Backing plate system for aircraft manufacturing

Abstract

To provide a method and an apparatus related to a process of hardening a composite part.SOLUTION: A method includes applying a preform 130 to a mandrel 110, covering the preform with a caul plate 150, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel, and hardening the preform into a composite part while the caul plate is held against the preform. An apparatus includes a mandrel, and a caul plate which defines a surface of a preform, and the caul plate may include a rigid material 111 and seal materials 156 and 158 disposed between the mandrel and the caul plate. In an additional aspect, the apparatus can include a sealed chamber 157 with a mandrel, a caul plate, and a circumferential seal material between the mandrel and the caul plate.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to the field of manufacturing, and more particularly, to the manufacture of composite parts for aircraft sections.

Background Art

[0002] Prior to autoclave processing, composite components are encapsulated in a vacuum bag during the curing cycle. For example, vacuum bagging processes for large and / or complex composite sections such as sections of fuselages or wings remain labor-intensive and the vacuum bags covering large preforms may experience unwanted elongation, tearing, breakage, etc. (such as during use, e.g., before or during autoclave processing). Seal failures, tears, or breakages can result in compromising the performance of the vacuum bag and may require rework or scrapping of the resulting parts. To address concerns related to seal failures, tears, and / or breakages, often "double bagging" and various pressure checks are required, which increases cycle time, material costs, and associated labor. All of these factors result in an undesirable increase in the overall cost of the composite component.

[0003] The abstract of WO2008 / 007043 states that "a method and apparatus for manufacturing a panel, the panel comprising a composite outer panel and at least one composite reinforcement, the method comprising disposing first and second mandrels on the front and back sides of the reinforcement, disposing first and second compression tools on the front and back sides of the outer panel, and compressing the outer panel between the first and second compression tools by moving one or both of the compression tools, the movement of the compression tools being capable of moving the first and second mandrels along an inclined path towards the reinforcement to compress the reinforcement between the mandrels."

[0004] The abstract of EP3287247 states: "The objective is to provide an apparatus and method for manufacturing fiber-reinforced plastic molded articles such that two components can be precisely positioned relative to each other once the components are integrally molded by the VaRTM method. The apparatus for manufacturing fiber-reinforced plastic molded articles comprises: a panel mold to which a panel, which is a cured fiber-reinforced composite member, is attached; a stringer mold configured to house a stringer, which is a material bonded to the panel; and a folded plate configured to house the stringer mold, the folded plate including a positioning portion for positioning with respect to a positioning portion provided on the panel."

[0005] The abstract of DE 10 2017 105343 states: “The method is specified to integrate a fiber composite structure with at least one thermoplastic and / or thermoelastic polymer, and comprises arranging the fiber composite structure between a plate-shaped base and a plate-shaped cover, wherein the cover is sealed to the base by a sealing element so as to be movable with respect to the base, and generating a negative pressure in the space between the base and the cover such that ambient pressure compresses the cover with respect to the base, compressing the fiber composite structure between the cover and the base, and heating of the fiber composite structure by electromagnetic radiation preferably reaches at least to the melting temperature range of the at least one thermoplastic and / or thermoelastic polymer.”

[0006] The method further includes the steps of: causing the cover to bend so that the surface of the fiber composite structure partially contacts the cover, by optionally lowering the cover further; and further bending and / or lowering the cover until the cover contacts the entire surface of the fiber composite structure and the fiber composite structure is positioned between the cover and the base being compressed.

[0007] Therefore, it would be desirable to obtain a method and apparatus that takes into account at least some of the above-mentioned problems, as well as other potential problems. [Overview of the project]

[0008] Embodiments described herein provide a backing plate that forms a vacuum seal together with a mandrel to apply integration pressure while the preform solidifies into a composite part. Typically, a vacuum bag to be in charge role to By using the backing plate itself, the vacuum bag itself No longer needed Therefore, the methods and apparatus described herein have the advantage of reducing the amount of work and material associated with the solidification process. The method involves applying a preform to a mandrel, covering the preform with a backing plate, sealing the backing plate to the mandrel, pressing the backing plate toward the preform and mandrel, and while the backing plate is held toward the preform, the preform solidified Composite parts to This includes doing.

[0009] In one embodiment, an apparatus for solidifying a fiber-reinforced material preform includes a mandrel, a backing plate defining the surface of the preform, the backing plate may include a rigid material and a sealant disposed between the mandrel and the backing plate. In an additional embodiment, an apparatus for compacting a fiber-reinforced material preform may include a chamber sealed by a mandrel, a backing plate, and a peripheral sealant between the mandrel and the backing plate.

[0010] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) may also be described later. The features, functions, and advantages described above may be realized individually in various embodiments or in combination in yet another embodiment, the further details of which can be understood by referring to the following description and drawings.

[0011] The term "mandrel" should be understood as it is used in this application to mean the mandrel where a component (e.g., an aircraft component) is placed. Therefore, the term "mandrel" means the surface or structure on which the component and / or material and / or layers of material and / or combinations thereof are placed.

[0012] The term “backing plate” refers to a tool that at least partially matches the shape of the workpiece being cured and used for curing. In some embodiments of this disclosure, the term “backing plate” encompasses tools that can be used in such applications, with respect to known backing plates used in conjunction with the vacuum bags described above, although differences are mentioned.

[0013] Some embodiments of this disclosure will now be described, for illustrative purposes only, with reference to the accompanying drawings. In all drawings, the same reference numerals represent the same or similar elements. [Brief explanation of the drawing]

[0014] [Figure 1] An aircraft according to an exemplary embodiment is shown. [Figure 2] This is a block diagram of an assembly system for directly vacuum-sealing a backing plate to a mandrel, according to an exemplary embodiment. [Figure 2A] This is a block diagram of an alternative assembly system for directly vacuum-sealing a backing plate to a mandrel, according to an exemplary embodiment. [Figure 2B] This is a cross-sectional view of a bladder reinforcing a stringer, according to an exemplary embodiment. [Figure 2C] This is a cross-sectional view of a bladder reinforcing a stringer, according to an exemplary embodiment. [Figure 2D] An exemplary embodiment shows a backing plate for a wing panel. [Figure 2E] An exemplary embodiment shows a backing plate for a wing panel. [Figure 2F] An exemplary embodiment of the flow cycle for a backing plate is shown. [Figure 3] A flow diagram of a process for operating an assembly system to perform work on a structure, according to an exemplary embodiment. [Figure 4] A side view of a mandrel including a platen operating as a vacuum bag, according to an exemplary embodiment. [Figure 5] A cross-sectional view of a mandrel including a platen operating as a vacuum bag, according to an exemplary embodiment. [Figure 6] A top view of a platen including a peripheral chamber subdivided into quadrants, according to an exemplary embodiment. [Figure 7] A side view of a banjo bolt that seals a platen to a bladder and, on the other hand, provides a passage for air to enter the bladder, according to an exemplary embodiment. [Figure 8] A top view of a banjo bolt that seals a platen to a bladder and, on the other hand, provides a passage for air to enter the bladder, according to an exemplary embodiment. [Figure 9] A perspective view of the insertion of a mandrel into an autoclave, according to an exemplary embodiment. [Figure 10] A perspective view of the insertion of a mandrel into an autoclave, according to an exemplary embodiment. [Figure 11] A flow diagram of a method of manufacturing and maintaining an aircraft, according to an exemplary embodiment. [Figure 12] A block diagram of an aircraft, according to an exemplary embodiment.

MODE FOR CARRYING OUT THE INVENTION

[0015] The figures and the following description provide specific exemplary embodiments of the present disclosure. Accordingly, those skilled in the art will recognize that various configurations within the scope of the present disclosure that embody the principles of the present disclosure can be devised (even if not explicitly described or illustrated herein). Further, any examples described herein are for the purpose of aiding in the understanding of the principles of the present disclosure and are not to be construed as being limited to the specifically recited examples and conditions. As a result, the present disclosure is not limited to the specific embodiments or examples described hereinafter, but is limited by the claims.

[0016] The backing plates and mandrels described herein are utilized for manufacturing composite parts. Composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are first laid on multiple layers of carbon fiber reinforced materials collectively referred to as preforms. The individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to enhance strength along different dimensional directions of the resulting composite part. The preform contains a viscous resin that solidifies to form the composite part (e.g., for use in an aircraft). Carbon fibers impregnated with an uncured thermosetting resin or thermoplastic resin are referred to as "prepregs". Other types of carbon fibers include "dry fibers" that are not impregnated with a thermosetting resin but may contain a tackifier or binder. Resin is injected into the dry fibers prior to solidification. With respect to thermosetting resins, solidification is a unidirectional process called curing, while with respect to thermoplastic resins, the resin becomes viscous when reheated and can be consolidated and solidified into the desired shape. As used herein, the general term for the process of transitioning the preform to its final solidified shape (i.e., the transition from the preform to the composite part) is referred to as "solidification", and this term encompasses both the curing of thermosetting preforms and the forming / solidifying of thermoplastic preforms into their final desired shapes.

[0017] Figure 1 shows an aircraft on which an exemplary embodiment may be implemented. Aircraft 10 is an embodiment of an aircraft that may be formed with the backing plates 150 and 150-1 in Figures 2 and 2A, respectively. Aircraft 10 is an embodiment of an aircraft that is formed in a half-barrel shape as a half-barrel section 24 of the fuselage 12.

[0018] In this exemplary embodiment, the aircraft 10 has wings 15 and wings 16 attached to a fuselage 38. The aircraft 10 includes an engine 14 attached to the wing 15 and an engine 14 attached to the wing 16.

[0019] The aircraft 28 has a tail section 18. Horizontal stabilizers 20, 21, and 22 are attached to the tail section 18 of the aircraft 38.

[0020] The fuselage 12 is manufactured from half-barrel sections 24, with the upper half-barrel section 26 being joined to the lower half-barrel section 28 to form full-barrel sections 29 (e.g., 29-1, 29-2, 29-3, 29-4, 29-5). The full-barrel sections are joined in a continuous manner to form the fuselage 12.

[0021] The wings 15 and 16 are formed from a wing panel 30 comprising an upper wing panel 32 and a lower wing panel 34 joined together. The section cut 46 is a cut portion of the wing panel 32, corresponding to preforms 189, 189-1 (Figures 2D and 2E) before solidification. The section cut 46 is oriented in the chord direction approximately perpendicular to the stringer 182.

