cured, the formed composite structure 550 is removed from the tool 350 ( 406 ).
- FIG. 7 illustrated a tool formation flow diagram 700 pursuant to the lay up illustrated in FIG. 6 .
- the flow diagram 700 starts similar to the flow diagram 100 described above.
- the resin is selected ( 102 ).
- the nano tube percentage is selected ( 104 ).
- the nano tubes and resin are mixed to form the nano tube impregnated resin 302 ( 106 ).
- Plies of pre-preg material are layed up on the master ( 708 ).
- the plies are then cured ( 710 ) to form the tool forming surface portion 312 on a surface of the master 702 .
- a first insulation layer 300 is then laminated on a back side of the tool forming surface portion 312 ( 712 ).
- the first insulation layer 300 is then cured ( 713 ).
- a first coat of nano tube resin 302 a is then applied to the cured first insulation layer 300 ( 714 ). It is then determined what the spacing should be for the conductive strips ( 716 ). The conductive strips 306 are then placed on the first coat of nano tube resin 302 a ( 718 ). A second coat of nano tube resin 302 b is then applied covering the conductive strips 306 ( 720 ). The nano tube resin 302 a and 320 b is then cured ( 722 ). A second layer of insulation 310 is then laminated over the nano tube resin 302 a and 320 b ( 724 ). The insulation layer 310 is then cured ( 725 ). Plies of pre-preg material are then layed up on the second layer of insulation 310 ( 726 ).
- the plies of pre-preg material are then cured to form the support base portion ( 128 ). Bores are then formed through the support base portion 204 to the conductive strips ( 130 ) as described above in regards to FIG. 3J . Conductive wires are then coupled to the conductive strips ( 132 ). As understood in the art, curing of the various materials to make the tool 350 may include various forms of vacuum bagging techniques.
Abstract
Description
- This application claims priority to co-pending U.S. patent application Ser. No. 12/870,556 filed on Aug. 27, 2010, entitled the same as above, is herein incorporated by reference.
- The United States Government may have certain rights to this application under contract No. FA9453-06-D0368-0003.
- Composite structures formed from pre-impregnated (pre-preg) material are used in the formation of high strength-low weight structures such as, but not limited to, parts used to build aircraft and spacecraft. Pre-preg material is made of composite fibers such as carbon, glass, aramid and the like, that are bonded together with a resin that is activated with heat to cure. The pre-preg material is typically supplied in sheets or plies. The manufacturer then forms stacks of plies of pre-preg material on a forming surface of a tool having a desired shape. Once the pre-preg material is formed on the tool, the tool is placed in an autoclave or conventional oven to cure the resin. The aerospace industry's desire for increasingly larger structures has resulted in larger autoclaves and conventional ovens needed to cure the pre-preg material. The larger the autoclaves and conventional ovens, the more costs associated with building and operating them.
- For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an effective and efficient method of forming composite structures without the use of an autoclave or conventional oven.
- The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. Embodiments of the present invention include both apparatuses and methods. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
- In one embodiment, a method of curing composite material to form a composite structure is provided. The method including, laying up and forming pre-preg material on a forming surface of cured pre-preg material of a composite structure forming tool and passing current through nano tube impregnated resin within the forming tool to heat the tool internally to cure the pre-preg material.
- In another embodiment, a curing tool is provided. The curing tool includes cured nano tube impregnated resin. At least two conductors are formed in the nano tube impregnated resin. The curing tool also includes a forming surface portion. The forming surface portion includes cured composite material of pre-preg material. The curing tool further includes at least a first insulation layer that separates the cured composite material from the nano tube impregnated resin.
