Patent Description:
Methods that enable rapid fabrication of molded thermoplastic articles may be desirable in some applications. Conventional thermoplastic fabrication includes autoclave processing with resistive heating. Rapid fabrication using conventional fabrication may be challenging.

Another method uses induction heating of tool interfaces with integral water cooling of the induction coils within the tooling. However, integral water cooling may be challenging, particularly when molding thermoplastic articles requiring high temperatures and high pressures.

Accordingly, those skilled in the art continue with research and development in the field of molding of thermoplastic articles.

The abstract of <CIT> recites: 'An induction heating device for manufacturing a part by heating the part to a predetermined temperature. The induction heating device includes an induction coil connected to an electrical power supply for generating an electromagnetic flux field. A smart susceptor of the heating device is positioned in the electromagnetic flux field and includes a magnetically permeable material supported by a mesh structure. The magnetically permeable material generates heat in response to the flux field. The mesh structure provides support for the magnetically permeable material and closely conforms to the desired outer geometry of the part. The magnetically permeable material may be applied as a powder to the mesh using a hot spray gun, allowing tight conformance of the susceptor to the part geometry while avoiding forming limits of sheet metal susceptors.

In a first non-claimed aspect the present disclosure refers to an induction heating system for molding a thermoplastic article including a first mold and a second mold defining a mold cavity therebetween for molding the thermoplastic article, a first metallic susceptor as part of or adjacent to the first mold, a first armature-supported induction coil array in proximity to the first metallic susceptor and a first induction generator electrically coupled with the first armature-supported induction coil array.

In a second claimed aspect the present disclosure refers to a method for processing a thermoplastic article comprising generating heat by frequency matching induction generation using a modular induction coil and air cooling the modular induction coil, wherein the step of air cooling the modular induction coil includes removing the modular induction coil from a mold containing the thermoplastic article.

In a third non-claimed claimed aspect, the present disclosure refers to a method for molding a thermoplastic article includes positioning a thermoplastic article between a first mold including a first metallic susceptor and a second mold including a second metallic susceptor, inductively heating the first metallic susceptor using a first induction frequency, detecting a magnetic hysteresis from the inductively heated first metallic susceptor, adjusting the first induction frequency based on the magnetic hysteresis from the inductively heated first metallic susceptor, and pressing together the first mold and the second mold.

Further claimed aspects of the disclosure are the subject of claims <NUM>-<NUM>.

In a further non-claimed aspect, the disclosure refers to a induction heating system for molding a thermoplastic article, comprising a first mold and a second mold defining a mold cavity therebetween for molding the thermoplastic article, a first metallic susceptor as part of or adjacent to the first mold, a first armature-supported induction coil array in proximity to the first metallic susceptor and a first induction generator electrically coupled with the first armature-supported induction coil array.

The first mold can comprise a plurality of first slots and the first armature-supported induction coil array comprises a plurality of first fingers positionable within the plurality of first slots.

A first magnetic hysteresis detector can be associated with the first armature-supported induction coil array.

A second metallic susceptor can be part of or adjacent to the second mold.

A second armature-supported induction coil array can be in proximity to the second metallic susceptor.

A mold support can support the second mold.

The mold support can comprise a plurality of second slots and the second armature-supported induction coil array comprises a plurality of second fingers positionable within the plurality of second slots.

A second magnetic hysteresis detector can be associated with the second armature-supported induction coil array.

A press platen can be included for pressing together the first mold and the second mold.

At least a portion of the first mold can form the first metallic susceptor.

The first metallic susceptor can be positioned adjacent to the first mold.

At least a portion of the second mold can form the second metallic susceptor.

The second metallic susceptor can be positioned adjacent to the second mold.

The first metallic susceptor can be formed from a smart susceptor material.

The second metallic susceptor can be formed from a smart susceptor material. A further non-claimed aspect refers to a method for molding a thermoplastic article, comprising positioning a thermoplastic article between a first mold including a first metallic susceptor and a second mold including a second metallic susceptor; inductively heating the first metallic susceptor using a first induction frequency; detecting a magnetic hysteresis from the inductively heated first metallic susceptor; adjusting the first induction frequency based on the magnetic hysteresis from the inductively heated first metallic susceptor; and pressing together the first mold and the second mold.