[0022] Section cuts 44 are cut composite panels 194 that correspond to preforms 130, 130-1 (Figures 2B and 2C) before solidification. Section cuts 44 are oriented longitudinally along the stringer and through contour 112-1.

[0023] Figure 2 is a block diagram of an assembly system 100 in which, in an exemplary embodiment, a backing plate 150 is directly vacuum-sealed to a mandrel 110 (e.g., a layup mandrel). The backing plate 150 is made from a rigid material 111 such as metal or composite material. The backing plate 150 maintains rigidity relative to the preform 130 at the solidification temperature and compressive force. In this embodiment, the backing plate 150 defines mold lines 137, such as an outer mold line (OML) 131, relative to the preform 130, and the mandrel 110 forms an inner mold line (IML) 133 relative to the preform 130. In some embodiments, a release film 113 is placed between the mandrel 110 and the preform 130. The release film 113 is placed on the mandrel 110 to facilitate demolding after solidification is performed in an autoclave 180. In some embodiments, the breather treatment 115 facilitates the solidification process by allowing trapped gases to escape the preform 130 during solidification and by facilitating the dispersion of exhausted gases throughout the preform.

[0024] In this embodiment, the mandrel 110 includes a rigid body 111-1 that forms a half-barrel shape, which appears rectangular from the viewpoint of this cross-section (i.e., half of the half-barrel is visible). In this embodiment, the mandrel 110 defines the IML 133 with respect to the preform 130. The mandrel 110 includes a layup surface 112 that defines the contour 112-1 with respect to the preform 130 which includes multiple layers 132 of fibers 134 and resin 136. The mandrel 110 further includes an indexing feature 114 that engages with an indexing feature 142 of a strong back 140 that transports the backing plate 150 to the mandrel 110. This makes it possible to accurately position the backing plate 150 on the mandrel 110 each time the backing plate 150 is placed on the mandrel 110.

[0025] The mandrel 110 further includes a vacuum system 120. The vacuum system 120 applies vacuum to a vacuum hole 116 via a vacuum line 118, either controllably or otherwise, and the vacuum line functions as a kind of manifold distributing vacuum to selected locations on the mandrel 110. The vacuum hole 116 is located on the mandrel 110 and applies vacuum beyond the layup surface 112. That is, the vacuum hole 116 applies vacuum directly to a sealed chamber 157, including its position 154 on the backing plate 150. The vacuum system 120 is operated by the backing plate 150, the sealant 156 and the mandrel 110. Boundaries are defined. Air is exhausted from the sealed chamber 157. The exhaust of the sealed chamber 157, in conjunction with the atmospheric pressure outside the backing plate 150, sealant 156, and mandrel 110 housing, presses the backing plate 150 toward the mandrel 110, resulting in the compaction of the preform 130. (This process is repeated.) It will be dead By reducing the pressure below the backing plate 150 to below atmospheric pressure inside the autoclave, the backing plate 150 is pressed down by the atmospheric pressure above the mandrel 110. In a further embodiment, a vacuum is introduced into the sealed chamber 157 by the mandrel 110 and / or by the backing plate 150, but not by the sealants 156 and 158, or in addition to these.

[0026] The sealants 156 and 158 are positioned between the mandrel 110 and the backing plate 150 along the periphery of the intersection 159 between the mandrel 110 and the backing plate 150. In this embodiment, the sealants 156 and 158 include a first peripheral sealant 156 and a second peripheral sealant 158 ​​that is positioned entirely within the first peripheral sealant 156. However, in further embodiments, triple or more sealants may be implemented, and each sealant is pressure-tested to ensure that it forms a sealed chamber 157. The sealants 156 and 158 seal the chamber 153 between them. Multiple sealants provide a substitute for the redundant sealants 156 and 158 in case one of the sealants fails. The remaining sealant 156 or 158 helps maintain the vacuum within the sealed chamber 157 and prevents the preform from being exposed to atmospheric pressure within the sealed chamber 157 during processing. The peripheral sealants 156 and 158 extend along the entire periphery of the backing plate 150, but for clarity they are shown in separate cross-sectional positions in Figure 2. These components allow the backing plate 150 to be peripherally sealed to the mandrel 110. The sealants 156 and 158 can be implemented as disposable or reusable components. Hereafter, boxes referred to as sealant 156 both represent the first sealant 156, and boxes referred to as sealant 158 ​​both represent a second sealant 158, distinct from the first sealant 156. In some embodiments, a third sealant 155 may be included, although it is not shown in Figure 2. Several intermediate materials and layers between the backing plate 150 and the mandrel 110, such as breather treatment and release film, are not shown in Figure 2 for clarity.

[0027] Figure 2 further depicts one or more bladders 160 positioned within the stringer preform 164 to provide expansion pressure to resist collapse during solidification while the backing plate 150 presses against the preform 130. The interior 160-8 of the bladder 160 is open to atmospheric pressure 178, which is the internal or external pressure of the autoclave 180. When the bladder 160 is open to atmospheric pressure 178, the atmospheric pressure expands the bladder 160 as the sealed chamber 157 is evacuated. That is, the bladder 160 acts as an internal tool to maintain structural support for the stringer preform 164 during solidification. Specifically, the bladder 160 resists the collapse forces applied to the stringer preform 164 during processing, allowing the stringer preform 164 to maintain its shape. The bladder 160 includes expansion ports 162 for pressurizing and forming one or more portions of the stringer preform 164. The bladder 160 is positioned between the backing plate 150 and the mandrel 110, and the backing plate 150 includes an opening for an expansion port 162 for the bladder 160. The expansion port 162 is aligned with the opening 152 in the backing plate 150. The expansion port 162 is attached to the backing plate 150 through the opening. A banjo bolt 170 seals the backing plate 150 to the bladder 160 and provides a passage for air to enter the bladder 160 through the backing plate 150. A sealant 152-1 prevents air from leaking / escaping through the opening 152.

[0028] Furthermore, Figure 2 is a cross-sectional view taken along the longitudinal length of the trough 139 of the mandrel 110. The mandrel 110 includes a trough 139 that encloses the bladder 160 and holds the stringer preform 164, which is located beneath the preform 130 and the mandrel 110. The cross-section 179 between the troughs 139 shown in Figure 2B has the same cross-sectional components from the strongback 140 to the mandrel 110, as shown in Figure 2, with the exception of the trough 139 and its contents, which include the stringer preform 164 and the enclosed bladder 160. This cross-section is located between the troughs 139 and is the embodiment depicted in Figure 2B.

[0029] An autoclave 180 (only a portion thereof is shown) receives the mandrel 110 and applies heat and pressure to solidify the preform 130 into a composite part 194. After solidification is complete, the backing plate 150 is removed. Alignment features and other components may be added to the composite part 194 and / or its manufacturing excess. The composite part 194 is demolded from the mandrel 110, and the mandrel 110 and backing plate 150 are reused to manufacture other composite parts 194. In further embodiments, the mandrel 110 and backing plate 150 are advanced in pulses or continuously through various stations described herein.

[0030] Figure 2A is a block diagram of an assembly system or apparatus 100-1 for directly vacuum sealing a backing plate 150-1 onto a mandrel 110-1, such as a layup mandrel, in an exemplary embodiment. The backing plate 150-1 is made from a rigid material 111-3, such as a metal or composite material. The backing plate 150-1 maintains rigidity relative to the preform 130-1 at the solidification temperature and compressive force. In this embodiment, the backing plate 150-1 defines mold lines 137-1, such as an inner mold line (IML) 133, relative to the preform 130-1, and the mandrel 110-1 forms an outer mold line (OML) 131 relative to the preform 130-1. In some embodiments, a release film 113 is located between the mandrel 110-1 and the preform 130-1. The release film 113 is placed on the mandrel 110-1 to facilitate demolding after solidification has been performed. In some embodiments, the breather treatment 115 facilitates the solidification process by allowing trapped gases to escape from the preform 130-1 during solidification and by facilitating the dispersion of exhausted gases throughout the preform.

[0031] In this embodiment, the mandrel 110-1 includes a rigid body 111-2 that forms a semi-cylindrical shape complementing the half-barrel section 1034 in Figure 12. The two half-barrel sections 1034 are joined to form a full-barrel section 1032. In the cross-sectional view of Figure 2A, the mandrel 110-1 appears rectangular. In this embodiment, the mandrel 110-1 defines the OML 131 with respect to the preform 130-1. The mandrel 110-1 includes a layup surface 141 that defines the contour 141-1 with respect to the preform 130-1 which includes multiple layers 132 of fibers 134 and resin 136. The mandrel 110-1 further includes an alignment feature 114 that engages with an alignment feature 142 of a strong back 140 that transports the backing plate 150-1 to the mandrel 110-1. This makes it possible to accurately position the backing plate 150-1 relative to the mandrel 110-1 each time the backing plate 150-1 is placed on the mandrel 110-1.

[0032] The embodiment includes a vacuum system 120-1 that evacuates a sealed chamber 157-1 via sealants 156 and 158. The vacuum system 120-1 applies vacuum to vacuum holes 116-1 and 116-2 via vacuum lines 118-1 and 118-2, respectively, either controllably or otherwise. Vacuum hole 116-1 is provided via sealants 156 and 158 and / or via backing plate 150-1 and applies vacuum to the sealed chamber 157. That is, vacuum holes 116-1 and / or 116-2 apply vacuum directly to the sealed chamber 157, including position 154-1 on backing plate 150-1. The vacuum system 120-1 evacuates air from the sealed chamber 157 directly adjacent to backing plate 150-1 and mandrel 110-1. By evacuating the sealed chamber 157 in conjunction with the atmospheric pressure outside the housing of the backing plate 150-1, sealant 156, and mandrel 110-1, the backing plate 150-1 is pressed toward the mandrel 110-1, resulting in the compaction of the preform 130-1. To repeat, by reducing the pressure below the backing plate 150-1 to below the atmospheric pressure inside the autoclave, the backing plate 150-1 is pressed down by the atmospheric pressure above the mandrel 110-1. In a further embodiment, vacuum is introduced into the sealed chamber 157 by the mandrel 110-1 and / or by the backing plate 150-1, in addition to the sealant 156 and sealant 158, as shown in Figure 2.

