Integrated Conductive Foam Core for Composite Processing

A method for forming a self-heating aircraft component, the method comprising:

• forming a conductive foam core into a suitable shape for establishing the desired shape of the self-heating aircraft component;
• wrapping one or more layers of uncured composite material around the conductive core such that the one or more layers of uncured composite material assume the particular shape of the conductive foam core;
• supplying an electric current to the conductive core to resistively heat the one or more layers of uncured composite material to a temperature sufficient to cure the one or more layers of uncured composite material and form one or more cured composite walls;
• and
• retaining the conductive foam core within the one or more cured composite walls, wherein the conductive foam core resistively heats the self-heating aircraft component when an electric current is supplied to the conductive core.

A method for forming a self-heating aircraft component, the method comprising:

• forming a conductive foam core into a suitable shape for establishing the desired shape of the self-heating aircraft component;
• laying one or more layers of uncured composite material onto the conductive core such that the one or more layers of uncured composite material assume the particular shape of the conductive foam core;
• placing the conductive foam core and the one or more layers of uncured composite material in a cavity of a vacuum bag;
• creating a vacuum in the cavity of the vacuum bag to squeeze the one or more layers of uncured composite material and the conductive foam core;
• supplying an electric current to the conductive core to resistively heat the one or more layers of uncured composite material to a temperature above the glass transition temperature of the one or more layers of uncured composite material to cure the one or more layers of uncured composite material and form one or more cured composite walls;
• and
• retaining the conductive foam core in contact with the one or more cured composite walls, wherein the conductive foam core resistively heats the self-heating aircraft component when an electric current is supplied to the conductive core.