# US 2014/0190629 A1 · Induction heating compaction system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0190629 A1 - Document ID: US20140190629A1 - Status: Published application - Kind: A1 - Application number: 13/734,661 - Filed: 2013-01-04 - Published: 2014-07-10 - Earliest claimed: 2013-01-04 - Assignees: Alliant Techsystems Inc. - Inventors: Vernon M. Benson; David R. Machac; Bryan J. Loveless - Web page: https://patentgrep.com/patent/US20140190629A1 ## CPC - B29C 70/386: {Automated tape laying [ATL]} - B29C 35/0805: {using electromagnetic radiation} - 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)} - B29C 65/1403: {characterised by the type of electromagnetic or particle radiation (B29C65/1603 takes precedence)} - B29C 65/34: using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" - B29C 65/36: heated by induction - B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)} - B29C 66/349: {Cooling the welding zone on the welding spot} - B29C 66/45: {Joining of substantially the whole surface of the articles (methods or apparatus for laminating B32B37/00)} - B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)} - B29C 66/8181: {characterised by the cooling constructional aspects} - B29C 66/8362: {Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined} - B29C 70/388: {Tape placement heads, e.g. component parts, details or accessories} - B29C 65/3616: {comprising discontinuous fibre-reinforcements} - B29C 66/7392: {characterised by the material of at least one of the parts being a thermoplastic} - B29C 66/7394: {characterised by the material of at least one of the parts being a thermoset} - B29C 2035/0811: {using induction} - B29K 2105/0872: {Prepregs} - B29K 2307/04: Carbon - B29K 2995/0013: Conductive - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - 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 ## Abstract An induction heating compaction system is provided. The system includes an induction heating member and a compaction member. The induction heating member is configured to generate an electromagnetic field at a select frequency. The select frequency causes at least one of the fibers and matrix in pre-preg material to heat up. The compaction member has at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member. The compaction member includes a cooling assembly that is configured and arranged to extract heat from the pre-preg material while compacting the pre-preg material. ## Claims ### Claim 1 An induction heating compaction system, the system comprising: an induction heating member configured to generate an electromagnetic field at a select frequency, the select frequency causing at least one of the fibers and matrix in pre-preg material to heat up; and a compaction member configured and arranged to extract heat from the pre-preg material while compacting the pre-preg material. ### Claim 2 (depends on 1) The system of claim 1, further comprising: the induction heating member being contained within the compaction member, the compaction member having at least one portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member such that the induction field can be directed at a composite pre-preg material to be consolidated while not heating up the at least one portion of the compaction device. ### Claim 3 (depends on 2) The system of claim 2, further comprising: at least one shielding member positioned to shield at least one reactive portion of the compaction device that is not transparent to the electromagnetic field generated by the induction heating member to prevent the at least one reactive portion of the compaction device from the heating effects of the induction field. ### Claim 4 (depends on 1) The system of claim 1, wherein the compaction member is a compaction roller. ### Claim 5 (depends on 4) The system of claim 4, wherein the compaction roller further comprises: a roller axle having opposed first and second end portions; a cylindrical shielding configured and arranged to be received over the roller axel; an induction heating member configured and arranged to be received over the shielding; a first bearing received on the first end portion of the roller axel; a second bearing received on the second end portion of the roller axel; a main roller support received over the roller axel and engaging the first and second bearings such that the main roller support is rotationally coupled to the roller axel; and a roller cover received over the main roller support, the roller cover configured and arranged to compact composite pre-preg material. ### Claim 6 (depends on 5) The system of claim 5, further comprising: the roller axis further having a cylindrical mid-portion between the opposed first and second end portions, the first and second end portions having a smaller diameter than the mid-portion; the cylindrical shielding received over the mid-portion of the roller axis; the first bearing engaging a first shoulder formed between the first end portion and mid-portion of the roller axel; the second bearing engaging a second shoulder formed between the second end portion and mid-portion of the roller axel; and the main roller support including a plurality of cooling passages. ### Claim 7 (depends on 6) The system of claim 6, further comprising: a cooling device configured and arranged to provide a flow for at least one of a gas or liquid through the plurality of cooling passages in the main roller support. ### Claim 8 (depends on 1) The system of claim 1, wherein the compaction member is a compaction foot. ### Claim 9 (depends on 8) The system of claim 8, wherein the compaction foot further comprises: a stamp member, the stamp member including at least one base portion, opposed first and second end walls extending from opposed ends of the base portion, opposed first and second side walls extending from opposed sides of the base portion, the first and second end walls, the first and second side walls and the base portion forming an inner chamber of the stamp member an engaging member coupled to a bottom of the base portion of the stamp member, the engaging member configured and arranged to compact pre-preg material; and an induction heating member received in the inner chamber of the stamp member. ### Claim 10 (depends on 9) The system of claim 9, further comprising: the first and second side walls having a plurality of cooling passages; and a shield member, the shield member including a