Ultraviolet-based, large-area scanning system for photothermal processing of composite structures
First Claim
1. A system for curing a plastic three-dimensional solid composite part (110, 112) characterized by:
- a) an illumination source module (101) which produces a high-powered radiation beam;
b) a beam processing module (103) arranged to accept the beam output of said illumination source module (101) and deliver as its output a set of one or more sub-beams, each sub-beam of said set having a pre-determined numerical aperture, having a homogenizer (105) arranged to accept said beam output and forward a shaped, uniformized beam, having condenser means (106) arranged to accept the shaped, uniformized sub-beam output of said homogenizer (105) and to reconfigure the sub-beam output into a set of at least one operational sub-beam of predetermined characteristics;
c) a translation stage subsystem (99) for presenting a pattern of photo-curing radiation to different segments of said composite part (110,
112) for photocuring, andd) control means (100) to control said translation stage subsystem to control said beam processing module, to provide a pattern selectively to each one of a plurality of individual segments of said composite part (110,
112).
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Abstract
In making thermoset and photo-set polymer-matrix composite parts, curing is the key process step that transforms the molecular structure of the composite material, stabilizing it in the desired shape. This curing system applies carefully controlled ultraviolet (UV) radiation dosages, appropriately distributed over the entire surface of the composite part, thereby rapidly curing the material while enabling direct monitoring and control of the curing energy. Previous photo-curing methods have applied generalized radiation to a part with conventional UV lamps. We provide great benefits in cure depth, speed and process control by precisely controlling all parameters of UV dosage, by computed control, by markings on the part, or by dynamic feedback control from embedded sensors or non-contact sensors. This system can apply greater radiation dose to areas of increased quantities of resin, such as support ribs, and lesser radiation dose to areas of decreased quantities of resin. This method can be enhanced by using differing resins which respond to differing wavelengths, and also by controlled changes of radiation field size or duration. This curing system also enables temporary joining of parts by sufficient partial or controlled-area photo-setting, which may also be integrated with lay-up or winding operations. As a result, these partially cured parts can be handled safely through later stages of the manufacturing process, such as final photo-setting or baking operation in an oven or autoclave.
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Citations
33 Claims
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1. A system for curing a plastic three-dimensional solid composite part (110, 112) characterized by:
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a) an illumination source module (101) which produces a high-powered radiation beam; b) a beam processing module (103) arranged to accept the beam output of said illumination source module (101) and deliver as its output a set of one or more sub-beams, each sub-beam of said set having a pre-determined numerical aperture, having a homogenizer (105) arranged to accept said beam output and forward a shaped, uniformized beam, having condenser means (106) arranged to accept the shaped, uniformized sub-beam output of said homogenizer (105) and to reconfigure the sub-beam output into a set of at least one operational sub-beam of predetermined characteristics; c) a translation stage subsystem (99) for presenting a pattern of photo-curing radiation to different segments of said composite part (110,
112) for photocuring, andd) control means (100) to control said translation stage subsystem to control said beam processing module, to provide a pattern selectively to each one of a plurality of individual segments of said composite part (110,
112).
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2. A system for curing a photo-curable composite part (110, 112), having a subsystem (99) for presenting different segments of said composite part (110, 112) for photocuring, characterized by:
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a) an illumination source module (101) which produces a high-powered radiation beam; b) a beam processing module (103) arranged to accept the beam output of said illumination source module (101) and deliver as its output a set of one or more sub-beams, each sub-beam of said set having a pre-determined numerical aperture, having a homogenizer (105) arranged to accept said beam output and forward a shaped, uniformized beam, having condenser means (106) arranged to accept the shaped, uniformized sub-beam output of said homogenizer (105) and to reconfigure the sub-beam output into a set of at least one operational sub-beam of predetermined characteristics; c) a translation stage subsystem (99) for presenting a pattern of photocuring radiation to different segments of said composite part (110,
112) for photocuring;d) control means (100) to control said translation stage subsystem to control said beam processing module, to provide a pattern selectively to each one of a plurality of individual segments of said composite part (110,
112); ande) means (113) for completing a photo-setting reaction of said composite part (110,
112). - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of initiating photo-curing reactions in a composite part (110, 112), characterized by the following steps:
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(step
1) Allocating an illumination source module (101) having sufficient power to irradiate said composite part over a polygonal area;(step
2) Arranging a beam processing module (103) to accept the beam output of said illumination source module (101) and forward a set of one or more subbeams, each with the selected numerical aperture;(step
3) Arranging a homogenizer (105) to accept the sub-beam output of said beam processing module (103) and forward a set of shaped, uniformized sub-beams;(step
4) Arranging condenser means (106) to accept the sub-beam output of said homogenizer (105) and to reconfigure the sub-beam output into a set of one or more sub-beams of predetermined characteristics, which expose an increment of said composite part (110,
112) to initiate selective photo-curing; and(step
5) Activating said illumination source module to initiate photo-curing reactions. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 29, 30, 31, 32, 33)
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28. A method of initiating photo-curing reactions in a three-dimensional composite part built up in incremental layers by selective illumination characterized by
step 1 providing a set of first, second . . . nth specific photo-initiators having different sensitivities to first, second . . . nth specific wavelengths of ultraviolet radiation, step 2 exposing said first photo-initiator with said first wavelength ultraviolet radiation at selected positions at specific times during the process; -
step 3 exposing said second photo-initiator with said second wavelength ultraviolet-radiation at selected positions at specific times during the process; and step n exposing said nth photo-initiator with said nth wavelength ultraviolet-radiation at selected positions at specific times during the process, whereby said three-dimensional composite part is built up in incremental layers by selective illumination.
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Specification