When the first metallic susceptor reaches a predetermined temperature, the inductive heating of the first metallic susceptor can be stopped.

The second metallic susceptor can be inductively heated using a second induction frequency.

A magnetic hysteresis can be detected from the inductively heated second metallic susceptor.

The second induction frequency can be adjusted based on the magnetic hysteresis from the inductively heated second metallic susceptor.

When the second metallic susceptor reaches a predetermined temperature, the inductive heating of the second metallic susceptor can be stopped.

A further non-claimed aspect refers to a method for processing a thermoplastic article, comprising generating heat by frequency matching induction generation using a modular induction coil; and air cooling the modular induction coil.

Generating heat by frequency matching induction generation using a modular induction coil may include inductively heating a metallic susceptor to heat the thermoplastic article using a first induction frequency; detecting a magnetic hysteresis from the inductively heated metallic susceptor; and adjusting the first induction frequency based on the magnetic hysteresis from the inductively heated metallic susceptor.

Air cooling the modular induction coil may include removing the modular induction coil from a mold containing the thermoplastic article; and passive air cooling the modular induction coil in ambient air.

Other aspects of the disclosed induction heating system and method for molding a thermoplastic article will become apparent from the following detailed description, the accompanying drawings and the appended claims.

<FIG> is a perspective view of an induction heating system in an assembled condition disposed between press platens. <FIG> is a perspective view of the induction heating system of <FIG> further showing removed armature-supported induction coil arrays. <FIG> is an exploded perspective view of the induction heating system of <FIG> further showing metallic susceptors that are part of molds of the induction heating system. <FIG> is an exploded perspective view of a variation of induction heating system of <FIG> further showing metallic susceptors that are adjacent to the molds of the induction heating system. <FIG> is a first perspective view of an armature-supported induction coil array. <FIG> is a second perspective view of the armature-supported induction coil array of <FIG>. <FIG> is a third perspective view of the armature-supported induction coil array of <FIG>. <FIG> is a side view of a finger of the armature-supported induction coil array. <FIG> is a first perspective view of the finger of <FIG> is a second perspective view of the finger of <FIG>.

Referring to <FIG>, there is an induction heating system <NUM>. The induction heating system <NUM> includes a first mold <NUM> and a second mold <NUM> defining a mold cavity therebetween, a first metallic susceptor <NUM> as part of the first mold <NUM>, a first armature-supported induction coil array <NUM> in proximity to the first metallic susceptor <NUM>, and a first induction generator <NUM> electrically coupled with the first armature-supported induction coil array <NUM>. <FIG> is a variation of <FIG> in which the first metallic susceptor <NUM> is adjacent to the first mold <NUM>. By providing these combinations of features, regardless of whether the first metallic susceptor <NUM> is as part of or adjacent to the first mold <NUM>, the induction heating system <NUM> facilitates use of the induction heating system <NUM> to heat and mold a thermoplastic article A.

Although the first mold <NUM> and second mold <NUM> are illustrated as providing a simple-shaped mold cavity therebetween, the present description facilitates molding of complex contoured articles.

Referring to <FIG>, the first mold <NUM> includes a plurality of first slots <NUM>. Referring to <FIG>, the first armature-supported induction coil array <NUM> is shown as a modular induction coil comprising a plurality of first fingers <NUM> positionable within the plurality of first slots <NUM>. Accordingly, by providing the plurality of first slots <NUM> in the first mold <NUM> and the plurality of first fingers <NUM> in the first armature-supported induction coil array <NUM>, the induction heating system <NUM> facilitates removal of the first armature-supported induction coil array <NUM> from the first mold <NUM>. In an aspect, the first armature-supported induction coil array <NUM> may include an endcap <NUM> supporting the plurality of first fingers <NUM>.

By removing the first armature-supported induction coil array <NUM> from the first mold <NUM>, the induction heating system <NUM> facilitates air cooling, e.g. passive air cooling, of the thermoplastic article A and the first armature-supported induction coil array <NUM>. Also, the separated finger structure of the first armature-supported induction coil array <NUM> facilitates faster air cooling by permitting convection of area between each of the plurality of first fingers <NUM>.

