Method and Apparatus For Curing a Composite Part Layup

• US 20110229720A1
• Filed: 03/16/2010
• Published: 09/22/2011
• Est. Priority Date: 03/16/2010
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Negley, Mark A., Matsen, Marc R., Peterson, Kim E.
• Granted Patent: US 8,865,050 B2
• Time in Patent Office: Days
• US Class Current: 428/411.1
• CPC Class Codes: B29C 2035/0811 using induction
• CPC Class Codes: B29C 2035/1616 using liquids
• CPC Class Codes: B29C 35/0288 Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process controlling or regulating chemical, physical or physico- chemical processes in general B01J19/0006
• CPC Class Codes: B29C 35/16 Cooling cooling extruded material B29C48/911; cooling preforms for blow moulding B29C49/6427; cooling blown articles B29C49/66; cooling tyres during post cure inflation B29D30/0643
• CPC Class Codes: B29C 70/345 using matched moulds
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: H05B 6/105 using a susceptor
• CPC Class Codes: H05B 6/14 Tools, e.g. nozzles, rollers, calenders
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

A composite part layup is cured using a set of tools adapted to hold the layup and which include at least one tool face contacting the layup. Means are provided for heating the tool face to cure the part layup, and for selectively cooling sections of the tool face.

Claims

1. Apparatus for curing a composite part, comprising:

a set of tools adapted to hold a composite part layup and including at least one tool face contacting the part layup;

means for heating the tool face to cure the part layup; and

,

means coupled with each of the tools for selectively cooling individual sections of the tool face.

2. The apparatus of claim 1, further comprising:

means for sensing the temperature of the tool face within each of the sections; and

a controller for selecting sections of the tool face to be cooled based on the sensed temperatures and for controlling the cooling means to cool the selected sections of the tool face.

3. The apparatus of claim 1, further comprising:

a plurality of thermocouples coupled with the tool face respectively within the sections for sensing the temperature of the tool face in the section and for controlling the cooling means based in the sensed temperature.

4. The apparatus of claim 1, wherein the means for selectively cooling includes a plurality of nozzles adapted to be coupled with a source of a coolant fluid for directing the coolant fluid onto the tool face.

5. The apparatus of claim 1, wherein:

each of the tools includes a plurality of laminations and the tool face includes a susceptor having a front side contacting the part layup and a backside connected to the laminations,

the heating means includes a plurality of electrical induction coils for inductively heating the susceptors, and

the cooling means includes nozzles for directing coolant onto the backside of the susceptors.

6. The apparatus of claim 5, wherein the cooling means further includes a plurality of electrically controlled valves for controlling the flow of the coolant to the nozzles.

7. The apparatus of claim 5, wherein:

at least certain of the laminations are spaced apart from each other, and

the nozzles are located between the spaced apart laminations.

8. Apparatus for curing a composite thermoset resin part layup having a varying thickness, comprising:

a tool having at least one tool face adapted to contact the part layup;

a heating system for heating the tool face to a temperature sufficient to cure the part layup;

a plurality of sensors for respectively sensing the temperature of the tool face within each of a plurality of sections of the tool face;

a cooling system for cooling selected sections of the tool face; and

,

a controller for selecting the sections of the tool face to be cooled based on the sensed temperatures.

9. The apparatus of claim 8, wherein the controller is coupled with the cooling system for controlling the cooling system to cool the tool face within the selected sections.

10. The apparatus of claim 8, wherein:

the tool includes a plurality of spaced apart laminations and a susceptor having a front side defining the tool face and a backside connected to the laminations, and

the cooling system includes means for individually cooling the backside of the susceptor within the selected sections of the tool face.

11. The apparatus of claim 10, wherein the heating system includes a plurality of electrical induction coils extending transversely through the laminations for inductively heating the susceptor.

12. The apparatus of claim 8, wherein the cooling system includes:

a plurality of nozzles respectively associated with the sections of the tool face and located in proximity to the backside of the tool face,

a source of coolant fluid coupled with each of the nozzles, and

a plurality of valves operated by the controller for respectively controlling the flow of the coolant fluid from the source to each of the nozzles.