[0033] The sealants 156 and 158 are positioned between the mandrel 110-1 and the backing plate 150-1 along the periphery of the intersection 159 between the mandrel 110-1 and the backing plate 150-1. In this embodiment, the sealants 156 and 158 include a first peripheral sealant 156 and a second peripheral sealant 158 ​​that is positioned entirely within the first peripheral sealant 156. However, in further embodiments, triple or more sealants may be implemented, and each sealant is pressure-tested to ensure that it forms a sealed chamber 157. The sealants 156 and 158 seal the chamber 153-1 between them. Multiple sealants provide a substitute for the redundant sealants 156 and 158 in case one of the sealants fails. The remaining sealant 156 or 158 helps maintain the vacuum within the sealed chamber 157 and prevents the preform from being exposed to atmospheric pressure within the sealed chamber 157 during processing. The peripheral sealants 156 and 158 extend along the entire periphery of the backing plate 150-1, but for clarity they are shown in separate cross-sectional positions in Figure 2A. These components allow the backing plate 150-1 to be peripherally sealed to the mandrel 110-1. The sealants 156 and 158 can be implemented as disposable or reusable components. Hereafter, boxes referred to as sealant 156 both represent the first sealant 156, and boxes referred to as sealant 158 ​​both represent a second sealant 158, distinct from the first sealant 156. In some embodiments, a third sealant 155 may be included, although it is not shown in Figure 2A. Several intermediate materials and layers between the backing plate 150 and the mandrel 110, such as breather treatment and release film, are not shown in Figure 2A for clarity.

[0034] Figure 2A further depicts one or more bladders 160-1 positioned within the stringer preform 164 to provide expansion pressure to resist collapse during solidification while the backing plate 150-1 presses against the preform 130-1. The interior 160-9 of the bladders 160-1 is open to atmospheric pressure 178, which is the internal or external pressure of the autoclave 180. When the sealed chamber 157 is evacuated while the bladders 160-1 are open to atmospheric pressure 178, the bladders 160-1 expand. That is, during solidification, the bladders 160-1 act as internal tools that maintain structural support to the stringer preform 164. Specifically, the bladder 160-1 resists the collapse forces applied to the stringer preform 164 during processing, allowing the stringer preform 164 to maintain its shape. The bladder 160-1 includes an expansion port 162 for pressurizing during solidification to form one or more portions of the stringer preform 164-1. The bladder 160-1 is positioned between the backing plate 150-1 and the mandrel 110-1. In one embodiment shown in Figure 2A, the expansion port 162-1 passes through the sealants 156 and 158, providing a passage for air to enter the bladder 160.

[0035] Furthermore, Figure 2A is a cross-sectional view of the backing plate 150-1 through the longitudinal length of the trough 139-1. The backing plate 150-1 includes a trough 139-1 that encloses the bladder 160-1 and holds the stringer preform 164, which is positioned below the preform 130-1 and the mandrel 110-1. The cross section 179-1 between the troughs 139-1 shown in Figure 2C has the same cross-sectional components as shown in Figure 2A, from the strongback 140 to the mandrel 110-1, with the exception of the trough 139-1 and its contents, which include the stringer preform 164 and the enclosed bladder 160-1. This cross section 179-1 is positioned between the troughs 139-1 and is the embodiment depicted in Figure 2C.

[0036] Autoclave 180 (shown in more detail as autoclave 820 in Figure 9) receives mandrel 110-1, preform 130-1 and backing plate 150-1, and applies heat and pressure to solidify preform 130-1 into composite part 194. After solidification is complete, backing plate 150-1 is removed. Alignment features and other components may be added to composite part 194 and / or its manufacturing surplus. Composite part 194 is demolded from mandrel 110-1, and mandrel 110-1 and backing plate 150-1 are reused to manufacture other composite parts 194. In further embodiments, mandrel 110-1 and backing plate 150-1 are advanced in pulses or continuously through various stations described herein.

[0037] Figure 2B corresponds to the arrow 2B in Figure 2 and shows cross-sectional views of the various components described above. As shown in Figure 2B, the bladder 160 is positioned within the stringer preform 164 in the trough 139 and is positively pressurized when the backing plate 150 is sealed to the mandrel 110, and the sealed chamber 157 is vented around the stringer preform 164. The bladder 160 helps maintain structural support for the stringer preform 164 and prevents the shape of the stringer preform 164 from changing during the solidification process. In this embodiment, the mandrel 110 defines the IML 133 and the backing plate 150 defines the OML 131 relative to the preform 130. This embodiment facilitates the placement of the stringer preform 164 and bladder 160 on the mandrel 110, and then the preform 130 is laid on top of the stringer preform 164, bladder 160 and mandrel 110. This embodiment supports the IML133 tool for a half-barrel section 24.

[0038] Figure 2C corresponds to the arrow 2C indicated in Figure 2A and shows cross-sectional views of the various components described above. As shown in Figure 2C, the bladder 160-1 is positioned within the stringer preform 164 of the trough 139-1 and is positively pressurized when the backing plate 150-1 is sealed to the mandrel 110-1, and the sealed chamber 157 is vented around the stringer preform 164 and preform 130-1. The bladder 160-1 helps maintain structural support for the stringer preform 164 and prevents the shape of the stringer preform 164 from changing during the solidification process. In this embodiment, the mandrel 110-1 defines the OML 131 and the backing plate 150-1 defines the IML 133 relative to the preform 130-1. The embodiment facilitates the laying of the preform 130-1 on the mandrel 110-1, then the placement of the stringer preform 164 and bladder 160 on the mandrel 110, and then the sealing of the backing plate on the mandrel 110-1 to control the assembly prepared for solidification in the autoclave 180. This embodiment supports the OML131 tool for the half-barrel section 24.

[0039] Figure 2D shows a backing plate 181 for a wing panel preform 189 according to an exemplary embodiment. The wing panel preform 189 is laid on a mandrel 184. Next, a blade stringer 182 is placed on the preform 189. Then, support tools 183 and 183-1 are placed on the blade stringer 182 and on the preform 189. The backing plate 181 has a custom shape for providing IML 133-2 but is superimposed on the tops of the blade stringer 182 and support tools 183 and 183-1 such as the stringer mandrel. Sealing materials 156 and 158 are placed around the periphery of the backing plate 181 and the mandrel 184 to provide redundancy for sealing. As shown in Figure 2, the vacuum system 120 applies vacuum to the vacuum hole 116 via a vacuum line 118, either controllably or otherwise, and the vacuum line acts as a kind of manifold distributing vacuum to selected locations on the mandrel 110. A vacuum hole 116 is located on the mandrel 110-1 and applies a vacuum beyond the layup surface 112. That is, the vacuum hole 116 applies a vacuum directly to the sealed chamber 157, including its position 154 on the backing plate 150. As shown in Figure 2D, the embodiment has a mandrel 184 including a passage 185 through the sealants 156 and 158, and applies a vacuum to evacuate the sealed chamber 157-3 formed from the backing plate 181, sealants 156 and 158 and the mandrel 184, either controllably or otherwise, so that the atmospheric pressure outside the sealed chamber 157-1 pushes the backing plate 181 toward the mandrel 184, resulting in the compaction of the wing panel preform 189. The preform 189 is laid on the layup surface 112-2 on the mandrel 184. The backing plate 181 then compacts the stringer 182 and the wing panel preform 189. In this embodiment, the mandrel 184 defines OML 131, and the backing plate 181 defines IML 133 relative to the wing panel preform 189. The wing panel preform 189 corresponds to the cross section 46 of the wing panel 30 when the wing panel preform 189 is solidified. Thus, the mandrel 184 in Figure 2D provides the backing plate 181 to OML 131-2, thereby providing IML 133-2.

[0040] Figure 2E shows a backing plate 181-1 for a wing panel preform 189-1 in an exemplary embodiment. The backing plate 181-1, which has a custom shape to provide OML 131-3, is placed on top of the preform 189-1. Support tools 183-2, 183-3, such as blade stringers 182 and stringer mandrels, are positioned relative to the mandrel 184-1. In one embodiment, the preform 189-1 is then laid on top of the stringers 182 and support tools 183-4. The backing plate 181-1 is then placed on top of the preform 189-1. Sealing materials 156 and 158 are placed around the periphery of the backing plate 181-1 and the mandrel 184-1 to provide redundancy in the seal. In Figure 2A, the vacuum system 120-1 applies vacuum to the vacuum port 116 via the vacuum line 118, either controllably or otherwise, and the vacuum line acts as a kind of vacuum distribution manifold to selected locations on the backing plate 150-1. The vacuum port 116-2 is located on the mandrel 150-1 and applies vacuum over the layup surface 141. That is, the vacuum port 116 applies vacuum directly to the sealed chamber 157. As shown in Figure 2E, the embodiment has a mandrel 184-1 and backing plate 181-1 with a passage 185 through sealants 156 and 158. Vacuum moves from the vacuum system 120-1 through the passage 185 to evacuate the sealed chamber 157-4 formed by the backing plate 181-1, sealants 156 and 158, and the mandrel 184-1. When atmospheric pressure outside the sealed chamber 157-4 presses the backing plate 181-1 toward the mandrel 184-1, the backing plate 181-1 slides toward the mandrel 184-1, thereby compacting the wing panel preform 189-1. Thus, the backing plate 181-1 compacts the blade stringer 182 and the wing panel preform 189-1. In this embodiment, the mandrel 184-1 defines the IML 133-3, and the backing plate 181-1 defines the OML 131-3 toward the wing panel preform 189-1. The preform 189-1 is laid on the layup surface 112-3 created by the blade stringer 182, the support tool 183-3, and the mandrel 184-1.When the wing panel preform 189-1 is solidified, it corresponds to the cross section 46 of the wing panel 30. Thus, the mandrel 184-1 in Figure 2E provides a backing plate 181-1 to the IML 133-3, thereby providing the OML 131-3.