Additionally, by providing a removable first armature-supported induction coil array <NUM>, the first armature-supported induction coil array <NUM> can be removed and placed into another tool as needed. This modularity reduced the total cost and complexity of the molding tool. Additionally, by making the first armature-supported induction coil array <NUM> as a plurality first fingers <NUM>, the first armature-supported induction coil array <NUM> can be shaped to best approximate the contour of the lowermost surface <NUM> of the first mold <NUM> for more efficient inductive coupling.

Referring to <FIG>, the induction heating system <NUM> includes a first magnetic hysteresis detector <NUM> associated with the first armature-supported induction coil array <NUM>. By providing the first magnetic hysteresis detector <NUM>, a magnetic hysteresis from the inductively heated first metallic susceptor <NUM> can be detected. By detecting a magnetic hysteresis from the inductively heated first metallic susceptor <NUM>, a frequency generated by the first induction generator <NUM> can be adjusted to minimize heating of the first armature-supported induction coil array <NUM>. The adjustment of the frequency generated by the first induction generator <NUM> may frequency match the magnetic hysteresis from the inductively heated first metallic susceptor <NUM>. Heating the first metallic susceptor <NUM> by this frequency matching induction generation can minimize heat generated in the first armature-supported induction coil array <NUM>. The adjustment of the frequency generated by the first induction generator <NUM> may be performed, for example, by using a controller (not shown), which may be computer hardware device. The controller may be communicatively coupled to the first magnetic hysteresis detector <NUM> and the first induction generator <NUM>.

By minimizing heating of the first armature-supported induction coil array <NUM>, water cooling of the first armature-supported induction coil array <NUM> can be avoided.

The above-described feature of the first magnetic hysteresis detector <NUM> may be employed in combination with the first armature-supported induction coil array <NUM> having the plurality of first fingers <NUM>.

Referring to <FIG>, the induction heating system <NUM> includes a second metallic susceptor <NUM> as part of the second mold <NUM>. <FIG> is a variation of <FIG> in which the second metallic susceptor <NUM> is adjacent to the second mold <NUM>. By providing the second metallic susceptor <NUM>, regardless of whether the second metallic susceptor <NUM> is as part of or adjacent to the second mold <NUM>, the induction heating system <NUM> facilitates use of the induction heating system <NUM> to heat the thermoplastic article A from both sides of the thermoplastic article A. In another variation, the first metallic susceptor <NUM> is part of the first mold <NUM> while the second metallic susceptor <NUM> is adjacent to the second mold <NUM>. In yet another variation, the first metallic susceptor <NUM> is adjacent to the first mold <NUM> while the second metallic susceptor <NUM> is part of the second mold <NUM>.

The above-described feature of second metallic susceptor may be employed in combination with the first armature-supported induction coil array <NUM> having the plurality of first fingers <NUM>.

Referring to <FIG>, the induction heating system <NUM> includes a second armature-supported induction coil array <NUM> shown as a modular induction coil in proximity to the second metallic susceptor <NUM>. By providing the second armature-supported induction coil array <NUM>, a heating of the second metallic susceptor <NUM> by the second armature-supported induction coil array <NUM> may be independently controlled from the heating of the first metallic susceptor <NUM> by the first armature-supported induction coil array <NUM>.

, The first induction generator <NUM> can be electrically coupled with the second armature-supported induction coil array <NUM>. In a variation, the induction heating system <NUM> may include a second induction generator (not shown) and the second induction generator may be electrically coupled with the second armature-supported induction coil array <NUM>.

Referring to <FIG>, the induction heating system <NUM> includes a mold support <NUM> supporting the second mold <NUM>. By providing the mold support <NUM>, the second mold <NUM> may have a small overall size. In a variation, the mold support <NUM> may instead support the first mold <NUM>. In another variation, there may be two mold supports, each mold support supporting one of the first mold <NUM> and second mold <NUM>. In yet another variation, there may be no mold supports, and the second mold <NUM> may be substantially similar to the first mold <NUM>.