13. The apparatus of claim 12, wherein:

the tool includes a plurality of spaced apart laminations coupled with the backside of the tool face, and

the nozzles are located between at least certain of the laminations and are oriented to direct the coolant fluid onto the backside of the tool face.

14. The apparatus of claim 8, wherein at least one of the sensors is coupled with the backside of the tool face within each of the sections of the tool face.

15. A method of controlling the temperature of a tool face used to cure a composite part layup, comprising:

heating the tool face;

sensing the temperature of the tool face at each of a plurality of sections of the tool face; and

,

selectively cooling at least one section of the tool face based on the temperatures sensed within each of the sections.

16. The method of claim 15, wherein sensing the temperatures includes sensing when the temperature within each of the sections exceeds the cure temperature of the part layup by a prescribed amount.

17. The method of claim 16, wherein sensing the temperatures is performed using a plurality of thermocouples.

18. The method of claim 15, further comprising:

using a programmed controller to select the sections of the tool face that are to be cooled; and

using the programmed controller to command the cooling system to cool the tool face within the selected sections.

19. The method of claim 16, wherein:

the heating is performed by inductively heating a smart susceptor, and

the cooling is performed by directing a coolant fluid onto the backside of the susceptor from locations between the laminations.

20. A composite part cured with a tool having a tool face temperature controlled by the method of claim 15.

21. A method of curing a thermoset resin composite part layup having a varying thickness, comprising:

placing the part layup in contact with a cure tool;

heating the part layup to a cure temperature by heating a face of the tool in contact with the layup;

sensing sections on the tool face where the temperature of the tool exceeds the cure temperature due to heat produced by an exothermic reaction of the thermoset resin in areas of the part layup having a greater thickness; and

,

directing a coolant fluid onto the backside of the tool within the sections where the temperature of the tool face exceeds the cure temperature.

22. The method of claim 21, further comprising:

using a programmed controller to automatically determine the sections on the tool face where the temperature of the tool exceeds the cure temperature and to determine which of a plurality of nozzles should be used to direct the coolant fluid onto the backside of the tool.

23. A composite thermoset part layup cured by the method of claim 21.

24. A method of controlling the temperature of a tool used to cure a thermoset resin composite part having a varying thickness, comprising:

placing the layup in a tool having a pair of smart susceptors each including a contoured tool face matching the part;

inductively heating the smart susceptors to the cure temperature of the layup, the heating of the layup resulting in exothermic reactions of the thermoset resin that generates reaction heat causing overheating of at least certain sections of the layup beyond the cure temperature;

compressing the layup between the susceptors to consolidate the layup as it is being cured;

individually sensing the temperature in each of a plurality of sections of each of the susceptors;

determining when the sensed temperature in each of the sections of the susceptors exceeds the cure temperature by a preselected amount;

using a programmed controlled to select which of the sections of the susceptors is overheated and is to be cooled based on the sensed temperatures;

pumping a coolant fluid to each of the susceptors; and

,

cooling the overheated sections of the susceptors, including using nozzles to direct the coolant fluid onto the backside of the susceptors within the overheated areas and controlling the rate at which the coolant fluid is directed onto the backside of the susceptors.

25. Apparatus for curing and consolidating a composite part layup that includes a thermosetting resin binder, comprising:

a press;

a set of matched tools mounted in the press, the tools including first and second smart susceptors each having a contoured tool face matching the part and a set of spaced apart laminations connected to the susceptors;

a system for heating the susceptors, including induction coils passing transversely through the laminations for inductively heating the susceptors to the cure temperature of the layup;

a source of coolant fluid;

a fluid pump coupled with the source of coolant fluid;

a plurality of nozzles located between the laminations and each adapted to direct coolant fluid onto the susceptors;

a set valves for controlling the flow of the coolant fluid from the source to the nozzles;

a set of tubes coupling the valves with the source and the nozzles;

a plurality of sensors for sensing the temperature in each of a plurality of sections of each of the susceptors; and

a programmed controller for selecting the sections of the susceptors to be cooled and for controlling the operation of the pump and the valves to direct the coolant fluid onto the susceptors within the sections selected to be cooled.