[0041] Figure 2F shows processing direction 191-1 for the backing plate 191 in an exemplary embodiment. The backing plate 191 includes backing plates 181 and 181-1, as well as backing plates 150 and 150-1. The mandrel 192 includes mandrels 184 and 184-1, as well as mandrels 110 and 110-1. As shown in Figure 2F, the preform 193 is processed in an autoclave 198 on the mandrel 192, with the backing plate 191 positioned above the preform 193. After autoclaving, the backing plate 191 is separated from the composite part 194 and the mandrel 192. The backing plate 191 is then cleaned and reconditioned in a cleaning station 195-1 and a reconditioning station 195 located outside the cleanroom environment 197-1. In one embodiment, this includes returning the backing plate 191 at the cowling mounting station 196 so that the backing plate can be installed above the preform 193 and on the layup mandrel 192. The preform 193 includes preforms 189, 189-1, and preforms 130, 130-1. The backing plate 191 is then placed at the cowling mounting station 196 on the layup mandrel 192 and the preform 193. In one embodiment, the layup mandrel 192 defines the shape of the preform 193 which will solidify to become the wing panels 30 of the wings 15, 16. In another embodiment, the layup mandrel 192 defines the shape of the preform 193 which will solidify to become the half-barrel section 24 of the fuselage 12.

[0042] In some embodiments, the cleaning station 195-1, the reconditioning station 195, and / or the cowl mounting station 196 are located on a mezzanine level overlooking the factory floor 197-3. This increases the size of the available space on the factory floor 197-3. In another embodiment, the cleaning station 195-1 and the reconditioning station 195 are located on the factory floor 197-3. The preform 193 is solidified in the autoclave 198 to form the composite part 194. The backing plate 191, preform 193, mandrel 192, and composite part 194 are then removed from the autoclave 198. The backing plate 191 is then separated from the mandrel 192. After the backing plate 191 is removed, the composite part 194 remains on the mandrel 192. After the backing plate 191 is removed, the composite part 194 has a burred edge extending outward from the composite part 194 and a manufacturing surplus portion 194-3 consisting of the bearing edge 194-1 material before trimming. Trimming occurs as part of the demolding process 194-4. The composite part 194 is trimmed on the mandrels 110 and 110-1. The manufacturing surplus portion 194-3 on the composite part 194 is then trimmed to separate the burred edge 194-2 from the bearing edge 194-1. The composite part 194 is separated from the mandrel 192, but the composite part 194 is accompanied by the bearing edge 194-1. The cut-off burred edge 194-2 is discarded. The composite part 194 is sent in direction 199 for assembly with other parts. The backing plate 191 may then be lifted to the mezzanine level 197, pass through at least one cleaning station 195-1 and at least one readjustment station 195, and then returned from the non-cleanroom 197-2 to the cleanroom 197-1. Another embodiment has a backing plate 191 that passes through at least one cleaning station 195-1 and at least one readjustment station 195, is lifted to the mezzanine level 197, and then returned from the non-cleanroom 197-2 to the cleanroom 197-1. At least one cleaning station 195-1 and at least one readjustment station 195 are located on the factory floor 197-3 or the mezzanine level 197 or both.The embodiment has a portion of a mezzanine within a cleanroom 197-1 and a non-cleanroom 197-2. The use of the mezzanine 197 reduces the footprint of the factory floor 197-3 for the backing plate 191 cycle, from placement at the cowl mounting station 196 to separation from the mandrel 192 via at least one cleaning station 195-1 and at least one readjustment station 195, and return to the cowl mounting station 196. The embodiment has at least one cleaning station 195-1 and at least one readjustment station 195 inside the cleanroom 197-1, but the exemplary embodiment has at least one cleaning station 195-1 and at least one readjustment station 195 located in the non-cleanroom 197-2. In one embodiment, the backing plate 191 engages with a strongback (e.g., a strongback 140 in Figures 2 and 2A) before being returned to the cowl mounting station 196 via at least one cleaning station 195-1 and at least one readjustment station 195.

[0043] The details of the operation of the assembly system 100 will be described in relation to Figure 3. In this embodiment, it is assumed that the mandrel 110 is located in a cleanroom (e.g., cleanroom 197-1) and is ready for use in the manufacture of the composite part 194. Furthermore, in some embodiments, it is assumed that the release film 113 is applied to the layup surface 112 of the mandrel 110.

[0044] Figure 3 is a flowchart showing a method for operating the assembly system 100 to solidify the preform 130 in an autoclave 180 of an exemplary embodiment. The steps of Method 200 will be described with reference to the assembly system 100 of Figure 2, but those skilled in the art will recognize that Method 200 may be carried out in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may also be carried out in an alternative order. Furthermore, although the steps herein are described in relation to the manufacture of a half-barrel section of the fuselage, they may be applied to any suitable arched section of the fuselage, such as a full-barrel section, half-barrel sections 24, 1034, quarter-barrel sections, or other segment sizes. In addition, the steps herein may be used in the manufacture of wing panels 30, 1038 as described herein.

[0045] Step 202 includes applying preforms 130, 130-1, 189, 189-1, and 193 to mandrels 110, 110-1, 184, 184-1, and 192. In one embodiment, applying preforms 130, 130-1, 189, and 189-1 includes laying CFRP tows on mandrels 110, 110-1, 184, 184-1, and 192 via an automated fiber placement (AFP) machine, a flat tape laying machine (FTLM), a contour tape laying machine (CTLM), an end effector, or other device to form multilayer charges of material having a desired shape. In further embodiments, applying preforms 130, 130-1, 189, 189-1, and 193 includes lifting the completed preforms 130, 130-1, 189, 189-1, and 193, or components of the completed preform 130, and placing them on mandrels 110, 110-1, 184, 184-1, and 192.

[0046] After preforms 130, 130-1, 189, 189-1, and 193 are applied, they are covered during solidification with a breather treatment 115 that facilitates degassing of the preforms 130, 130-1, 189, 189-1, and 193, with uniform exhaust in a sealed chamber 157, 157-1 and relatively small in scale. Furthermore, in some embodiments, bladders 160, 160-1 (or other internal mandrels) are positioned in the desired location to selectively support the stringer preform 164 of preforms 130, 130-1, 189, 189-1, and 193 (such as preforms for hat-type stringers). Bladders 160, 160-1 are inflated by atmospheric pressure, typically the pressure of the autoclave. The sealing materials 156 and 158 may be placed between the backing plates 150, 150-1, 191, 181, 181-1 and the mandrels 110, 110-1, 184, 184-1, 192 and fixed in place by adhesive.

[0047] Step 203 includes aligning backing plates 150, 150-1, 191, 181, 181-1 with respect to mandrels 110, 110-1, 184, 184-1, 192. In one embodiment, covering preforms 130, 130-1, 189, 189-1, 193 is ,vinegar Tallback 140 Using backing plates 150, 150-1, 191, 181, and 181-1 The purpose is to transport the material and to align the alignment feature 142 on the strongback 140 with the alignment feature 114 on the mandrels 110, 110-1, 184, 184-1, and 192. (to make consistent)This includes aligning the strongback 140 with the mandrels 110, 110-1, 184, 184-1, and 192. The backing plates 150, 150-1, 191, 181, and 181-1 are carried with the strongback 140 in precisely known positions and orientations, so that the positions of the backing plates 150, 150-1, 191, 181, and 181-1 are also aligned with the mandrels 110, 110-1, 184, 184-1, and 192. In another embodiment, this includes aligning the alignment feature 142 on the backing plates 150, 150-1, 191, 181, and 181-1 with the alignment feature 114 on the mandrels 110, 110-1, 184, 184-1, and 192. In a further embodiment, the alignment includes aligning the opening 152 in the backing plates 150, 150-1, 191, 181, and 181-1 with the port 162 in the bladder 160, 160-1, which is positioned on the preforms 130, 130-1, 189, 189-1, and 193. This provides a two-stage alignment process, where the alignment of the strongback 140 relative to the mandrels 110, 110-1, 184, 184-1, and 192 provides the initial alignment, and the alignment of the port 162 and the opening 152 provides the finer alignment. Alternatively, a two-stage alignment process may include the alignment of backing plates 150, 150-1, 191, 181, and 181-1 relative to mandrels 110, 110-1, 184, 184-1, and 192, which provides initial alignment, and the alignment of ports 162 and openings 152, which provides fine alignment. That is, the openings 152 in backing plates 150, 150-1, 191, 181, and 181-1 also facilitate the alignment of backing plates 150, 150-1, 191, 181, and 181-1 relative to bladder 160 and 160-1.Therefore, in one embodiment, method 200 includes applying bladder 160, 160-1 with preforms 130, 130-1, 189, 189-1, 193 before covering the preforms 130, 130-1, 189, 189-1, 193 with backing plates 150, 150-1, 191, 181, 181-1, and aligning the opening 152 of backing plates 150, 150-1, 191, 181, 181-1 with the expansion port 162 for bladder 160, 160 to facilitate periphery and / or front and rear alignment.

[0048] In step 204, preforms 130, 130-1, 189, 189-1, and 193 are covered with backing plates 150, 150-1, 191, 181, and 181-1. This involves lowering backing plates 150, 150-1, 191, 181, and 181-1 to the top positions of preforms 130, 130-1, 189, 189-1, and 193.

[0049] In step 206, the backing plates 150, 150-1, 191, 181, and 181-1 are sealed to the mandrels 110, 110-1, 184, 184-1, and 192. In one embodiment, sealing the backing plates 150, 150-1, 191, 181, and 181-1 to the mandrels 110, 110-1, 184, 184-1, and 192 includes applying a first peripheral sealant 156 and applying a second peripheral sealant 158 ​​which is arranged throughout the first peripheral sealant 156. In further embodiments, sealing the backing plates 150, 150-1, 191, 181, and 181-1 to the mandrels 110, 110-1, 184, 184-1, and 192 includes applying a third periphery seal 155 which is arranged entirely within the second periphery seal 158. Step 206 may further include positioning the backing plates 150, 150-1, 191, 181, and 181-1 with respect to the seals 156 and 158, and may include applying an adhesive or other compound to ensure an airtight bond between the backing plates 150, 150-1, 191, 181, and 181-1 and the seals 156 and 158. Furthermore, the space between the first periphery seal 156 and the second periphery seal 158 may be subdivided into four sections (as further illustrated in Figure 6), thereby providing an additional level of sealing redundancy. Banjo bolts 170, including threads that complement the threading at each expansion port 162, are fixed / mounted to the expansion ports 162 of the bladder 160. These serve to seal the openings 152 of the backing plates 150, 150-1, 191, 181, and 181-1 along with other sealing materials if necessary, thereby preventing air from escaping from the backing plates 150, 150-1, 191, 181, and 181-1 through the openings 152.

