CURING SYSTEM AND METHOD USING ELECTROMAGNETIC FORCE AND CONDUCTIVE HEAT TRANSFER

• US 20110006460A1
• Filed: 07/07/2009
• Published: 01/13/2011
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Vander Wel, Michael M., Rubin, Alexander M.
• Granted Patent: US 8,268,226 B2
• Time in Patent Office: Days
• US Class Current: 264/403
• CPC Class Codes: B29C 2043/3211 magnets
• CPC Class Codes: B29C 2043/522 selectively heating a part of the mould to achieve partial heating, differential heating
• CPC Class Codes: B29C 2043/5808 pressure or compressing force
• CPC Class Codes: B29C 2043/5816 temperature
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29K 2105/0854 in the form of a non-woven mat
• CPC Class Codes: B30B 1/42 by magnetic means, e.g. electromagnetic
• CPC Class Codes: B30B 15/34 Heating or cooling presses or parts thereof

Abstract

A system for forming a composite structure comprises an electromagnetic press including an upper die, a lower die and an electromagnet. The lower die may be mounted in spaced relation to the upper die for receiving a composite layup therebetween. The electromagnet is energizable such that the upper and lower dies apply a compressive force to the composite layup.

Claims

1. A system for forming a composite structure, comprising:

an electromagnetic press, including;

an upper die;

a lower die mounted in spaced relation to the upper die for receiving a composite layup; and

at least one electromagnet being energizable such that the upper and lower dies apply a compressive force to the composite layup; and

a heating mechanism mountable to at least one of the upper and lower dies.

2. The system of claim 1 wherein:

the electromagnet includes a magnetic coil and a conductive frame at least partially surrounding the magnetic coil;

at least one of the upper and lower dies being coupled to the conductive frame such that energization of the magnetic coil causes inductive heating of at least one of the upper and lower dies.

3. The system of claim 1 wherein:

the electromagnet comprises a plurality of magnetic coils for applying the compressive force to the composite layup.

4. The system of claim 3 wherein:

the magnetic coils comprise a first coil and a second coil for applying corresponding first and second compressive forces to corresponding first and second areas of the composite layup.

5. The system of claim 1 wherein:

the heating mechanism includes a first heating zone for heating a portion of the composite layup to a first temperature and a second heating zone for heating a portion of the composite layup to a second temperature.

6. The system of claim 1 further comprising:

at least one cooling mechanism mounted to the electromagnetic press for cooling at least one of the upper and lower dies.

7. The system of claim 1 further comprising:

a stationary magnetic member fixedly mounted in spaced relation to the lower die and having the electromagnet mounted thereto; and

a movable magnetic member coupled to the upper die and being mounted on a side of the stationary magnetic member opposite the upper die, the movable magnetic member being drawn toward the stationary magnetic member upon energization of the electromagnet to cause the upper and lower dies to apply the compressive force to the composite layup.

8. A system for forming a composite structure from a composite layup, comprising:

an electromagnetic press, including;

an upper die;

a lower die mounted in spaced relation to the upper die for receiving the composite layup, the upper and lower dies being movable into contacting relation with the composite layup; and

at least one electromagnet having a magnetic coil, the electromagnet being coupled to one of the upper and lower dies and being energizable by applying an electric current to the magnetic coil such that the upper and lower dies apply a compressive force to the composite layup; and

a heating mechanism configured to apply heat to the composite layup, the heating mechanism comprising the magnetic coil and a conductive frame at least partially surrounding the magnetic coil, the conductive frame being coupled to one of the upper and lower dies and being configured such that energization of the magnetic coil causes inductive heating of one of the upper and lower dies for conductively heating the composite layup.

9. A system for forming a composite structure, comprising:

an electromagnetic press, including;

an upper die having a first electromagnetic mechanism coupled thereto;

a lower die mounted in spaced relation to the upper die; and

a second electromagnetic mechanism mounted on a side of the first electromagnetic mechanism opposite the lower die and being energizable to generate an attractive force relative to the first electromagnetic mechanism such that a composite layup is receivable between the upper and lower dies, the second electromagnetic mechanism having reversible polarity such that a repulsive force is generated relative to the first electromagnetic mechanism, the first electromagnetic mechanism being energizable to cause the upper and lower dies to apply a compressive force to the composite layup.

10. The system of claim 9 wherein:

the first electromagnetic mechanism is configured to be de-energized when the second electromagnetic mechanism is energized.

11. The system of claim 9 wherein:

the first electromagnetic mechanism includes a magnetic coil and a conductive frame at least partially surrounding the magnetic coil such that energization of the magnetic coil causes inductive heating of the upper die.

12. The system of claim 9 further comprising:

at least one of a heating mechanism and a cooling mechanism mounted to the electromagnetic press for respectively heating and cooling at least one of the upper and lower dies.