- The present invention can be more easily understood and further advantages and uses thereof will be more readily apparent, when considered in view of the detailed description and the following figures in which:
-
FIG. 1 is a tool formation flow diagram of one embodiment of the present invention; -
FIG. 2 is a partial side perspective view illustration of the formation of a support base portion of a tool of one embodiment of the present invention; -
FIGS. 3A-3I are partial side perspective views illustrating the further formation of a heating tool of one embodiment of the present invention; -
FIG. 3J is a bottom perspective view of the tool with formed passages of one embodiment of the present invention; -
FIG. 3K is a cross-sectional end view of a heating tool of one embodiment of the present invention; -
FIG. 3L is a cross section end view of the heating tool ofFIG. 3H coupled to a controller and power source of one embodiment of the present invention; -
FIG. 3M is a side perspective view of the forming of conductors in a heating tool of another embodiment of the present invention; -
FIG. 4 is a composite structure forming flow diagram of one embodiment of the present invention; -
FIG. 5A and 5B are partial side perspective views in forming a composite structure on a self heated tool of one embodiment of the present invention; and -
FIG. 6 is a side perspective view of a lay up of the heating tool of another embodiment; and -
FIG. 7 is a tool formation flow diagram of the formation of the tool ofFIG. 6 . - In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text.
- In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.
- Embodiments of the present invention provide methods and apparatuses for fabricating molds, forms, or mandrels (that can be generally referred to as a tool) that are self heating. Hence, in embodiments, a tool is provided that includes an internal heating source. Embodiments allow composite structures to be cured on the same tool as they were fabricated on without the need for an autoclave or an oven. Hence, large out-of-autoclave structures are cured while sitting on a production floor thereby eliminating size constraints on autoclaves and ovens. Also, embodiments of the self heating tools allow for the mass production of smaller composite parts. Rather than stacking hundreds of uncured parts into an autoclave in a time-consuming process, each part could have its own self heating tool. Each self heating tool can be heated on the production floor thereby providing an efficient part flow through the manufacturing plant.
- In embodiments, a tool is formed with resin impregnated with nano tubes. The nano tubes in embodiments are electrically conductive. In one embodiment the nano tubes used to impregnate the resin are carbon nanofibers (nano tubes). Passing current through the resin results in heat being generated due to electrical resistance in the nano tube impregnated resin. In embodiments, by varying the electrical power, the amount of heat created by the tool is varied. Moreover, in embodiments, conductive strips, such as, but not limited to, copper strips are embedded in the cured nano tube impregnated resin. An electrical potential is created between adjacent conductive strips (conductive strips that are near each other) which cause a current to pass through the nano tube impregnated resin. In an embodiment, an alternating current (AC) is applied to the adjacent conductive strips to produce the current through the nano tube impregnated resin.
- Referring to
FIG. 1 , a formation flow diagram 100 of one embodiment is illustrated. The formation flow diagram 100 is described below in concert with illustrations inFIGS. 2 through 3I . In forming a tool, a first step is determining what resin is compatible with a heat range needed to cure pre-preg material (out of autoclave material) used to form a composite structure (102). Then it is determined what the nano tube percentage should be in relation to the resin (104). The percentage ratio is based on a desired outcome (desired heat to be generated by a tool). The nano tubes are then mixed with the resin to form carbon nano tube impregnated resin (106). A type of resin that can be used is K-factor resin provided by Boyce Components LLC. Example nano tubes used are carbon nano tubes provided by Polygraf Products which is a part of Applied Sciences Inc. - A foundation for the nano tube impregnated resin has to be provided to form the self heating tool. In one embodiment, plies of