[0050] In other words, step 206 includes sealing the backing plates 150, 150-1, 191, 181, 181-1 to one or more bladders via the banjo bolt 170, and expanding the bladders 160, 160-1 while the preforms 130, 130-1, 189, 189-1, 193 solidify. Thus, in at least one embodiment, sealing the backing plates 150, 150-1, 191, 181, 181-1 to the bladders 160, 160-1 is performed by screwing the banjo bolt 170 into the expansion port 162.

[0051] In step 208, the vacuum systems 120, 120-1 evacuate air from the sealed chambers 157, 157-1 located between the mandrels 110, 110-1, 184, 184-1, 192 and the backing plates 150, 150-1, 191, 181, 181-1, thereby using atmospheric pressure to press the backing plates 150, 150-1, 191, 181, 181-1 toward / against the preforms 130, 130-1, 189, 189-1, 193. In one embodiment, this includes applying a vacuum to mandrels 110, 110-1, 184, 184-1, 192 that directly pull back plates 150, 150-1, 191, 181, 181-1 toward preforms 130, 130-1, 189, 189-1, 193. The vacuum in mandrels 110, 110-1, 184, 184-1, 192 is applied directly to back plates 150, 150-1, 191, 181, 181-1, either in a controllable manner or by other means. In another embodiment, exhaust of sealed chambers 157, 157-1 is achieved through sealants 156 and 158 and / or through back plates 150, 150-1, 191, 181, 181-1. This operation firmly holds the backing plates 150, 150-1, 191, 181, and 181-1 against the sealants 156 and 158 and compacts the preforms 130, 130-1, 189, 189-1, and 193. In one embodiment, the backing plates 150, 150-1, 191, 181, and 181-1 are pressed against mandrels 110, 110-1, 184, 184-1, and 192 with a pressure of 0.62 MPa (90 pounds per square inch) or more. The mandrels 110, 110-1, 184, 184-1, and 192 are then placed in a pressurized autoclave 180. After the autoclave 180 is heated to its solidification temperature, the pressure in the autoclave 180 expands the bladder 160, 160-1 via the banjo bolt 170. Therefore, during solidification, the stringer preform 164 is pressurized and formed through the expansion of the bladder 160, 160-1.

[0052] In step 210, while the backing plates 150, 150-1, 191, 181, and 181-1 are held against the preforms 130, 130-1, 189, 189-1, and 193, the preforms 130, 130-1, 189, 189-1, and 193 solidify to form a composite part 194. That is, after the backing plates 150, 150-1, 191, 181, and 181-1 are vacuum-suctioned, solidification occurs while the backing plates 150, 150-1, 191, 181, and 181-1 are held in place. In one embodiment, this includes operating an autoclave 180 to maintain heat and pressure, while simultaneously operating vacuum systems 120, 120-1 in mandrels 110, 110-1, 184, 184-1, 192 to compact and solidify the preforms 130, 130-1, 189, 189-1, 193, while forcing the preforms 130, 130-1, 189, 189-1, 193 into a desired shape.

[0053] In step 212, the backing plates 150, 150-1, 191, 181, and 181-1 are removed from the composite part 194. In step 214, the backing plates 150, 150-1, 191, 181, and 181-1 are cleaned, for example, by applying chemicals and liquids to remove the composite material, or by using cleaning agents / abrasives. In some embodiments, the backing plates 150, 150-1, 191, 181, and 181-1 are readjusted or repaired as necessary in step 215. In step 216, the backing plates 150, 150-1, 191, 181, and 181-1 are returned to the cleanroom 197-1 and may be reused to facilitate the solidification of other preforms 130, 130-1, 189, 189-1, and 193.

[0054] Method 200 offers technical advantages over prior systems and technologies by eliminating the need to place preforms 130, 130-1, 189, 189-1, and 193 into vacuum bags, test the vacuum bags, then position the backing plates, potentially perform another vacuum check of the vacuum bags, and then place the assemblies in the autoclave 180. Thus, the preceding two-step process, which requires placing and sealing the vacuum bags and testing them, and then aligning and positioning them on the backing plates, is replaced by a one-step process of positioning the backing plates 150, 150-1, 191, 181, and 181-1. Method 200 utilizes the backing plates 150, 150-1, 191, 181, and 181-1 to perform the same role that previously relied on vacuum bags. This reduces the amount of work and materials used in the solidification process, thereby advantageously increasing efficiency. For example, the need for vacuum bags and other disposable components may be reduced or eliminated, resulting in savings in materials and labor before solidification.

[0055] Figure 4 is a side view of a mandrel 310 including a backing plate 350 that acts as a vacuum bag in an exemplary embodiment. In this figure, the mandrel 310 appears rectangular so that half of the cylindrical shape appears rectangular when viewed from the side, but when only the currently visible side is solidified, the mandrel 310 forms a half-barrel shape 24. According to Figure 4, the backing plate 350 covers the preform 330, and the bladder 160, 160-1 is positioned within the stringer preform 164 in the preform 330. The bladder 160, 160-1 includes a port 362 that is exposed to the backing plate 350 through an opening 352. The backing plate 350 corresponds to backing plates 150, 150-1, 191, 181, 181-1. The mandrel 310 corresponds to mandrels 110, 110-1, 184, 184-1, 192. Preform 330 corresponds to Preforms 130, 130-1, 189, 189-1, and 193.

[0056] The mandrel 310 includes a vacuum hole 316 that applies a vacuum directly to the backing plate 350, pressing the backing plate 350 into the preform 330. When a vacuum is applied through the vacuum hole 316, the backing plate 350, the radial sealant 370, and the mandrel 310 together define a vacuum chamber 390 to be evacuated. The vacuum hole 316 extends beyond the outer periphery 332 of the preform but is located within the outer periphery 372 of the radial sealant 370. Since the backing plate 350 is sealed, for example, by a ramp 318, no air leaks into the autoclave 180 while the preform 330 solidifies into a composite part 194. Furthermore, the mandrel 310 includes alignment features 314 that engage with the strongback 140 and facilitate the positioning and orientation of the backing plate 350 on the mandrel 310. The radial sealant 370 and the bottom sealant 312 ensure that the mandrel 310 is sealed in a designated location within the autoclave 180.

[0057] Figure 5 is a cross-sectional view of a mandrel 310 including a backing plate 350 that functions as a vacuum bag and backing plate in an exemplary embodiment, corresponding to the viewpoint indicated by arrow 5 in Figure 4. In Figure 4, the ramp 318 of the mandrel 310 is visible, as is the backing plate 350. Peripheral seals 420, 430, and 440 are arranged in the channel 410 of the mandrel 310 (e.g., a channel with a semicircular cross-section) to seal the backing plate 350 into three independent chambers 422, 432, and 442. Chamber 442 corresponds to the sealed chambers 157, 157-1. This redundancy of sealing by the peripheral seals 420, 430, and 440 helps prevent the preform from encountering any vacuum leaks. In other words, having independent chambers 422, 432, and 442 offers a technical advantage because even if one of the peripheral seals 420, 430, and 440 is damaged during the solidification process, solidification can still be carried out without issue with the desired backing plate 350 compression. Furthermore, the vacuum hole 316 applies vacuum through a vacuum line 416 that pulls the backing plate 350 into contact with the sealant. The elastomer flap 450 extends from the backing plate 350 and is laid flat against the mandrel 310. The elastomer flap 450 provides additional sealant protection against leakage and may be sealed against the mandrel 310 with tape, adhesive, or by other means as needed, resulting in increased redundancy. In further embodiments, the ramp 318 is not utilized so as to ensure that the mandrel 310 and the backing plate 350 maintain a constant diameter. Although sealants 156 and 158 are shown in Figures 2D and 2E, three sealing systems of peripheral sealants 420, 430, and 440 can be used with the flap 450.

[0058] Figure 6 is a top view of the backing plate 350 and mandrel 310 corresponding to the viewpoint indicated by arrow 6 in Figure 4, and appears rectangular so that half of the cylindrical shape appears rectangular when viewed from above. In exemplary embodiments, the backing plate 350 and mandrel 310 include peripheral chambers 590 and 592 which are subdivided into four sections 510, 520, 530, and 540 by the sealant 550. In Figure 6, the backing plate 350 covers the peripheral sealants 420, 430, and 440 of Figure 5, and further covers the sealant 550 which subdivides the peripheral sealants 420, 430, and 440 into four sections 510, 520, 530, and 540. The pressure sensor 560 is disposed in each of the chambers 512, 514, 522, 524, 532, 534, 542, and 544 of the four divisions 510, 520, 530, and 540, and can be integrated with the backing plate 350 and the mandrel 310. For example, in one embodiment, the pressure sensor 560 is disposed in the chambers 512 and 514 of the four division 510, the chambers 522 and 524 of the four division 520, the chambers 532 and 534 of the four division 530, and the chambers 542 and 544 of the four division 540. The input from the pressure sensor 560 is used to determine which chamber, and specifically which of the four divisions, has a leak. Thus, the sealant 550 functions as an additional sealant that subdivides the space between the peripheral sealants into the four divisions 510, 520, 530, and 540, or into other segments. A vacuum hole 316 beneath the backing plate 350 is also depicted and is used to exhaust air between the backing plate 350 and the lower mandrel 310. The advantage of dividing it into four sections lies in the additional level of sealing redundancy. For example, if a seal leak occurs in chamber 522, the leak is isolated to the corresponding section 520 and does not impair chambers 532, 544, or 512. With respect to the seal material 550, if it is not divided into four sections 510, 520, 530, and 540, leaks through the seal material 156 in the chamber 522 region and leaks through the seal material 158 in the chamber 542 region could lead to preform 130 being exposed to atmospheric pressure during solidification.

[0059] Figures 7 and 8 show a banjo bolt 600 that seals the backing plate 650 to the bladder 660, while also, in an exemplary embodiment, providing a passage 630 through which air enters the bladder. The bladder 660 corresponds to bladders 160 and 160-1. The passage 630 allows air at autoclave pressure (P_AUTOCLAVE) to enter the bladder 660, causing it to inflate. The banjo bolt 600 includes a head 610 from which an annular sealant 640 protrudes. The annular sealant 640 seals the banjo bolt 600 to the backing plate 650 as the banjo bolt 600 is screwed into port 662 of the bladder 660, preventing air leakage from the opening 652. The sealant 640 corresponds to sealant 152-1. The opening 652 corresponds to opening 152. The banjo bolt 600 further includes a shaft 620 having threads 622 that complement the threads 664 at port 662. Figure 8 corresponds to the viewpoint of arrow 8 in Figure 7 and provides additional details showing the head 610, passage 630, annular sealant 640, and other components of the banjo bolt 600 not shown in Figure 7.

