Tool assembly and heating method, manufacturing method, and method for coating composite materials

Abstract

The present application relates to a tool assembly and a heating method, a manufacturing method, and a method for coating a composite material. A tool assembly for composite part manufacturing includes a first component, a second component, and a fastener. The first component has a first joint portion including a top surface and at least a first interlocking surface. The second component has a second joint portion configured to interlock with the first joint portion. The second joint portion includes a top surface and at least a second interlocking surface complementary to the first interlocking surface. The fastener extends through the first joint portion and the second joint portion. The first interlocking surface and the top surface of the first joint portion form an obtuse angle, and the second interlocking surface and the top surface of the second joint portion form an acute angle. The first interlocking surface is configured to contact the second interlocking surface to prohibit relative movement between the first component and the second component along the longitudinal axis of the tool assembly.

Description

[0001] Government licensing rights

[0002] This invention was made with U.S. Government support under Contract No. FA8650-17-C-5715 awarded by the U.S. Department of Defense. The U.S. Government has certain rights in this invention. Technical Field

[0003] The present disclosure generally relates to tool assemblies and joints therefor for composite part manufacturing. Background Art

[0004] Forming large composite parts (also referred to as workpieces) such as composite aircraft parts (e.g., wings, fuselages, sections, etc.) may require large tools. Such tools include draping tools, support tools, build-up face tools (often referred to as molds or mandrels), etc. These tools are used in various composite part forming processes such as hand layup, automated layup, draping, hot draping, automated fiber placement, automated tape laying, curing, and finishing. These tools include faces (e.g., build-up face surfaces) for forming composite parts or supporting the formation of composite parts. The build-up face surfaces may include shapes, contours, and / or geometries that meet design specifications and are complementary to the composite part being formed.

[0005] Such tools are often made of metal and are monolithic components (i.e., a single structure consisting of multiple permanently joined parts, such as welded or bonded joints). In addition, these tools have precisely formed surfaces (e.g., within allowable tolerances) and must be able to withstand the weight of the composite part and the stringent requirements of forming the composite part. For example, a particular tool may be subjected to vacuum conditions (e.g., vacuum pressure) and high temperature conditions during composite forming and curing. If the tool deforms under heating, weight, or vacuum conditions and becomes outside the tolerances from the prior art, the vacuum conditions cannot be maintained, or the tolerances cannot be maintained, the tool cannot create the part and a new tool must be created. The production of the part may be stopped until the new tool is available. Moreover, sometimes during the design process, multiple tool designs (e.g., prototype tools or iterations of tools) are generated to improve the part forming process. As can be seen, current tools may have high manufacturing costs and / or have long manufacturing cycles. Summary of the invention

[0006] In a particular embodiment, the tool assembly includes a first component having a first joint portion including a top surface and at least a first interlocking surface. The tool assembly also includes a second component having a second joint portion configured to interlock with the first joint portion, the second joint portion including a top surface and at least a second interlocking surface complementary to the first interlocking surface. The tool assembly also includes a fastener extending through the first joint portion and the second joint portion. The first interlocking surface and the top surface of the first joint portion form an obtuse angle, and the second interlocking surface and the top surface of the second joint portion form an acute angle. The first interlocking surface is configured to contact the second interlocking surface to prohibit relative movement between the first component and the second component along the longitudinal axis of the tool assembly.

[0007] In another specific embodiment, the tool assembly includes a first component having a top surface and a first joint portion including at least a first interlocking surface. The tool assembly also includes a second component having a second joint portion configured to interlock with the first joint portion, the second joint portion including a top surface and at least a second interlocking surface complementary to the first interlocking surface. The tool assembly also includes a fastener extending through the first joint portion and the second joint portion. The first interlocking surface and the top surface of the first component form an obtuse angle, and the second interlocking surface and the top surface of the second joint portion form an acute angle. The first interlocking surface is configured to contact the second interlocking surface to prohibit relative movement between the first component and the second component along the longitudinal axis of the tool assembly.

[0008] In certain embodiments, a method of heating a tool assembly includes the steps of: engaging a first component of the tool assembly with a second component of the tool assembly via a first joint portion and a second joint portion. The method also includes the steps of: inserting a fastener through the first joint portion and the second joint portion of the tool assembly. The method also includes the steps of: applying heat to the tool assembly, wherein, upon heating, interlocking surfaces of the first joint portion and the second joint portion abut against each other.