Referring to <FIG>, the mold support <NUM> includes a plurality of second slots <NUM>. Referring to <FIG>, the second armature-supported induction coil array <NUM> includes a plurality of second fingers <NUM> positionable within the plurality of second slots <NUM>. Accordingly, by providing the plurality of second slots <NUM> in the mold support <NUM> and the plurality of second fingers <NUM> in the second armature-supported induction coil array <NUM>, the induction heating system <NUM> facilitates removal of the second armature-supported induction coil array <NUM> from the mold support <NUM>. In an aspect, the armature-supported induction coil array <NUM> may include a second endcap <NUM> supporting the plurality of second fingers <NUM>.

By removing the second armature-supported induction coil array <NUM> from the mold support <NUM>, the induction heating system <NUM> facilitates air cooling, e.g. passive air cooling, of the thermoplastic article A and the second armature-supported induction coil array <NUM>. Also, the separated finger structure of the second armature-supported induction coil array <NUM> facilitates faster air cooling by permitting convection of area between each of the plurality of second fingers <NUM>.

Additionally, by providing a removable second armature-supported induction coil array <NUM>, the second armature-supported induction coil array <NUM> can be removed and placed into another tool as needed. This modularity reduced the total cost and complexity of the molding tool. Furthermore, by making the second armature-supported induction coil array <NUM> as a plurality second fingers <NUM>, the second armature-supported induction coil array <NUM> can be shaped to best approximate the contour of the uppermost surface <NUM> of the second mold <NUM> for more efficient inductive coupling.

As explained previously, variations include that the mold support <NUM> instead supports the first mold <NUM>, that there may be two mold supports <NUM>, each mold support <NUM> supporting one of the first mold <NUM> and second mold <NUM>, and that may be no mold supports <NUM>, and the second mold <NUM> may be substantially similar to the first mold <NUM>. In the case of the presence of mold supports <NUM> for the first mold <NUM> and/or the second mold <NUM>, the present description includes that possibility that one of the mold supports <NUM> may include the plurality of first slots <NUM> and such that the first armature-supported induction coil array <NUM> includes a plurality of first fingers <NUM> positionable within the plurality of first slots <NUM>, and that the other of the mold supports <NUM> may include the plurality of second slots <NUM> and such that the second armature-supported induction coil array <NUM> includes a plurality of second fingers <NUM> positionable within the plurality of second slots <NUM>.

Referring to <FIG>, the induction heating system <NUM> includes a second magnetic hysteresis detector <NUM> associated with the second armature-supported induction coil array <NUM>. By providing the second magnetic hysteresis detector <NUM>, a magnetic hysteresis from the inductively heated second metallic susceptor <NUM> can be detected. By detecting a magnetic hysteresis from the inductively heated second metallic susceptor <NUM>, a frequency generated by the first induction generator <NUM> can be adjusted to minimize heating of the second armature-supported induction coil array <NUM>. The adjustment of the frequency generated by the first induction generator <NUM> may frequency match the magnetic hysteresis from the inductively heated second metallic susceptor <NUM>. Heating the second metallic susceptor <NUM> by this frequency matching induction generation can minimize heat generated in the second armature-supported induction coil array <NUM>. The adjustment of the frequency generated by the first induction generator <NUM> may be performed, for example, by using a controller (not shown), which may be computer hardware device. The controller may be communicatively coupled to the second magnetic hysteresis detector <NUM> and the first induction generator <NUM>. By minimizing heating of the second armature-supported induction coil array <NUM>, water cooling of the second armature-supported induction coil array <NUM> can be avoided.

The first induction generator <NUM> can be electrically coupled with the second armature-supported induction coil array <NUM>. In a variation, the induction heating system <NUM> may include a second induction generator (not shown) and the second induction generator may be electrically coupled with the second armature-supported induction coil array <NUM>. Thus, by detecting a magnetic hysteresis from the inductively heated second metallic susceptor <NUM>, a frequency generated by the second induction generator can be adjusted to minimize heating of the second armature-supported induction coil array <NUM>.

The above-described feature of the second magnetic hysteresis detector <NUM> may be employed in combination with any one or more of the features of the induction heating system <NUM> described above.

