{"schema_version":1,"experiment_id":"eoa_inverse_innovation_exp09_archetype_breadth150_20260804","research_id":"eoa_inverse_innovation_exp09_light_prior_art_20260804","cell_id":"feedback_loop_redirection__chemistry_materials","search_lanes":{"direct_problem_and_intervention":{"queries":["thick thermoset composite cure exotherm internal temperature surface thermocouple control dielectric sensor","adaptive closed loop composite cure control degree of cure dielectric sensor heater"],"source_ids":["SRC1","SRC2","SRC3","SRC4"],"no_result_note":null},"synonyms_and_historical_terms":{"queries":["autoclave composite cure adaptive control degree of cure exothermic reaction thick laminate","smart cure cycle control resin exotherm internal temperature dielectric analysis","qualitative process automation autoclave cure dielectric temporal gradient"],"source_ids":["SRC2","SRC3"],"no_result_note":null},"products_practices_and_standards":{"queries":["commercial dielectric cure monitoring closed loop control composites","ASTM dielectric cure monitoring thermosetting resins composite processing standard","automated exotherm control thick composite processing"],"source_ids":["SRC2","SRC3","SRC4"],"no_result_note":"No retained commercial product page or control-specific standard was closer than the retained patent and experimentally demonstrated active-control practices."},"component_combination":{"queries":["embedded thermocouple dielectric cure sensor adaptive heating control thermoset composite","model predictive control thick composite cure temperature degree of cure thermal gradient","surface core temperature dielectric cure monitoring active control thick composite laminate"],"source_ids":["SRC2","SRC3","SRC4"],"no_result_note":null}},"sources":[{"source_id":"SRC1","title":"Evaluation of Temperature Gradients During Cure of a Thick Carbon Fiber/Epoxy Composite","publisher":"NASA Glenn Research Center","url":"https://ntrs.nasa.gov/api/citations/20200000350/downloads/20200000350.pdf","source_type":"PRIMARY_RESEARCH","claims_supported":["Thick thermoset composites generate internal heat during cure, and slow heat diffusion produces center-to-surface temperature differences.","Embedded thermocouples showed the thicker laminate's central regions reaching the cure temperature ahead of the tool-side region.","NASA identifies premature central vitrification, residual stress, uncontrolled temperature increase, and material degradation as possible consequences of internal heat buildup."]},{"source_id":"SRC2","title":"US5032525A — Qualitative process automation for autoclave cure of composite parts","publisher":"United States Patent and Trademark Office record via Google Patents","url":"https://patents.google.com/patent/US5032525A/en","source_type":"OTHER","claims_supported":["The 1988 filing discloses automated closed-loop autoclave cure control using arrays of temperature sensors, dielectric temporal-gradient measurements, and a PID controller.","It combines temperature-gradient and dielectric information to determine material state and dynamically manipulate autoclave temperature, pressure, and vacuum.","It expressly describes increasing or decreasing heat flow subject to damage-prevention limits and minimizing laminate temperature gradients, including removal of heat from hotter regions."]},{"source_id":"SRC3","title":"Online optimisation and active control of the cure process of thick composite laminates","publisher":"Elsevier, author manuscript hosted by Cranfield University","url":"https://dspace.lib.cranfield.ac.uk/bitstream/1826/19003/1/Cure_process_of_thick_composite_laminates-2023.pdf","source_type":"PRIMARY_RESEARCH","claims_supported":["The study demonstrates active control of thick-composite curing using real-time monitoring and a cure model to periodically change an oven PID setpoint.","The experimental arrangement includes an outer-surface control thermocouple and a cable-core thermocouple, while candidate dwells are accepted or rejected under temperature-overshoot constraints.","The reported thick carbon-fiber/epoxy cable trial reduced cure duration by about 70% while keeping maximum overshoot below 10 degrees Celsius."]},{"source_id":"SRC4","title":"On Line Optimisation and Active Control of the Cure Process of Thick Composite Laminates","publisher":"The University of Delaware / 24th International Conference on Composite Materials","url":"https://zenodo.org/records/18596893","source_type":"PRIMARY_RESEARCH","claims_supported":["The 2025 conference paper reports an active-control tool combining simulation with cure monitoring for thick composite laminates.","The reported demonstration reduced cure time by about 65% while maintaining temperature uniformity and minimizing temperature overshoot.","This provides recent evidence that cure-state monitoring is being incorporated into actively adjusted thick-composite cure schedules."]