[0009] In another specific embodiment, a method of applying a composite material to a tool assembly includes the steps of: joining a first part of the tool assembly to a second part of the tool assembly via a first joint portion and a second joint portion, wherein the tool assembly includes a buildup layer. The method also includes the steps of: applying the composite material to the buildup layer. The buildup layer is configured to support the formation of a composite part and has a shape that is complementary to the shape of the composite part.

[0010] In yet another specific embodiment, a method of manufacturing a tool assembly includes the steps of: forming a first joint portion of a first component of the tool assembly using an additive manufacturing process. The first joint portion includes a top surface and at least a first interlocking surface. The method also includes the steps of: forming a second joint portion of a second component of the tool assembly using an additive manufacturing process. The second joint portion includes a top surface and at least a second interlocking surface complementary to the first interlocking surface.

[0011] By using tool assemblies (e.g., multi-component tools), composite parts can be formed more quickly and at a reduced cost, as compared to single-component tools. In addition, by using tool assemblies having joints and interlocking surfaces, tool assemblies that support the formation of large composite parts (such as wing and fuselage sections) can be manufactured. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a block diagram illustrating an example of a composite part manufacturing system;

[0013] Figure 2 is an example of a method for Figure 1 Figure 2 is an isometric view of an example of a tool assembly for use with the system;

[0014] Figure 3 It is an example Figure 2 a diagram of an isometric view of a section of a tool assembly depicting a joint of the tool assembly;

[0015] Figure 4 It is an example Figure 3 another diagram of an exploded isometric view of a section of a tool assembly depicting a joint of the tool assembly;

[0016] Figure 5 It is an example Figure 2 FIG. 1 is an exploded front view of a joint portion of a tool assembly;

[0017] Figure 6 It is an example Figure 2 a diagram of a cross-sectional front view of a tool assembly depicting a particular joint of the tool assembly;

[0018] Figure 7 is a diagram illustrating a cross-section of another example of a tool assembly including a fastener;

[0019] Figure 8 The second fastener is illustrated. Figure 6 a cross-sectional view of a tool assembly;

[0020] Fig. 9A , Fig. 9B , Fig. 9C , Fig.9D , Fig.9E , Fig.9F , Figure 9G , Figure 9H , Fig.9I , Figure 9J , Figure 9K , Figure 9L , Figure 9M , Figure 9N as well as Fig.9OEach is a diagram illustrating an example of a joint portion of another example of a tool assembly;

[0021] Fig.10 is a diagram illustrating an example of components of a tool assembly including an O-ring;

[0022] Fig.11 is a diagram illustrating an example of a tool assembly including an O-ring and a backing plate;

[0023] Fig.12 is a diagram illustrating a specific example of components of a tool assembly including an O-ring and a band;

[0024] Fig.13 is a diagram illustrating another example of components of a tool assembly including an O-ring and a band;

[0025] Fig.14 is a flow chart of an example of a method of heating a tool assembly;

[0026] Fig.15 is a flow chart of another example of a method of applying a composite material to a tool assembly;

[0027] Fig.16 is a flow chart of an example of a method of operating a composite part manufacturing system; and

[0028] Fig.17 is a block diagram of an illustrative embodiment of a vehicle including a composite part formed using a tool assembly. DETAILED DESCRIPTION

[0029] Embodiments disclosed herein enable the formation of composite parts (e.g., curing of large composite parts) using tool assemblies (i.e., multi-component tools). Examples of large composite parts in the context of aircraft are wing components, other parts such as leading edges, flaps, or wings, and fuselage components of aircraft. Other examples of large composite parts include rocket fuselages and stabilizers and ship hulls or boat shells. The components of the tool assembly are joined together by a joint portion to form a joint. The joint portion includes one or more interlocking surfaces that are self-interlocking and can withstand thermal expansion when heated and maintain a vacuum seal and vacuum integrity. For example, thermal expansion of the components of the tool assembly tightens the vacuum seal between the interlocking surfaces. The joint portions interlock so that the building surface of the tool assembly is within the design tolerance (i.e., not deformed to a shape outside the designed or desired tolerance). In addition, the joint portion is strong enough to enable handling of the working assembly. In some embodiments, the tool assembly includes: one or more fasteners that allow thermal expansion and improve joint strength to enable tool handling; and / or an adhesive material (e.g., an adhesive film or paste adhesive) that further secures the tool assembly and maintains the vacuum seal and vacuum integrity. Although "adhesive material" is described herein, any suitable type of material that adheres or bonds parts together (permanently or temporarily) can be used.