Referring to <FIG>, the induction heating system <NUM> includes a press platen <NUM> for pressing together the first mold <NUM> and the mold support <NUM> supporting the second mold <NUM> (not shown in <FIG>). The illustrated press platen <NUM> is merely a representative illustration. It will be understood that any press platen <NUM> may be employed for pressing together the first mold <NUM> and the second mold <NUM>, whether or not one or both of the first mold <NUM> and the second mold <NUM> are supported by mold supports <NUM>. By providing the press platen <NUM>, the induction heating system <NUM> facilitates consolidation of the thermoplastic article A during a process of molding the thermoplastic article A.

The above-described feature of the press platen <NUM> may be employed in combination with any one or more of the features of the induction heating system <NUM> described above.

Referring to <FIG>, in an example, at least a portion of the first mold <NUM> forms the first metallic susceptor <NUM>. The lowermost surface <NUM> of the first mold <NUM> preferably forms the first metallic susceptor <NUM>. By providing the first metallic susceptor <NUM> as at least a portion of the first mold <NUM>, a process of assembling the induction heating system <NUM> for molding the thermoplastic article A may be simplified.

Referring to <FIG>, in an example, the first metallic susceptor <NUM> is positioned adjacent to the first mold <NUM>. By providing the first metallic susceptor <NUM> as being positioned adjacent to the first mold <NUM>, a process of making the first mold <NUM> and first metallic susceptor <NUM> may be simplified. Additionally, the first mold <NUM> may be made entirely of non-conductive materials.

Referring to <FIG>, in an example, at least a portion of the second mold <NUM> forms the second metallic susceptor <NUM> and the uppermost surface <NUM> of the second mold <NUM> preferably forms the second metallic susceptor <NUM>. By preferably providing the second metallic susceptor <NUM> as at least a portion of the second mold <NUM>, a process of assembling the induction heating system <NUM> for molding the thermoplastic article A may be simplified.

Referring to <FIG>, in an example, the second metallic susceptor <NUM> is positioned adjacent to the second mold <NUM>. By providing the second metallic susceptor <NUM> as being positioned adjacent to the second mold <NUM>, a process of making the second mold <NUM> and second metallic susceptor <NUM> may be simplified. Additionally, the second mold <NUM> may be made entirely of non-conductive materials.

A variation of the induction heating system <NUM> includes that at least a portion of the first mold <NUM> forms the first metallic susceptor <NUM> while at least a portion of the second mold <NUM> forms the second metallic susceptor <NUM>. Another variation of the induction heating system <NUM> includes that at least a portion of the first mold <NUM> forms the first metallic susceptor <NUM> while the second metallic susceptor <NUM> is positioned adjacent to the second mold <NUM>. Yet another variation of the induction heating system <NUM> includes that the first metallic susceptor <NUM> is positioned adjacent to the first mold <NUM> while at least a portion of the second mold <NUM> forms the second metallic susceptor <NUM>. Yet another variation of the induction heating system <NUM> includes that the first metallic susceptor <NUM> is positioned adjacent to the first mold <NUM> while the second metallic susceptor <NUM> is positioned adjacent to the second mold <NUM>.

The above-described features of the first metallic susceptor <NUM> and the second metal susceptor <NUM>, according to any of the variations, may be employed in combination with any one or more of the features of the induction heating system <NUM> described above.

In an aspect, the first metallic susceptor <NUM> is formed from a smart susceptor material. In another aspect, the second metallic susceptor <NUM> is formed from a smart susceptor material. In yet another aspect, both the first metallic susceptor <NUM> and the second metallic susceptor <NUM> are formed from smart susceptor materials.

A smart susceptor material is a material having a predetermined Curie point causing a reduction of magnetic properties of the material as the material nears the Curie point. Thus, the smart susceptor material facilitates a limiting temperature to which the material may be inductively heated. By way of example, the smart susceptor material of the first metallic susceptor <NUM> and the second metallic susceptor <NUM> includes nickel-iron alloys.

By providing the first metallic susceptor <NUM> and/or the second metallic susceptor <NUM> as a smart susceptor material, the temperature to which the first metallic susceptor <NUM> and/or the second metallic susceptor <NUM> may be heated is limited, thereby preventing overheating of the thermoplastic article A.

The above-described smart susceptor materials of the first metallic susceptor <NUM> and the second metal susceptor <NUM>, according to any of the variations, may be employed in combination with any one or more of the features of the induction heating system <NUM> described above.