pre-preg material support base portion 204. In one embodiment six to eight layers (plies) of carbon pre-preg material are used to form thesupport base portion 204 which is approximately 0.180 to 0.250 inches thick.FIG. 2 illustrates plylayers mandrel 202. In one embodiment, the ply layers ofpre-preg material support base portion 204 are then cured (110). After thesupport base portion 204 is cured, afirst insulation layer 300 is applied (112). This is illustrated inFIG. 3A . In one embodiment, thefirst insulation layer 300 is a dry wovenglass layer 300 that is laminated on thesupport base portion 204. The insulation layer (dry woven glass layer 300) is then cured on the support base portion 204 (113). The thickness of theinsulation layer 300 in one embodiment is in the range of 0.003 to 0.005 inches. - Once the first dry woven
glass layer 300 has been cured, a first coat of carbon nanotube impregnatedresin 302 a is applied over the dry woven glass layer 300 (114). This is illustrated inFIGS. 3B and 3C . In one embodiment, asponge brush 304 is used to apply the first coat of carbon nano tube impregnatedresin 302 a to the first dry wovenglass layer 300. In one embodiment, the first coat of carbon nano tube impregnatedresin 302 a is applied with a uniform thickness of approximately 10 to 11 mils. The desired spacing of theconductive strips 306 to be used in the tool is then determined (116). In one embodiment, the conductive strips 306 (conductors) are made of a metal such as copper. Theconductive strips 306 are then placed on a surface of the first coat carbon nano tube impregnatedresin 302 a (118) as illustrated inFIG. 3D . A second coat of carbon nano tube impregnatedresin 302 b is then applied over the first coat of carbon nano tube impregnatedresin 302 a and the conductive strips 306 (120). The first and second coats of carbon nano tube impregnatedresin FIG. 3F . Although, theconductive strips 306 are illustrated above as being substantially straight in the embodiment illustrated inFIGS. 3D and 3E , in other embodiments, theconductive strips 306 a can take any shape as needed to distribute the heat in thetool 350 as desired. For example, inFIG. 3M theconductive strips - A
second insulation layer 310 is laminated then laid up and laminated on the carbon nano tube impregnatedresin 302 b (124). This layer of theinsulation 310 is then cured (125). In one embodiment, thesecond insulation layer 310 is a dry wovenglass layer 310 having a thickness in the range of 0.003 to 0.005 inches. The addition of thesecond insulation layer 310 is illustrated inFIG. 3G . Once thesecond insulation layer 310 has been formed, plylayers tool forming surface 312 of thetool 350. The lying up of the ply layers 312 a and 312 b are illustrated inFIG. 3H and the formedtool forming surface 312 is illustrated inFIG. 3I .FIG. 3I also illustrates the layers of a formedtool 350 in an embodiment. In one embodiment, the ply layers ofpre-preg material surface portion 312 can vary depending on a desired outcome. In one embodiment, the thickness of thetool forming surface 312 is in a range of 0.035 to 0.040 inches. Although, the formedtool 350 illustrated inFIG. 3I is generally C-shaped, the tool can have any desired cross-sectional shape desired depending on the application. Moreover, the tool can be straight along its length, it can be curved along its length and its cross-sectional geometry can vary along its length. Hence, any shaped tool is contemplated andtool 350 ofFIG. 3I is merely an example of one shape of a tool used to form a C-shaped composite structure. - In one embodiment, the
tool 350 is removed from thebase mold 124 once the tool is formed.Bores 330 are then selectively formed through thebase support portion 204, thefirst insulation layer 300 and the first cured carbon nano tube impregnatedresin 302 a to the conducting strips 306 (130). This is illustrated inFIG. 3J andFIG. 3K . In one embodiment, a Dremel® power tool by the Robert Bosch Tool Corporation, or similar tool, is used to make the bores through thetool 350 to the respective conducting strips 306.Conductive wires 340 are then coupled to the conductive strips 306 (132) as illustrated inFIG. 3L .FIG. 3L further illustrates, apower source 342 coupled to theconductive wires 340 and acontroller 344. Thecontroller 344 is designed to control thepower source 342. As stated above, in one embodiment, thepower source 342 provides an alternating current (AC) to respectiveconductive strips 306 to heat up thetool 350. As illustrated inFIG. 3L , the first and second insulation layers 300 and 310 insulate theconductors 306 and nano tube impregnatedresin 302 a from the material that makes up thesupport base portion 204 and the tool formingsurface portion 312. This prevents thesupport base portion 204 and the tool formingsurface portion 312 from passing current out of thetool 350. This would be an issue in an embodiment where thesupport base portion 204 and thetool forming surface 312 include conductive material such as carbon fibers. The insulation layers 300 and 310 also help prevent the nano tube impregnated resin from spreading onto the composite material of thesupport base portion 204 and the tool formingsurface portion 312 during formation of the tool. - Referring to