[0030] In some embodiments, the tool assembly includes one or more additively manufactured parts, such as pieces made by fused filament fabrication (FFF), such as fused deposition modeling (FDM), plastic jet printing (PJP), three-dimensional (3D) printing, powder bed machining, selective heat sintering (SHS), stereolithography (SLA), selective laser melting (SLM), selective laser sintering (SLS), etc. The additively manufactured tool pieces of the tool assembly are typically made of materials that are generally chemically inert, and thus, bonded joints or bonded butt joints between additively manufactured tool pieces may be difficult to form. In addition, the additively manufactured tool parts of the tool assembly are typically formed of materials that have anisotropic thermal expansion coefficients (i.e., the tool parts expand differently in different directions). This anisotropic thermal expansion may reduce the ability of the tool assembly to maintain vacuum integrity in a heated tool use environment (e.g., the manufacture of composite parts). By using a joint portion having interlocking surfaces as described herein, the tool assembly can include one or more additively manufactured parts and can support the formation of large composite parts.

[0031] Multi-component tool assemblies, such as the tool assemblies described herein, can have lower costs and reduced tool manufacturing cycles, as compared to solid metal tools. Additionally, multi-component tool assemblies having additively manufactured pieces can have lower costs and reduced tool manufacturing cycles, as compared to solid metal tools or metal tool assemblies. The lower costs and reduced manufacturing cycles of tool assemblies having additively manufactured pieces can reduce costs and manufacturing cycles associated with manufacturing composite parts (e.g., large composite parts) and systems including composite parts.

[0032] Figure 1 An example of a composite part manufacturing system 100 is illustrated, which includes a tool assembly 102, a layup apparatus 104, a vacuum system 106, a curing apparatus 108, and a controller 110. Composite part manufacturing system 100 enables the formation of a composite part such as composite part 190. Composite part manufacturing system 100 may include or correspond to a hand layup manufacturing system, an automated layup manufacturing system, a draping system, a thermal draping system, an automated fiber placement system, an automated tape laying system, a composite part finishing system, or a combination thereof.

[0033] The tool assembly 102 includes two or more components 112, 114. Figure 1 The illustrated embodiment illustrates that the tool assembly includes a first component 112 and a second component 114. In some embodiments, the first component 112 and the second component 114 are joined together, such as by interlocking, to form a build-up surface 116. In other embodiments, specific components of the two or more components 112, 114 include a build-up surface 116, or a subset of components of the two or more components 112, 114 of the tool assembly 102 include a build-up surface 116. The two or more components 112, 114 of the tool assembly 102 each include one or more joint portions 122, 124. Figure 1 The illustrated embodiment illustrates that the first component 112 includes a first joint portion 122, and the second component 114 includes a second joint portion 124. The second joint portion 124 is configured to interlock with the first joint portion 122. Each joint portion 122, 124 includes one or more interlocking surfaces 132, 134. Figure 1 The illustrated embodiment illustrates that the first joint portion 122 includes a first interlocking surface 132, and the second joint portion 124 includes a second interlocking surface 134. In addition, each joint portion 122, 124 includes a corresponding top surface 136. Further reference is made to Figures 3 to 6 as well as 9A to 9O Describes specific joints and interlocking surface structures (e.g., two interlocking surfaces that are configured to interlock).

[0034] The first interlocking surface 132 and the second interlocking surface 134 are complementary interlocking surfaces. For example, the first interlocking surface 132 and the second interlocking surface 134 are positioned at complementary angles relative to a particular reference plane or face. The first interlocking surface 132 and the second interlocking surface 134 are configured to interlock with each other and form a vacuum seal or maintain vacuum integrity. For illustration, the first interlocking surface 132 is configured to contact the second interlocking surface 134 to inhibit relative movement between the first component 112 and the second component 114. The interlocking surfaces 132, 134 can inhibit relative movement between the first component 112 and the second component 114 along a particular direction or axis or within a particular plane. Figure 2 As an example, the interlocking surfaces 132, 134 inhibit relative movement between the first component 112 and the second component 114 along the longitudinal axis 254. In other embodiments, the interlocking surfaces 132, 134 inhibit relative movement between the first component 112 and the second component 114 along the longitudinal axis 254. Figure 2 Relative movement of the horizontal axis 256.

[0035] The first interlocking surface 132 and the second interlocking surface 134 are also configured to release stress and strain from thermal expansion and processing. In some embodiments, the first interlocking surface 132 and the second interlocking surface 134 are configured to be "tightened" (e.g., by pushing the other and / or pushing toward each other to form a tighter seal) under high temperature conditions and / or vacuum conditions. For example, increasing the temperature of the joint portion 122, 124 may cause the joint portion 122, 124 to undergo thermal expansion, and the thermal expansion increases the force and pressure on the first interlocking surface 132 and the second interlocking surface 134, so that the first interlocking surface 132 and the second interlocking surface 134 are deformed at a microscopic level to engage with each other to a greater extent (e.g., as compared with the contact between the interlocking surfaces 132, 134 before thermal expansion, a larger portion of the first interlocking surface 132 and the second interlocking surface 134 contacts each other at a microscopic level). This deformation can enable a more airtight seal and / or generate more friction (i.e., more resistance to movement).