<FIG> is a flow diagram representing a method <NUM> for molding a thermoplastic article A, such as a thermoplastic composite article. The method <NUM> includes positioning <NUM> a thermoplastic article A between a first mold <NUM> including a first metallic susceptor <NUM> and a second mold <NUM> including a second metallic susceptor <NUM>, inductively heating <NUM> the first metallic susceptor <NUM> using a first induction frequency, detecting a magnetic hysteresis <NUM> from the inductively heated first metallic susceptor <NUM>, adjusting the first induction frequency <NUM> based on the magnetic hysteresis from the inductively heated first metallic susceptor <NUM>, and pressing together <NUM> the first mold <NUM> and the second mold <NUM>. <FIG> further includes optional steps shown in dashed lines.

By this the method <NUM>, the steps of positioning, inductively heating, and pressing of the thermoplastic article A between the first mold <NUM> and the second mold <NUM> effectuate the process of molding of the thermoplastic article A while the steps of detecting the magnetic hysteresis and adjusting the first induction frequency avoid the need for water cooling of the first mold <NUM>.

The above-described method <NUM> may be employed in combination with any of the features of the induction heating system <NUM> as described above.

Referring to <FIG>, the method <NUM> includes, when the first metallic susceptor <NUM> reaches a predetermined temperature, stopping the inductive heating <NUM> of the first metallic susceptor <NUM>. By way of example, the stopping of the inductive heating <NUM> of the first metallic susceptor <NUM> may be facilitated by forming the first metallic susceptor <NUM> from a smart susceptor material. By stopping the inductive heating <NUM> of the first metallic susceptor <NUM>, the temperature to which the first metallic susceptor <NUM> may be heated is limited, thereby preventing overheating of the thermoplastic article A. In an example, the predetermined temperature at which the inductive heating of the first metallic susceptor <NUM> is stopped is above a curing temperature of the thermoplastic article A.

The step of stopping the inductive heating <NUM> of the first metallic susceptor <NUM> may be employed in combination with any of the features of the induction heating system <NUM> as described above.

Referring to <FIG>, the method <NUM> includes, air cooling <NUM> the first mold <NUM>. By way of example, air cooling <NUM> of the first mold <NUM> may be facilitated by providing a first armature-supported induction coil array <NUM>, which is removable from the first mold <NUM>. By removing the first armature-supported induction coil array <NUM> from the first mold <NUM>, the first armature-supported induction coil array <NUM> can be easily air cooled in the ambient air surrounding the removed first armature-supported induction coil array <NUM>. In addition to facilitating the air cooling of the first mold <NUM>, air cooling of the thermoplastic article A and the first armature-supported induction coil array <NUM> may be facilitated.

The step of air cooling <NUM> the first mold <NUM> may be employed in combination with the step of stopping the inductive heating <NUM> of the first metallic susceptor <NUM> and may be combined with any of the features of the induction heating system <NUM> as described above.

Referring to <FIG>, the method <NUM> includes, inductively heating <NUM> the second metallic susceptor <NUM> using a second induction frequency, detecting a magnetic hysteresis <NUM> from the inductively heated second metallic susceptor <NUM>, and adjusting the second induction frequency <NUM> based on the magnetic hysteresis from the inductively heated second metallic susceptor <NUM>. By providing the steps, the method <NUM> facilitates heating the thermoplastic article A from both sides of the thermoplastic article A and avoids the need for water cooling of the second mold <NUM>.

These steps of inductively heating <NUM> the second metallic susceptor <NUM> using a second induction frequency, detecting a magnetic hysteresis <NUM> from the inductively heated second metallic susceptor <NUM>, and adjusting the second induction frequency <NUM> based on the magnetic hysteresis from the inductively heated second metallic susceptor <NUM> may be employed in combination with the step of stopping the inductive heating <NUM> of the first metallic susceptor <NUM> and/or with air cooling <NUM> the first mold <NUM> and may further be combined with any of the features of the induction heating system <NUM> as described above.