FIG. 4 , an illustration of a composite structure forming flow diagram 400 is illustrated. The flow diagram 400 is described in concert withFIGS. 5A and 5B . The process starts by laying up and forming pre-preg material on the tool (402). In one embodiment, this is done by applying one or more layers of pre-preg material on the tool formingsurface portion 312 of thetool 350 and pressing the one or more layers of pre-preg material onto the tool formingsurface portion 312 of thetool 350 to form the pre-preg material into the shape of the tool formingsurface portion 312. An example of laying up a layer ofply material 500 on atool 350 is illustrated inFIG. 5A . Any method known in the art to lay up and form thepre-preg material 500 on thetool 350 can be used. An example method of laying up and forming pre-preg material on a tool is illustrated in commonly assigned U.S. Pat. No. 7,249,943 entitled “Apparatus for Forming Composite Stiffeners and Reinforced Structures” that issued on Jul. 31, 2007 and U.S. Pat. No. 7,513,769 entitled “Apparatus and Methods for Forming Composite Stiffeners and Reinforcing Structures” that issued on Apr. 7, 2009 both of which are incorporated herein by reference. Moreover, any other method of laying up and forming the pre-preg material on a tool can be used, such as hot drape forming and other methods known in the art. Once the pre-preg material is positioned on the tool, thepower source 342 provides power to theconductive strips 306 in the tool 350 (404). An example, of thepower source 342 coupled to heat atool 350 is illustrated inFIG. 5B . InFIG. 5B pre-preg material on thetool 350 is cured to form acomposite structure 550. In particular, the heat of thetool 350, as a result of the power being supplied to conductors (conductive strips) in thetool 350, cures the pre-preg material (404) to form thecomposite structure 550. In one embodiment, a vacuum bag system known in the art is used to compact the pre-preg material during curing (403). Once the pre-preg material is cured, the formedcomposite structure 550 is removed from the tool 350 (406). - Referring to
FIG. 6 , a lay up (formation) of thetool 350 of another embodiment is illustrated. In this embodiment the tool is formed on a master 602 (mandrel) in an opposite manner as the embodiment discussed above. In this embodiment, themaster 602 is generally in the shape of the part to be made on the heated tool 305. Hence, the formation of the tool on a mandrel can be made in different ways. One advantage to the formation of thetool 350 as illustrated inFIG. 6 is that the tool formingsurface portion 312 will be relatively smooth and provide a good surface on which to form the composite structures. Conversely, a surface of thesupport base portion 102 will be rougher due to the use of one or more vacuum bags used to cure thetool 350. -
FIG. 7 illustrated a tool formation flow diagram 700 pursuant to the lay up illustrated inFIG. 6 . The flow diagram 700 starts similar to the flow diagram 100 described above. The resin is selected (102). The nano tube percentage is selected (104). The nano tubes and resin are mixed to form the nano tube impregnated resin 302 (106). Plies of pre-preg material are layed up on the master (708). The plies are then cured (710) to form the tool formingsurface portion 312 on a surface of the master 702. Afirst insulation layer 300 is then laminated on a back side of the tool forming surface portion 312 (712). Thefirst insulation layer 300 is then cured (713). A first coat ofnano tube resin 302 a is then applied to the cured first insulation layer 300 (714). It is then determined what the spacing should be for the conductive strips (716). Theconductive strips 306 are then placed on the first coat ofnano tube resin 302 a (718). A second coat ofnano tube resin 302 b is then applied covering the conductive strips 306 (720). Thenano tube resin 302 a and 320 b is then cured (722). A second layer ofinsulation 310 is then laminated over thenano tube resin 302 a and 320 b (724). Theinsulation layer 310 is then cured (725). Plies of pre-preg material are then layed up on the second layer of insulation 310 (726). The plies of pre-preg material are then cured to form the support base portion (128). Bores are then formed through thesupport base portion 204 to the conductive strips (130) as described above in regards toFIG. 