shield top cover and a shield side portions that extends from the shield top cover, the shield side portions received in the inner chamber of the stamp member, the shield top cover configured and arranged to cover the inner chamber of the stamp member. ### Claim 11 (depends on 1) The system of claim 1, further comprising: a cooling assembly to extract heat from the pre-preg material. ### Claim 12 (depends on 1) The system of claim 1, further comprising: a positioning assembly configured and arranged to position the compaction member in a desired location. ### Claim 13 (depends on 12) The system of claim 12, further comprising: a controller coupled to control the positioning assembly. ### Claim 14 (depends on 13) The system of claim 13, wherein the controller is further configured to control the heating, compaction and cooling of the pre-preg material to a solidified state as the system passes over the material in a continuous compaction process. ### Claim 15 An induction heating compaction system, the system comprising: a compaction member configured and arranged to compact ply layers of pre-preg material; an induction heating member received within the compaction member, the induction heating member configured to generate an electromagnetic field at a select frequency, the select frequency causing at least one of the fibers and matrix in pre-preg material to heat up; the compaction member having at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member, such that the induction field can be directed at a composite pre-preg material to be consolidated, while not heating up the compaction device; and a cooling assembly configured and arranged to extract heat from the pre-pre material to solidify the ply layers of pre-preg material in a compact configuration during an in-situ compaction buildup process. ### Claim 16 (depends on 15) The induction heating compaction system of claim 15, wherein the cooling assembly is within the compaction member. ### Claim 17 (depends on 15) The system of claim 15, wherein the compaction member is one of a compaction roller and a compaction foot. ### Claim 18 (depends on 15) The system of claim 15, wherein the cooling assembly includes at least one cooling passage. ### Claim 19 (depends on 15) The system of claim 15, wherein the cooling assembly is one of a passive and active cooling system. ### Claim 20 (depends on 15) The system of claim 15, wherein the compaction member is a compaction roller, the compaction roller further comprising: a roller axel having opposed first and second end portions, a cylindrical shielding configured and arranged to be received over the roller axel; an induction heating member configured and arranged to be received over the shielding; a first bearing received on the first end portion of the roller axel; a second bearing received on the second end portion of the roller axel; a main roller support received over the roller axel and engaging the first and second bearings such that the main roller support is rotationally coupled to the roller axel; and a roller cover received over the main roller support, the roller cover configured and arranged to compact pre-preg material. ### Claim 21 (depends on 20) The system of claim 20, wherein the main roller support includes a plurality of cooling passages. ### Claim 22 (depends on 15) The system of claim 15, wherein the compaction member is a compaction foot, the compaction foot further comprising: a stamp member, the stamp member including a base portion, opposed first and second end walls extending from opposed ends of the base portion, opposed first and second side walls extending from opposed sides of the rectangular base portion, the first and second end walls, the first and second side walls and the base portion forming an inner chamber of the stamp member; an engaging member coupled to a bottom of the base portion of the stamp member, the engaging member configured and arranged to compact pre-preg material; and an induction heating member received in the inner chamber of the stamp member. ### Claim 23 (depends on 22) The system of claim 22 wherein the stamp member includes a plurality of cooling passages. ### Claim 24 A method of consolidating pre-preg material ply layers, the method comprising: inductively heating an area of at least one of fibers and matrix in at least one first pre-preg material ply layer to soften the matrix in the heated area; and compacting the heated area of the at least one first pre-preg material ply layer during layup of the at least one first pre-preg material ply layer over a second pre-preg material ply layer. ### Claim 25 (depends on 24) The method of claim 24, further comprising: extracting heat from the at least one first pre-preg material ply layer and the second pre-preg material layer while compacting the heated area to solidify the at least one first pre-preg material layer and the second pre-preg material ply layer in a compact state. ### Claim 26 (depends on 24) The method of claim 24, further comprising: automatically laying up at least a portion of the first pre-preg material ply layer over the at least one second pre-preg material ply layer; inductively heating at least one of fibers and matrix in the at least a portion of the first pre-preg material ply layer to soften the matrix in the at least a portion of the first pre-preg material ply layer; compacting the at least a portion of the first pre-preg material ply layer over the at least one second pre-preg material ply layer; and extracting heat from the at least a portion of the first pre-preg material layer and the at least one second pre-preg material ply layer during the compacting to solidify the ply layers in a compact state. ### Claim 27 (depends on 24) The method of claim 24, further comprising: generating induction heat of a given frequency that heats up at least one of the fibers and matrix in the at least one first pre-preg material ply layer with an induction heater housed within the a compaction member. ### Claim 28 (depends on 24) The method of claim 24, further comprising: shielding at least some elements of the compaction member from the heating effects of the induction heating. ### Claim 29 (depends on 24) The method of claim 24, further comprising: cooling a compaction member that compacts the heated area to extract the heat from the at least one first pre-preg material ply layer and the second pre-preg material layer.