13. A system for forming a composite structure, comprising:

an electromagnetic press, including;

an upper die having a first electromagnet mechanism coupled thereto; and

a lower die mounted in spaced relation to the upper die and having a second electromagnetic mechanism coupled thereto, the second electromagnetic mechanism being energizable to generate a repulsive force relative to the first electromagnetic mechanism such that a composite layup is receivable between the first and second dies, the second electromagnetic mechanism being de-energizable when the first electromagnetic mechanism is energized to cause the first electromagnetic mechanism to generate an attractive force relative to the second electromagnetic mechanism such that the upper and lower dies apply a compressive force to the composite layup.

14. The system of claim 13 wherein:

at least one of the first and second electromagnetic mechanisms includes a magnetic coil and a conductive frame at least partially surrounding the magnetic coil;

at least one of the upper and lower dies being coupled to the conductive frame such that energization of the magnetic coil causes inductive heating of at least one of the upper and lower dies.

15. The system of claim 13 further comprising:

at least one of a heating mechanism and a cooling mechanism mounted to the electromagnetic press for respectively heating and cooling at least one of the upper and lower dies.

16. A system for fabricating a composite structure, comprising:

an electromagnetic press, including;

an inner die;

an outer die mountable in spaced relation to the inner die for receiving a composite layup; and

an electromagnet coupled to one of the inner and outer dies and being energizable such that the inner and outer dies apply a compressive force to the composite layup, the electromagnetic press being movable along a length of the composite layup.

17. The system of claim 16 further comprising:

a heating mechanism configured to heat at least one of the inner and outer dies for conductively heating the composite layup.

18. The system of claim 17 wherein:

the electromagnet includes a magnetic coil and a conductive frame at least partially surrounding the magnetic coil;

at least one of the inner and outer dies being coupled to the conductive frame such that energization of the magnetic coil causes inductive heating of the conductive frame and the one of the inner and outer dies coupled thereto.

19. The system of claim 16 wherein:

the composite layup is configured as a barrel section having inner and outer surfaces;

at least one of the inner and outer dies is configured complementary to a corresponding one of the inner and outer surfaces.

20. The system of claim 16 further comprising at least one of the following:

a pre-heating portion, a curing portion, a cooling portion, an inspection portion.

21. A method of fabricating a composite structure from a composite layup including fiber-reinforced material and uncured resin, the method comprising:

consolidating the fiber-reinforced material in the composite layup; and

compressing the composite layup electromagnetically during the consolidation of the fiber-reinforced material.

22. The method of claim 21 further comprising reducing the viscosity of the uncured resin in the composite layup during the consolidation of the fiber-reinforced material.

23. The method of claim 21 wherein the step of consolidating the composite layup comprises heating the composite layup.

24. The method of claim 23 wherein the step of heating the composite layup comprises creating a heated environment in which the composite layup is present, the step of compressing the composite layup electromagnetically comprises applying an electromagnetic force across the heated environment.

25. The method of claim 21 wherein the steps of consolidating the fiber-reinforced material and compressing the composite layup electromagnetically are performed using an electromagnetic press having an upper die, a lower die and an electromagnet, the method further comprising:

inserting the composite layup into a spacing between the upper and lower dies;

moving the upper and lower dies into contacting relation with the composite layup; and

energizing the electromagnet such that the upper and lower dies to apply a compressive force to the composite layup.

26. The method of claim 25 further comprising the step of pre-heating the upper and lower dies prior to inserting the composite layup into the spacing.

27. The method of claim 25 wherein the step of heating the composite layup comprises:

conductively heating the composite layup with at least one of the upper and lower dies.

28. The method of claim 25 wherein the step of energizing the electromagnet comprises applying current to the electromagnet, the method further comprising the step of:

varying an amount of the electrical current applied to the electromagnet to vary a magnitude of the compressive force applied to the composite layup.

29. The method of claim 25 wherein the electromagnet includes a conductive frame at least partially surrounding a magnetic coil and having at least one of the upper and lower dies coupled to the conductive frame, the step of heating the composite layup comprising:

inductively heating the conductive frame and at least one of the upper and lower dies when energizing the electromagnet; and

conductively heating the composite layup with the one of the inductively heated upper and lower dies.

30. The method of claim 21 further comprising the step of s:

increasing the temperature of the composite layup from an initial temperature to a first temperature; and

maintaining the composite layup at the first temperature over a first time period.

31. The method of claim 25 wherein the electromagnetic press includes a stationary magnetic member and a movable magnetic member, the stationary magnetic member being mounted in spaced relation to the lower die and having the electromagnetic press mounted thereto, the movable magnetic member being coupled to the upper die and positioned on a side of the stationary magnetic member opposite the upper die, the method further comprising the step of:

drawing the movable magnetic member toward the stationary magnetic member upon energization of the electromagnet to cause the upper and lower dies to apply the compressive force to the composite layup.