[0060] Figures 9 and 10 are perspective views showing the insertion of mandrel 810 into autoclave 820 on the factory floor 197-3 according to an exemplary embodiment. Mandrel 810 corresponds to mandrels 110, 110-1, 310, and 192. As shown in Figure 9, mandrel 810 forms a half-barrel shape, over which backing plate 830 covers the preform (below backing plate 830) and solidifies to form a composite material. Backing plate 830 corresponds to backing plates 150, 150-1, 350, and 181-1. Preform 840 corresponds to preforms 130, 130-1, 330, and 193. Backing plate 830 is held in place by the vacuum applied by mandrel 810. Mandrel 810 is moved into autoclave 820 in Figure 10 and then sealed in place. Autoclave 820 is heated and pressurized, the preform is solidified to form composite part 194, and demolded after mandrel 810 is removed from autoclave 820. Figures 9 and 10 show only one autoclave configuration out of many possibilities, but other configurations for autoclave 820 may be used in conjunction with the systems and methods described herein.

[0061] In the following embodiments, additional processes, systems, and methods are described in relation to a backing plate that is vacuum-sealed directly to a mandrel in order to apply a compaction force to the preform during solidification.

[0062] More specifically with reference to the drawings, embodiments of the present disclosure may be described in reference to the manufacture and maintenance of an aircraft by method 1000 shown in Figure 11 and the aircraft 1002 shown in Figure 12. In the pre-manufacturing stage, method 1000 may include the specification and design 1004 of the aircraft 1002 and the procurement of materials 1006. In the manufacturing stage, the manufacture 1008 of the components and subassemblies of the aircraft 1002 and system integration 1010 are carried out. The aircraft 1002 may then be put into operation 1014 after approval and delivery 1012. During the period of operation by the customer, the aircraft 1002 is scheduled for periodic maintenance and servicing 1016 (which may also include modifications, reconfigurations, and refurbishments). The apparatus and methods embodied in this book may be used in any one or more preferred stages of manufacturing and maintenance described in Method 1000 (e.g., specification and design 1004, material procurement 1006, manufacturing of components and subassemblies 1008, system integration 1010, authorization and delivery 1012, operation 1014, maintenance and servicing 1016), and / or in any preferred component of the aircraft 1002 (e.g., airframe 1018, systems 1020, interior 1022, propulsion system 1024, electrical system 1026, hydraulic system 1028, environmental system 1030).

[0063] Each process of Method 1000 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). In this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, service organization, etc.

[0064] As shown in Figure 12, an aircraft 1002 manufactured by Method 1000 may include a fuselage 1018 with a plurality of systems 1020 and interior 1022. Embodiments of system 1020 include one or more of the propulsion system 1024, electrical system 1026, hydraulic system 1028, and environmental system 1030. The fuselage 1018 includes a full-barrel section 1032 with a half-barrel section 1034, and the wing assembly 1036 further includes wing panels 1038. Any number of other systems may be included. Although aerospace-related embodiments are shown, the principles of the present invention can also be applied to other industries (such as the automotive industry).

[0065] As described above, the devices and methods embodied herein may be employed at any stage of one or more of the manufacturing and maintenance described in Method 1000. For example, the components or subassemblies corresponding to the manufacturing of components and subassemblies 1008 may be manufactured or produced in the same manner as the components or subassemblies manufactured during the operation of the aircraft 1002. Also, one or more embodiments of devices, embodiments of methods, or combinations thereof may be used in the manufacturing of subassemblies 1008 and system integration 1010, for example, to substantially streamline the assembly of the aircraft 1002 or to reduce the cost of the aircraft 1002. Similarly, one or more embodiments of devices, embodiments of methods, or combinations thereof may be used during the operation of the aircraft 1002, for example, during maintenance and servicing 1016, but not limited to these. It may be used in any stage or any combination thereof as described herein, for example, specification and design 1004, material procurement 1006, manufacturing of components and subassemblies 1008, system integration 1010, authorization and delivery 1012, operation 1014, maintenance and servicing 1016, and / or in any suitable component of the aircraft 1002 (e.g., airframe 1018, systems 1020, interior 1022, propulsion system 1024, electrical system 1026, hydraulic system 1028, environmental system 1030).

[0066] In one embodiment, the component includes part of the airframe 1018 and is manufactured during the manufacture of components and subassemblies 1008. This component is then assembled to form the aircraft in system integration 1010, but may subsequently be used in operation 1014 until the component becomes unusable due to wear. Thereafter, in maintenance and servicing 1016, the component may be discarded and replaced with a newly manufactured component. Components and methods of the invention may be utilized throughout the manufacture of components and subassemblies 1008 to manufacture a new component.

[0067] Any of the various control elements (e.g., electrical components or electronic components) shown in the figures or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or any combination thereof. For example, some elements may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors,” “controllers,” or some similar terminology. If functions are provided by processors, they may be provided by a single dedicated processor, a single shared processor, or a number of separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be interpreted as referring only to software-executable hardware, but implicitly includes, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for software storage, random-access memory (RAM), non-volatile memory, logic, or any other physical hardware components or modules.

[0068] Furthermore, control elements may be implemented as instructions that can be executed by a processor or computer to perform the function of that element. Some examples of instructions are software, program code, and firmware. When executed by a processor, an instruction is actuated to instruct the processor to perform the function of the element. Instructions may be stored in a memory device that is readable by the processor. Some embodiments of memory devices are digital or solid-state memory, magnetic storage media (such as magnetic disks and magnetic tapes), hard drives, or optically readable digital data storage media.

[0069] The present invention also relates to the manufacture of aircraft parts using the apparatus according to the present invention. Manufacture of aircraft parts using the apparatus according to the present invention has the same advantages and effects as the method and apparatus according to the present invention.

[0070] In a preferred embodiment of the present invention, which involves the manufacture of an aircraft part using an apparatus for solidifying a fiber-reinforced material preform, the apparatus is: Mandrels (110, 110-1) and A backing plate (150, 150-1) that defines the surface of a preform (130, 130-1), comprising a backing plate containing a rigid material (111), A sealing material (156, 158, 155) is placed between the mandrel (110, 110-1) and the backing plate (150, 150-1), It is equipped with. This provides the same advantages and effects as the method and apparatus according to the present invention.

[0071] A more preferred embodiment of the present invention, relating to the manufacture of an aircraft part using an apparatus (100, 100-1) for compacting fiber-reinforced material preforms (130, 130-1), the apparatus is The device comprises a chamber (157) sealed by a mandrel (110, 110-1), a backing plate (150, 150-1), and peripheral sealing material (156, 158, 155) between the mandrel and the backing plate, This provides the same advantages and effects as the method and apparatus according to the present invention.

[0072] This disclosure also includes the following embodiments, which should not be confused with the claims that determine the scope of protection. The embodiments relate to the following:

[0073] Example 1. A method (200) for solidifying a fiber-reinforced material preform (130, 130-1), wherein the method (200) is: - Applying preforms (130, 130-1) to mandrels (110, 110-1) (202), - Covering the aforementioned preform (130, 130-1) with backing plates (150, 150-1) (204), - Sealing the backing plate (150, 150-1) onto the mandrel (110, 110-1) (206), - Pressing the backing plate (150, 150-1) toward the preform (130, 130-1) and the mandrel (110, 110-1) (208), - While the backing plates (150, 150-1) are held against the preform (130, 130-1), the preform (130, 130-1) solidified Composite parts (194) to To do (210), A method including (200).

[0074] Example 2. The backing plates (150, 150-1), sealing material (156, 158, 155) and mandrel (110, 110-1) are arranged so that atmospheric pressure can press the backing plates (150, 150-1) toward the preform (130, 130-1). Boundaries were established The method according to Example 1 (200), comprising exhausting the air from a sealed chamber (157).

[0075] Example 3. The method (200) of Example 2, comprising pressing the backing plate (150, 150-1) toward the preform (130, 130-1) and the mandrel (110, 110-1) as the sealed chamber (157) is evacuated while surrounded by atmospheric pressure.

[0076] Example 4. The method according to any one of Examples 1 to 3 (200), further comprising aligning the backing plates (150, 150-1) with respect to the mandrels (110, 110-1) (203).

[0077] Example 5. The backing plates (150, 150-1) are placed on the strong back (140). Using The method according to Example 4 (200), further comprising transporting and aligning the alignment feature (142) on the strong back (140) with the alignment feature (114) on the mandrel (110, 110-1).

[0078] Example 6. The method according to any one of Examples 1 to 5 (200), further comprising inserting a bladder (160, 160-1) into the stringer preform (164) before covering the preform (130, 130-1) with the backing plate (150, 150-1).

[0079] Example 7. - Align the opening (152) of the backing plate (150, 150-1) with the expansion port (162, 162-1) for the bladder (160, 160-1), - To seal the aforementioned backing plates (150, 150-1) to the aforementioned bladder (160, 160-1), - Inflating the bladder (160, 160-1), The method according to Example 6, further comprising (200).

[0080] Example 8. The method (200) of Example 7, wherein sealing the backing plate (150, 150-1) to the bladder (160, 160-1) is performed by screwing a banjo bolt (170) into the expansion port (162, 162-1).

[0081] Example 9. The method (200) of Example 7 or 8, further comprising expanding the bladder (160, 160-1) by opening the inside of the bladder (160, 160-1) to atmospheric pressure when the sealed chamber (157) is evacuated.

[0082] Example 10. The method according to Example 9 (200), further comprising pressurizing and molding the stringer preform (164) by expanding a bladder (160, 160-1).

[0083] Example 11. The method according to any one of Examples 1 to 10 (200), wherein sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) includes peripheral sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) via a first peripheral sealant (156).

[0084] Example 12. The method according to Example 11 (200), wherein sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) further comprises peripheral sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) via a second peripheral sealant (158) which is disposed throughout the first peripheral sealant (156).

[0085] Example 13. The method according to Example 12 (200), wherein sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) further includes peripheral sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) via a third peripheral seal (155) which is disposed throughout the second peripheral seal (158).

[0086] Example 14. The method (200) according to Example 12 or 13, further comprising subdividing the space between the first peripheral sealant (156) and the second peripheral sealant (158) into four sections (510, 520, 530, 540).