}],"problem_evidence":{"status":"PARTLY_SUPPORTED","finding":"The physical problem is clearly visible: thick laminates can develop exotherm-driven core-to-surface temperature and conversion differences, premature central vitrification, residual stress, and possible thermal degradation. Active-control research also treats a surface thermocouple/PID recipe as insufficient by itself for constraining internal overshoot. However, the retained sources do not directly isolate the proposal's strongest causal assertion that surface-error-driven heater duty materially amplifies the exotherm relative to an otherwise identical constant-power or heater-disabled condition.","source_ids":["SRC1","SRC2","SRC3"]},"closest_prior_art":[{"name":"US5032525A qualitative process automation for autoclave cure","source_ids":["SRC2"],"overlap":"Substantial overlap: closed-loop composite cure control uses spatial temperature gradients plus dielectric cure-state signals, feeds decisions to a PID controller, adjusts heat flow in real time, minimizes temperature gradients, and imposes damage-prevention limits.","remaining_difference":"The proposal specifies a simpler auditable rule centered on explicit core temperature, core-to-surface difference, and dielectric cure-rate thresholds, with gain reduction or a no-additional-heat hold, independent hard trips, shadow-mode commissioning, and immediate baseline reversion."},{"name":"2023 online optimisation and active control of thick-composite cure","source_ids":["SRC3"],"overlap":"Substantial overlap: a thick thermoset part is monitored at its surface and core, internal overshoot is predicted, candidate dwells are constrained, and the oven PID setpoint is changed during cure to exploit exotherm without exceeding an internal thermal limit.","remaining_difference":"The demonstrated controller is model-based and optimization-oriented; the proposal emphasizes directly measured dielectric cure-rate acceleration and a bounded threshold-triggered gain reduction or hold rather than repeated predictive simulations."},{"name":"2025 cure-monitoring-based active control for thick laminates","source_ids":["SRC4"],"overlap":"Recent work combines cure monitoring and simulation to actively adjust a thick-composite cure while controlling overshoot and thermal uniformity.","remaining_difference":"The retained public record does not establish the proposal's exact conjunctive threshold logic, no-additional-heat state, shadow-first commissioning procedure, or governance and fallback details."}],"prior_art_disposition":"SUBSTANTIAL_COLLISION","contrastive_claim_remaining":"For a thick thermoset cure presently governed by a surface-temperature PID, a non-model-based and auditable conjunctive rule using measured core temperature, core-to-surface temperature difference, and dielectric cure-rate rise can identify controller-reinforced exotherm early enough to recommend bounded gain reduction or a no-additional-heat hold, while producing fewer false interventions and less oscillation than trip-only control and without requiring the predictive or expert-system machinery of the closest prior art.","contrastive_claim_falsifier":"The remaining claim is falsified if synchronized baseline or shadow-replay data show that heater duty does not materially reinforce the divergence; the three-signal rule does not detect hazardous divergence earlier than the baseline trip or cited active-control approaches; its recommendations are unbounded, oscillatory, or associated with false holds and incomplete outer cure; or a closer disclosure is found that already implements the same explicit three-signal threshold, gain-reduction/no-additional-heat rule and fallback arrangement.","gates":{"adequate_source_search":{"status":"PASS","rationale":"The bounded search covered direct wording, historical adaptive/qualitative cure-control terminology, dielectric-monitoring practices and standards, and combinations of embedded temperature, cure-state, gradient, and heater-control components. Four opened sources span NASA research, an early patent disclosure, a peer-reviewed experimental study, and a recent conference demonstration.","source_ids":["SRC1","SRC2","SRC3","SRC4"]},"supported_problem":{"status":"PASS","rationale":"NASA measurements directly show exotherm-driven internal temperature and conversion divergence in thick composites and identify associated stress and degradation risks; the precise controller-amplification contribution remains only partly established, so overall problem evidence is PARTLY_SUPPORTED.","source_ids":["SRC1","SRC3"]},"distinct_testable_claim":{"status":"PASS","rationale":"Although the intervention substantially collides with prior art, the narrower contrast between explicit three-signal threshold/hold logic and model-based, expert-system, or trip-only control is operational and falsifiable using synchronized traces and shadow replay.","source_ids":["SRC2","SRC3","SRC4"]},"bounded_next_test":{"status":"PASS","rationale":"A single instrumented sacrificial-coupon cure with the candidate controller in non-actuating shadow mode can test signal ordering, controller contribution, detection lead time, command bounds, and oscillation without changing heater control. Embedded thermocouples and active-control comparisons are established experimental methods in the retained research.","source_ids":["SRC1","SRC3"]},"no_obvious_safety_or_authority_stop":{"status":"PASS","rationale":"The first test is non-actuating, retains the validated controller and independent trips, uses a sacrificial laboratory coupon, preserves operator stop authority, and specifies sensor-disagreement and temperature-limit halts. The sources confirm that internal overheating is a real hazard but reveal no obvious prohibition on this bounded monitoring-only trial.","source_ids":["SRC1","SRC3"]}},"screen_survival":false,"world_novelty_boundary":"This bounded public-web screen found substantial prior-art collision but cannot establish world novelty, patentability, freedom to operate, market size, expert acceptance, production qualification, or realized value."}