Referring to <FIG>, the method <NUM> includes, when the second metallic susceptor <NUM> reaches a predetermined temperature, stopping the inductive heating <NUM> of the second metallic susceptor <NUM>. By way of example, the stopping of the inductive heating <NUM> of the second metallic susceptor <NUM> may be facilitated by forming the second metallic susceptor <NUM> from a smart susceptor material. By stopping the inductive heating <NUM> of the second metallic susceptor <NUM>, the temperature to which the second metallic susceptor <NUM> may be heated is limited, thereby preventing overheating of the thermoplastic article A. In an example, the predetermined temperature at which the inductive heating of the first metallic susceptor <NUM> is stopped is above a curing temperature of the thermoplastic article A.

The step of stopping the inductive heating <NUM> of the second metallic susceptor <NUM> may be employed in combination with any of the previously-describes steps of the method <NUM> and with any of the features of the induction heating system <NUM> as described above.

Referring to <FIG>, the method <NUM> includes, air cooling <NUM> the second mold <NUM>. By way of example, air cooling <NUM> of the second mold <NUM> may be facilitated by providing a second armature-supported induction coil array <NUM>, which is removable from the second mold <NUM>. By removing the second armature-supported induction coil array <NUM> from the second mold <NUM>, the second armature-supported induction coil array <NUM> can be easily air cooled in the ambient air surrounding the removed second armature-supported induction coil array <NUM>. In addition to facilitating the air cooling of the second mold <NUM>, air cooling of the thermoplastic article A and the second armature-supported induction coil array <NUM> may be facilitated.

The step of air cooling <NUM> the second mold <NUM> may be employed in combination with any of the previously-describes steps of the method <NUM> and with any of the features of the induction heating system <NUM> as described above.

<FIG> is a flow diagram representing a method <NUM> for processing a thermoplastic article <NUM>, such as a thermoplastic composite article. The method includes generating <NUM> heat by frequency matching induction generation using a modular induction coil and air cooling <NUM> the modular induction coil. <FIG> further includes optional steps shown in dashed lines.

Referring to <FIG>, the step of generating heat <NUM> by frequency matching induction generation using a modular induction coil includes inductively heating <NUM> a metallic susceptor to heat the thermoplastic article using a first induction frequency, detecting <NUM> a magnetic hysteresis from the inductively heated metallic susceptor, and adjusting <NUM> the first induction frequency based on the magnetic hysteresis from the inductively heated metallic susceptor.

Referring to <FIG>, the step of air cooling <NUM> the modular induction coil includes removing <NUM> the modular induction coil from a mold containing the thermoplastic article, and passive air cooling <NUM> the removed modular induction coil in ambient air.

In an aspect, the modular induction coil may take the form of the first armature-supported induction coil array <NUM> or the second armature-supported induction coil array <NUM>. In another aspect, the metallic susceptor may take the form of the first metallic susceptor <NUM> or the second metallic susceptor <NUM>. In another aspect, detecting a magnetic hysteresis from the inductively heated metallic susceptor <NUM> may be performed by the first magnetic hysteresis detector <NUM> or the second magnetic hysteresis detector <NUM>. In yet another aspect, adjusting the first induction frequency based on the magnetic hysteresis from the inductively heated metallic susceptor <NUM> may be performed using a controller (not shown), which may be computer hardware device.

Examples of the present disclosure may be described in the context of an aircraft manufacturing and service method <NUM>, as shown in <FIG>, and an aircraft <NUM>, as shown in <FIG>. During pre-production, the aircraft manufacturing and service method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component/subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, the aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may also include modification, reconfiguration, refurbishment and the like.

For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

The disclosed induction heating system and method for molding a thermoplastic article of the present disclosure may be employed during any one or more of the stages of the aircraft manufacturing and service method <NUM>, including at least component/subassembly manufacturing <NUM>, system integration <NUM>, and routine maintenance and service <NUM>.

As shown in <FIG>, the aircraft <NUM> produced by example method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. Examples of the plurality of systems <NUM> may include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. Any number of other systems may be included. The disclosed induction heating system and method for molding a thermoplastic article of the present disclosure may be employed for any of the systems of the aircraft <NUM>, including at least airframe <NUM> and interior <NUM>.

Claim 1:
A method for processing a thermoplastic article, the method comprising: generating heat by frequency matching induction generation using a modular induction coil; and air cooling the modular induction coil; wherein the step of air cooling the modular induction coil includes removing the modular induction coil from a mold containing the thermoplastic article.