[0087] Example 15. The method (200) according to any one of Examples 1 to 14, wherein the backing plate (150, 150-1) is used to compact the stringer preform (164), support tool (183), and wing panel preform (189) against the mandrel (110, 110-1).

[0088] Example 16. The method according to any one of Examples 1 to 15 (200), wherein, with respect to a section of the fuselage (12), the backing plates (150, 150-1) form an outer mold line (OML) (131), and the mandrels (110, 110-1) form an inner mold line (IML) (133).

[0089] Example 17. The method according to any one of Examples 1 to 15 (200), wherein the backing plates (150, 150-1) form an inner mold line (IML) (133) and the mandrels (110, 110-1) form an outer mold line (OML) (131) for a section of the fuselage (12).

[0090] Example 18. The method according to Example 16 (200), wherein the section of the fuselage (12) is a half-barrel section (24).

[0091] Example 19. The method (200) according to Example 16 or 17, wherein the section of the fuselage (12) is a half-barrel section (29).

[0092] Example 20. The method according to any one of Examples 1 to 19 (200), wherein the mandrel (110, 110-1) forms an outer mold line (OML) (131) on the wing panel (30) and the backing plate (150, 150-1) forms an inner mold line (IML) (133).

[0093] Example 21. The method according to any one of Examples 1 to 19 (200), wherein the mandrel (110, 110-1) forms an inner mold line (IML) (133) on the wing panel (30) and the backing plate (150, 150-1) forms an outer mold line (OML) (131).

[0094] Example 22. The method (200) according to any one of Examples 11 to 14, further comprising sliding the mandrel (110, 110-1) against a backing plate (150, 150-1) with one of the first peripheral sealant (156), the second peripheral sealant (158), or the third peripheral sealant (155).

[0095] Example 23. The method according to any one of Examples 1 to 22 (200), wherein pressing the backing plate (150, 150-1) toward the preform (130, 130-1) and the mandrel (110, 110-1) is performed using atmospheric pressure.

[0096] Example 24. A portion of an aircraft (10) assembled according to the method (200) described in any one of Examples 1 to 23.

[0097] Example 25. Apparatus (100, 100-1) for solidifying a fiber-reinforced material preform, - Mandrels (110, 110-1), - A backing plate (150, 150-1) that defines the surface of a preform (130, 130-1), comprising a backing plate containing a rigid material (111), - A sealing material (156, 158, 155) is disposed between the mandrel (110, 110-1) and the backing plate (150, 150-1), A device (100, 100-1) equipped with the following.

[0098] Example 26. The apparatus (100, 100-1) of Example 25, further comprising a vacuum system (120) for controllably applying vacuum through vacuum holes (116) in the mandrels (110, 110-1).

[0099] Example 27. The apparatus (100, 100-1) according to Example 25 or 26, further comprising a vacuum system (120, 120-1) that controlsly applies vacuum through vacuum holes (116-2) in the backing plates (150, 150-1).

[0100] Example 28. The apparatus (100, 100-1) according to any one of Examples 25 to 27, wherein the vacuum system (120-1) applies a controllable vacuum through the vacuum holes (116-1) in the sealing material (156, 158, 155).

[0101] Example 29. The apparatus (100, 100-1) according to any one of Examples 25 to 28, further comprising a bladder (160, 160-1) disposed between the backing plate (150, 150-1) and the mandrel (110, 110-1).

[0102] Example 30. The apparatus (100, 100-1) described in Example 29, wherein the bladder (160, 160-1) is placed inside the stringer preform (164).

[0103] Example 31. The apparatus (100, 100-1) according to Example 29 or 30, wherein the expansion port (162, 162-1) for the bladder (160, 160-1) is installed through the opening of the backing plate (150, 150-1).

[0104] Example 32. The apparatus (100, 100-1) according to Example 31, further comprising a banjo bolt (170) for attaching the expansion port (162, 162-1) to the backing plate (150, 150-1).

[0105] Example 33. The apparatus (100, 100-1) according to any one of Examples 25 to 32, wherein the sealing material (156, 158, 155) includes a first peripheral sealing material (156).

[0106] Example 34. The apparatus (100, 100-1) according to Example 33, wherein the sealing material (156, 158, 155) includes a second peripheral sealing material (158) which is disposed entirely within the first peripheral sealing material (156).

[0107] Example 35. The apparatus (100, 100-1) according to Example 34, wherein the sealing material (156, 158, 155) includes a third peripheral sealing material (155) that is disposed entirely within the second peripheral sealing material (158).

[0108] Example 36. The apparatus (100, 100-1) according to Example 34 or 35, further comprising a space between the first peripheral sealant (156, 420) and the second peripheral sealant (158, 430) that is divided into four sections (510, 520, 530, 540).

[0109] Example 37. The apparatus (100, 100-1) according to any one of Examples 25 to 36, wherein the backing plates (150, 150-1) are configured to compact the stringer preform (164) and the wing panel preform (189).

[0110] Example 38. The apparatus (100, 100-1) according to any one of Examples 25 to 37, wherein the backing plates (150, 150-1) are configured to compact the half-barrel section (24).

[0111] Example 39. The apparatus (100, 100-1) according to any one of Examples 25 to 38, wherein the backing plates (150, 150-1) form an outer mold line (OML) (131) and the mandrels (110, 110-1) form an inner mold line (IML) (133).

[0112] Example 40. The apparatus (100, 100-1) according to any one of Examples 25 to 38, wherein the backing plates (150, 150-1) form an inner mold line (IML) (133) and the mandrels (110, 110-1) form an outer mold line (OML) (131).

[0113] Example 41. The apparatus (100, 100-1) according to any one of Examples 25 to 40, wherein the sealing material (156, 420, 158, 430, 155, 440) is disposed within the channel (410) on the mandrel (110, 110-1, 310).

[0114] Example 42. The apparatus (100, 100-1) according to any one of Examples 25 to 41, wherein the flap (450) extends from the backing plates (150, 150-1, 350).

[0115] Example 43. An apparatus (100, 100-1) according to any one of Examples 25 to 42, configured for compacting a fiber-reinforced material preform (130, 130-1), further comprising a chamber (157) sealed by a mandrel (110, 110-1), a backing plate (150, 150-1), and a peripheral sealant (156, 158, 155) between the mandrel (110, 110-1) and the backing plate (150, 150-1).

[0116] Example 44. The apparatus according to Example 43, wherein the mandrel (110, 110-1) further comprises a vacuum system (120, 120-1) for controllably applying vacuum between the backing plate (150, 150-1) and the layup surface (112) of the mandrel (110, 110-1).

[0117] Example 45. The apparatus (100, 100-1) according to Example 43 or 44, wherein the backing plate (150, 150-1) includes an opening (152) disposed in the expansion port (162, 162-1).

[0118] Example 46. The apparatus (100, 100-1) of Example 45, wherein the bladder (160, 160-1) is disposed between the backing plate (150, 150-1) and the mandrel (110, 110-1), and is disposed at the expansion port (162, 162-1).

[0119] Example 47. The apparatus (100, 100-1) of Example 46, further comprising a banjo bolt (170) for fixing the expansion port (162, 162-1) to the opening (152) of the backing plate (150, 150-1).

[0120] Example 48. The apparatus (100, 100-1) of Example 47, wherein the banjo bolt (170) includes threading that complements the threading at the expansion port (162, 162-1).

[0121] Example 49. The apparatus (100, 100-1) according to any one of Examples 43 to 48, wherein the peripheral sealant (156, 158, 155) includes the first peripheral sealant (156).

[0122] Example 50. The apparatus (100, 100-1) according to Example 49, wherein the peripheral sealants (156, 158, 155) include the second peripheral sealant (158) which is disposed entirely within the first peripheral sealant (156).

[0123] Example 51. The apparatus (100, 100-1) according to Example 50, wherein the peripheral sealants (156, 158, 155) include the third peripheral sealant (155) which is disposed entirely within the second peripheral sealant (158).

[0124] Example 52. The apparatus (100, 100-1) according to Example 50 or 51, further comprising a space between the first peripheral sealant (156) and the second peripheral sealant (158) that is divided into four sections (510, 520, 530, 540).

[0125] Example 53. Apparatus (100, 100-1) according to any one of Examples 46 to 48, wherein the expansion port (162, 162-1) passes through the peripheral sealant (156, 158, 155) to create a passage to the bladder (160, 160-1).

[0126] Example 54. The apparatus (100, 100-1) according to any one of Examples 43 to 53, wherein the backing plates (150, 150-1) are configured to compact the stringer preform (164) and the wing panel preform (189).

[0127] Example 55. The apparatus (100, 100-1) according to any one of Examples 43 to 54, wherein the backing plates (150, 150-2) form an outer mold line (OML) (131) and the mandrel (110) form an inner mold line (IML) (133).

[0128] Example 56. The apparatus (100, 100-1) according to any one of Examples 43 to 54, wherein the mandrel (110, 110-1) forms an outer mold line (OML) (131) and the backing plate (150, 150-1) forms an inner mold line (IML) (133).

[0129] Example 57. The apparatus (100, 100-1) according to any one of Examples 43 to 56, wherein the sealing material (156, 420, 158, 430, 155, 440) is disposed within the channel (410) on the mandrel (110, 110-1, 310).

[0130] Example 58. The apparatus (100, 100-1) described in Example 57, wherein the channel (410) has a semicircular cross-section.

[0131] Example 59. The apparatus (100, 100-1) according to any one of Examples 43 to 58, including the backing plates (150, 150-1, 350) and elastomer flap (450).

[0132] Example 60. The apparatus (100, 100-1) according to any one of Examples 43 to 59, wherein the backing plates (150, 150-1) form the half-barrel shape of the half-barrel section (24) relative to the section of the fuselage (12).

[0133] Example 61. The apparatus (100, 100-1) according to any one of Examples 43 to 60, wherein the backing plates (150, 150-1) form the shape of the wing panel (130) of the wing (15, 16).

[0134] Example 62. Manufacturing of a part of an aircraft (10) using the apparatus (100, 100-1) described in any one of Examples 25 to 61.

[0135] While this book describes specific embodiments, the scope of this disclosure is not limited to such specific embodiments. The scope of this disclosure is defined by the following claims.