3J . Conductive wires are then coupled to the conductive strips (132). As understood in the art, curing of the various materials to make thetool 350 may include various forms of vacuum bagging techniques. - Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
Claims (12)
Priority Applications (1)
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US13/651,814 US20130233476A1 (en) | 2010-08-27 | 2012-10-15 | Out-of-autoclave and alternative oven curing using a self heating tool |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US12/870,556 US8308889B2 (en) | 2010-08-27 | 2010-08-27 | Out-of-autoclave and alternative oven curing using a self heating tool |
US13/651,814 US20130233476A1 (en) | 2010-08-27 | 2012-10-15 | Out-of-autoclave and alternative oven curing using a self heating tool |
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US12/870,556 Division US8308889B2 (en) | 2010-08-27 | 2010-08-27 | Out-of-autoclave and alternative oven curing using a self heating tool |
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US20130233476A1 true US20130233476A1 (en) | 2013-09-12 |
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US12/870,556 Active 2030-12-04 US8308889B2 (en) | 2010-08-27 | 2010-08-27 | Out-of-autoclave and alternative oven curing using a self heating tool |
US13/651,814 Abandoned US20130233476A1 (en) | 2010-08-27 | 2012-10-15 | Out-of-autoclave and alternative oven curing using a self heating tool |
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US12/870,556 Active 2030-12-04 US8308889B2 (en) | 2010-08-27 | 2010-08-27 | Out-of-autoclave and alternative oven curing using a self heating tool |
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US (2) | US8308889B2 (en) |
EP (1) | EP2422949B1 (en) |
ES (1) | ES2536051T3 (en) |
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US10841980B2 (en) | 2015-10-19 | 2020-11-17 | Laminaheat Holding Ltd. | Laminar heating elements with customized or non-uniform resistance and/or irregular shapes and processes for manufacture |
US10925119B2 (en) | 2015-01-12 | 2021-02-16 | Laminaheat Holding Ltd. | Fabric heating element |
USD911038S1 (en) | 2019-10-11 | 2021-02-23 | Laminaheat Holding Ltd. | Heating element sheet having perforations |
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CA2799464A1 (en) * | 2010-02-04 | 2011-08-11 | Saab Ab | A smooth surface forming tool and manufacture thereof |
US10766232B2 (en) | 2012-10-23 | 2020-09-08 | Saab Ab | Smooth surface forming tool and manufacture thereof |
US9370902B2 (en) | 2013-10-03 | 2016-06-21 | Comerstone Research Group, Inc. | Fiber-reinforced epoxy composites and methods of making same without the use of oven or autoclave |
US9908993B1 (en) | 2014-10-06 | 2018-03-06 | Cornerstone Research Group, Inc. | Hybrid fiber layup and fiber-reinforced polymeric composites produced therefrom |
GB2535193A (en) | 2015-02-12 | 2016-08-17 | Zodiac Seats Uk Ltd | Tool for curing a composite component |
US10946594B1 (en) | 2017-01-06 | 2021-03-16 | Cornerstone Research Group, Inc. | Reinforced polymer-infused fiber composite repair system and methods for repairing composite materials |
CN107116810A (en) * | 2017-05-18 | 2017-09-01 | 张彤 | A kind of carbon fibre composite self-curing forming technique |
GB201712355D0 (en) * | 2017-08-01 | 2017-09-13 | Rolls Royce Plc | Rigid Raft |
CN110997290A (en) * | 2019-10-31 | 2020-04-10 | 深圳烯湾科技有限公司 | Fiber fabric reinforced composite material and preparation method thereof |
CN112092413B (en) * | 2020-09-29 | 2024-04-12 | 中国商用飞机有限责任公司北京民用飞机技术研究中心 | Self-heating platform and method for auxiliary automatic laying flexible carbon nanotube film |
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Also Published As
Publication number | Publication date |
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PT2422949E (en) | 2015-05-21 |
EP2422949A1 (en) | 2012-02-29 |
ES2536051T3 (en) | 2015-05-20 |
US8308889B2 (en) | 2012-11-13 |
EP2422949B1 (en) | 2015-02-25 |
US20120048472A1 (en) | 2012-03-01 |
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