32. A method of forming a plurality of consolidation zones in a composite layup at spaced locations therealong using an electromagnetic press having an upper die, a lower die and an electromagnet coupled to one of the upper and lower dies, the electromagnet including a conductive frame at least partially surrounding a magnetic coil and being coupled to the upper die, the method comprising the steps of:

pre-heating the upper and lower dies;

inserting a portion of the length of the composite layup into a spacing between the upper and lower dies;

applying heat to the composite layup;

providing a release film between the composite layup and at least one of the upper and lower dies;

moving the upper and lower dies into contacting relation with the composite layup;

energizing the electromagnet such that the upper and lower dies apply a compressive force to the composite layup to form one of the consolidation zones in the composite layup;

heating the conductive frame and the upper die inductively when energizing the electromagnet to conductively heat the composite layup;

separating the upper and lower dies; and

advancing the length of the composite layup along a material feed direction to form another one of the consolidation zones in the composite layup.

33. A method of fabricating a composite structure from a composite layup using an electromagnetic press including upper and lower dies and first and second electromagnetic mechanisms, the upper die being coupled to the first electromagnetic mechanism, the second electromagnetic mechanism being mounted on a side of the first electromagnetic mechanism opposite the lower die and having reversible polarity, the method comprising the steps of:

energizing the second electromagnetic mechanism to generate an attractive force between the first and second electromagnetic mechanisms such that a spacing is generated between the upper and lower dies;

inserting the composite layup into the spacing;

reversing the polarity of the second electromagnetic mechanism to generate a repulsive force between the first and second electromagnetic mechanisms; and

moving the upper and lower dies into contacting relation with the composite layup;

energizing the first electromagnetic mechanism such that the upper and lower dies apply a compressive force to the composite layup.

34. The method of claim 33 wherein the step of energizing the first electromagnetic mechanism such that the upper and lower dies apply a compressive force to the composite layup is followed by the steps of:

de-energizing the first electromagnetic mechanism;

reversing the polarity of the second electromagnetic mechanism to generate an attractive force between the first and second electromagnetic mechanisms;

separating the upper and lower dies; and

removing the composite layup from the electromagnetic press.

35. The method of claim 33 further comprising the step of:

applying heat to the composite layup.

36. The method of claim 35 wherein the first electromagnetic mechanism includes a conductive frame at least partially surrounding a magnetic coil and having the upper die coupled thereto, the step of applying heat to the composite layup comprising:

inductively heating the conductive frame and the upper die when energizing the magnetic coil; and

conductively heating the composite layup with the inductively heated upper die.

37. A method of fabricating a composite structure from a composite layup using an electromagnetic press including upper and lower dies respectively coupled to first and second electromagnetic mechanisms, the method comprising the steps of:

energizing the second electromagnetic mechanism to generate a repulsive force relative to the first electromagnetic mechanism such that a spacing is generated between the upper and lower dies;

inserting the composite layup into the spacing;

de-energizing the second electromagnetic mechanism and energizing the first electromagnetic mechanism to generate an attractive force between the first and second electromagnetic mechanisms;

moving the upper and lower dies into contacting relation with the composite layup; and

applying a compressive force to the composite layup.

38. The method of claim 37 further comprising the step of:

applying heat to the composite layup.

39. The system of claim 37 wherein:

at least one of the first and second electromagnetic mechanisms includes a magnetic coil and a conductive frame at least partially surrounding the magnetic coil;

at least one of the upper and lower dies being coupled to the conductive frame such that energization of the magnetic coil causes inductive heating of at least one of the upper and lower dies.

40. A method of fabricating a composite structure from a composite layup using an electromagnetic press having an electromagnet and inner and outer dies formed complementary to the composite layup, one of the inner and outer dies being coupled to the electromagnet, the method comprising the steps of:

engaging the electromagnetic press to the composite layup such that the inner and outer dies are positioned on opposing sides of the composite layup;

moving the inner and outer dies into contacting relation with the composite layup;

energizing the electromagnet such that the inner and outer dies apply a compressive force to the composite layup; and

advancing the electromagnetic press along a length of the composite layup.

41. The method of claim 40 wherein the step of applying heat to the composite layup comprises:

conductively heating the composite layup using at least one of the inner and outer dies.

42. The method of claim 41 wherein the electromagnet includes a conductive frame at least partially surrounding a magnetic coil, at least one of the inner and outer dies being coupled to the conductive frame, the step of applying heat to the composite layup comprises:

inductively heating the conductive frame and the one of the inner and outer dies coupled thereto when energizing the electromagnet; and

conductively heating the composite layup with the one of the inductively heated inner and outer dies.

43. The method of claim 40 further comprising the step of:

cooling the composite layup.