Claims

1. A method (200) for solidifying a fiber-reinforced material preform (130, 130-1), wherein the method (200) is - Applying the preform (130, 130-1) to the mandrel (110, 110-1) (202), - Covering the preform (130, 130-1) with a backing plate (150, 150-1) (204), - Sealing the backing plate (150, 150-1) onto the mandrel (110, 110-1) (206), - Pressing the backing plate (150, 150-1) toward the preform (130, 130-1) and the mandrel (110, 110-1) (208), - While the backing plates (150, 150-1) are held against the preform (130, 130-1), the preform (130, 130-1) is solidified to form a composite part (194) (210), - One or more bladders (160, 160-1) are placed between the backing plate (150, 150-1) and the mandrel (110, 110-1), - To provide a two-stage alignment process, Includes, The aforementioned two-stage alignment process, - Transporting the backing plates (150, 150-1) using the strong back (140), aligning the alignment feature (142) on the strong back (140) with the alignment feature (114) on the mandrel (110, 110-1) as an initial alignment, and aligning the port (162) of the bladder (160, 160-1) with the opening (152) of the backing plates (150, 150-1) to provide fine alignment, or - As an initial alignment, the alignment feature (142) on the backing plate (150, 150-1) is aligned with the alignment feature (114) on the mandrel (110, 110-1), and the port (162) of the bladder (160, 160-1) is aligned with the opening (152) of the backing plate (150, 150-1) to provide fine alignment. Method (200), including the method (200).

2. This includes exhausting the air in a sealed chamber (157) whose boundaries are defined by the backing plates (150, 150-1), the sealants (156, 158, 155), and the mandrels (110, 110-1) so that atmospheric pressure can press the backing plates (150, 150-1) toward the preforms (130, 130-1), preferably including pressing the backing plates (150, 150-1) toward the preforms (130, 130-1) and the mandrels (110, 110-1) when the sealed chamber (157) is exhausted while surrounded by atmospheric pressure, and / or For a section of the fuselage (12) or wing panel (30), the backing plates (150, 150-1) form an outer mold line (OML) (131) and the mandrels (110, 110-1) form an inner mold line (IML) (133), or for a section of the fuselage (12) or wing panel (30), the backing plates (150, 150-1) form an inner mold line (IML) (133) and the mandrels (110, 110-1) form an outer mold line (OML) (131). The method according to claim 1 (200).

3. - Multiple bladders, wherein the backing plate (150) includes an opening (152) provided at the expansion port (162) for the bladder (160), and / or - Further comprising inserting the bladder (160, 160-1) into the stringer preform (164) before covering the preform (130, 130-1) with the backing plate (150, 150-1), Preferably, - To seal the aforementioned backing plates (150, 150-1) to the aforementioned bladder (160, 160-1), - Further includes inflating the bladder (160, 160-1), The method according to claim 1 or 2 (200), wherein sealing the backing plate (150, 150-1) to the bladder (160, 160-1) is performed by screwing a banjo bolt (170) into the expansion port (162, 162-1).

4. The method according to claim 3 (200), further comprising expanding the bladder (160, 160-1) by opening the inside of the bladder (160, 160-1) to atmospheric pressure when the sealed chamber (157) is evacuated, and optionally further comprising pressurizing and molding the stringer preform (164) by the expansion of the bladder (160, 160-1).

5. Sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) includes peripheral sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) via a first peripheral sealant (156), and preferably includes peripheral sealing the backing plates (150, 150-1) to the mandrel (110, 110-1) via a second peripheral sealant (158) which is disposed entirely inside the first peripheral sealant (156). The method according to any one of claims 1 to 4 (200), more preferably comprising peripheral sealing the backing plate (150, 150-1) to the mandrel (110, 110-1) via a third peripheral sealing material (155) which is disposed entirely inside the second peripheral sealing material (158), and most preferably further comprising subdividing the space between the first peripheral sealing material (156) and the second peripheral sealing material (158) into four sections (510, 520, 530, 540).

6. A part of an aircraft (10) assembled according to the method (200) described in any one of claims 1 to 5.

7. Apparatus (100, 100-1) for solidifying a fiber-reinforced material preform, - A mandrel (110, 110-1) having alignment features (114), - A backing plate (150, 150-1) that defines the surface of a preform (130, 130-1), comprising a backing plate containing a rigid material (111), - A sealing material (156, 158, 155) is disposed between the mandrel (110, 110-1) and the backing plate (150, 150-1), - One or more bladders (160, 160-1) are disposed between the backing plate (150, 150-1) and the mandrel (110, 110-1), Equipped with, - The apparatus further comprises a strongback (140) configured to transport the backing plates (150, 150-1), wherein the strongback (140) includes an alignment feature (142) configured to align with the alignment feature (114) of the mandrel (110, 110-1) to provide initial alignment, or - The backing plate (150, 150-1) includes an alignment feature (142) configured to align with the alignment feature (114) of the mandrel (110, 110-1) in order to provide initial alignment, - Apparatus (100, 100-1) including an opening (152) configured so as to be aligned with a port (162) of the bladder (160, 160-1) to provide fine alignment.

8. The mandrel (110, 110-1) further comprises a vacuum system (120) that controlsly applies a vacuum through the vacuum holes (116) of the mandrel (110, 110-1), and / or The sealing material (156, 158, 155) includes a first peripheral sealing material (156), preferably the sealing material (156, 158, 155) includes a second peripheral sealing material (158) that is disposed entirely inside the first peripheral sealing material (156), more preferably the sealing material (156, 158, 155) includes a third peripheral sealing material (155) that is disposed entirely inside the second peripheral sealing material (158), most preferably further including a space divided into four sections (510, 520, 530, 540) between the first peripheral sealing material (156, 420) and the second peripheral sealing material (158, 430), and / or The aforementioned backing plates (150, 150-1) are configured to compact the stringer preform (164) and the wing panel preform (189), and / or The aforementioned backing plates (150, 150-1) are configured to compact the half-barrel section (24) and / or The backing plates (150, 150-1) form an outer molded line (OML) (131), and the mandrels (110, 110-1) form an inner molded line (IML) (133), or the backing plates (150, 150-1) form an inner molded line (IML) (133), and the mandrels (110, 110-1) form an inner molded line (OML) (131), and / or The sealing material (156, 420, 158, 430, 155, 440) is disposed within the channel (410) on the mandrel (110, 110-1, 310) and / or The flap (450) extends from the backing plate (150, 150-1, 350) and / or, The aforementioned backing plates (150, 150-1) further comprise a vacuum system (120, 120-1) that controlsly applies vacuum through vacuum holes (116-2) in the backing plates (150, 150-1), and / or The apparatus (100, 100-1) according to claim 7, wherein the vacuum system (120-1) applies a controllable vacuum through the vacuum holes (116-1) in the sealing material (156, 158, 155).

9. The bladder (160, 160-1) is placed within the stringer preform (164) and / or The expansion ports (162, 162-1) for the bladder (160, 160-1) are installed through the openings of the backing plates (150, 150-1), and preferably further comprising banjo bolts (170) for attaching the expansion ports (162, 162-1) to the backing plates (150, 150-1). The apparatus according to claim 7 or 8 (100, 100-1).

10. The apparatus is configured for compacting a fiber-reinforced material preform (130, 130-1), and further comprises a chamber (157) sealed by a mandrel (110, 110-1), a backing plate (150, 150-1), and a peripheral sealant (156, 158, 155) between the mandrel (110, 110-1) and the backing plate (150, 150-1), preferably the mandrel (110, 110-1) further comprises a vacuum system (120, 120-1) for controllably applying a vacuum between the backing plate (150, 150-1) and the layup surface (112) of the mandrel (110, 110-1), By choice, The sealing material (156, 420, 158, 430, 155, 440) is disposed within the channel (410) on the mandrel (110, 110-1, 310), preferably the channel (410) has a semicircular cross-section, and / or The aforementioned backing plates (150, 150-1, 350) include an elastomer flap (450) and / or The aforementioned backing plates (150, 150-1) form the half-barrel shape of the half-barrel section (24) with respect to the section of the fuselage (12), and / or The apparatus (100, 100-1) according to any one of claims 7 to 9, wherein the backing plates (150, 150-1) form the shape of the wing panel (130) of the wing (15, 16).

11. The apparatus (100, 100-1) according to claim 10, wherein the backing plate (150, 150-1) includes an opening (152) disposed at the expansion port (162, 162-1), preferably the bladder (160, 160-1) is disposed between the backing plate (150, 150-1) and the mandrel (110, 110-1) and disposed at the expansion port (162, 162-1), more preferably further comprising a banjo bolt (170) for fixing the expansion port (162, 162-1) to the opening (152) of the backing plate (150, 150-1), most preferably the banjo bolt (170) includes threading complementary to the threading at the expansion port (162, 162-1).

12. The peripheral sealant (156, 158, 155) includes the first peripheral sealant (156), preferably the peripheral sealant (156, 158, 155) includes the second peripheral sealant (158) which is disposed entirely inside the first peripheral sealant (156), more preferably the peripheral sealant (156, 158, 155) includes the third peripheral sealant (155) which is disposed entirely inside the second peripheral sealant (158), most preferably the peripheral sealant (156, 158, 155) further includes a space divided into four sections (510, 520, 530, 540) between the first peripheral sealant (156) and the second peripheral sealant (158). The apparatus according to claim 10 or 11 when dependent on claim 8 (100, 100-1).

13. The apparatus (100, 100-1) according to any one of claims 10 to 12, wherein the backing plates (150, 150-2) form an outer mold line (OML) (131), the mandrel (110) forms an inner mold line (IML) (133), and / or the mandrel (110, 110-1) forms an outer mold line (OML) (131), and the backing plates (150, 150-1) form an inner mold line (IML) (133).

14. The sealing material (156, 420, 158, 430, 155, 440) is disposed within the channel (410) on the mandrel (110, 110-1, 310), preferably the channel (410) has a semicircular cross-section, and / or The aforementioned backing plates (150, 150-1, 350) include an elastomer flap (450) and / or The aforementioned backing plates (150, 150-1) form a half-barrel shape of the half-barrel section (24) relative to the section of the fuselage (12), and / or The aforementioned backing plates (150, 150-1) form the shape of the wing panel (130) of the wing (15, 16). The apparatus according to any one of claims 10 to 13 (100, 100-1).

15. Manufacturing of a part of an aircraft (10) using the apparatus (100, 100-1) described in any one of claims 7 to 14.

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