[0036] When one or more faces (e.g., top face 136) of components 112, 114 of tool assembly 102 are joined together, they define a build-up face 116. In a particular example, any face of components 112, 114 may be or define a build-up face 116. The build-up face 116 is configured to support the formation of composite part 190. For example, the build-up face 116 acts as a form, mold, or mandrel for the build-up apparatus 104 and composite material 142. For illustration, the shape of the build-up face 116 of tool assembly 102 is similar to or complementary to the shape of composite part 190. Composite material 142 (e.g., plies of fiber material embedded in a resin matrix) conforms to the shape of the build-up face 116 of tool assembly 102 under heat and / or pressure to form composite part 190.

[0037] The lamination device 104 is configured to position or deposit a composite material 142 on a lamination surface 116 of the tool assembly 102. The lamination device 104 includes or corresponds to an automatic lamination machine, an automatic tape laying machine, or an automatic fiber placement machine. The composite material 142 can be in the form of a tow, a tape, a ply, etc. The composite material 142 is two or more constituent materials that are combined to create a material having material properties that are different from the properties of the individual materials, such as a honeycomb panel, a fiber, and a resin. In some examples, the tool assembly 102 described herein can be used to form a composite material 142 made of fabric or fiber (glass fiber, carbon fiber, metal carbon fiber, The parts are made of composite material 142 which is a combination of aramid, aluminized glass fiber, etc.) and resin (epoxy resin, bismaleimide (BMI), vinyl ester, polyester).

[0038] In other embodiments, composite part manufacturing system 100 does not include layup apparatus 104. In such embodiments, layup apparatus 104 is separate from composite part manufacturing system 100, or layup is performed manually by hand.

[0039] Vacuum system 106 includes one or more components configured to generate and maintain a vacuum condition (e.g., a vacuum pressure that is less than an ambient pressure, or a vacuum seal). For example, vacuum system 106 includes pump 172, vacuum plate 174, and bladder 176, which are configured to generate and maintain a vacuum condition between or around composite material 142 and tool assembly 102. As another example, vacuum system 106 includes pump 172 and vacuum bag 178. Vacuum system 106 generates and maintains a vacuum condition during at least a portion of a manufacturing process of composite part 190.

[0040] The curing device 108 is configured to cure the composite material 142 to form a composite part 190. The curing device 108 may include a heating device 182, an illumination device 184, or a combination thereof. For example, the curing device 108 may include or correspond to a heater, a laser, an oven, an autoclave, etc. Additionally or alternatively, the curing device 108 includes or corresponds to an ultraviolet light source.

[0041] The controller 110 includes a processor 162 and a memory 164. The memory 164 stores computer executable instructions (e.g., a program of one or more instructions). The processor 162 is configured to execute the computer executable instructions stored in the memory 164. When the instructions are executed, one or more components of the composite manufacturing system perform a reference Fig.14 and Fig.15 One or more operations of a method are described.

[0042] Controller 110 is configured to control one or more components of composite part manufacturing system 100. For example, controller 110 may control or coordinate the operation of lamination device 104, vacuum system 106, curing device 108, or a combination thereof. For illustration, controller 110 generates one or more commands and sends the commands to one or more components of composite part manufacturing system 100.

[0043] Prior to operation of composite part manufacturing system 100, tool assembly 102 is assembled. For example, first joint portion 122 of first component 112 is mated with second joint portion 124 of second component 114 to form tool assembly 102 and its build surface 116. Because first component 112 and second component 114 may be large components (e.g., 5 ft. x 5 ft. or 10 ft. x 10 ft. segments), machinery (e.g., forklift, power jack, etc.) may be used to move and manipulate first component 112 and second component 114.

[0044] During operation of the composite part manufacturing system 100, the lamination device 104 applies or deposits the composite material 142 onto the build-up layer 116 of the tool assembly 102 in response to receiving commands from the controller 110. The vacuum system 106 generates and maintains vacuum conditions (e.g., vacuum pressure or vacuum seal), and the curing device 108 applies heat, light, or both to cure the composite material 142 in response to receiving commands from the controller 110. The composite material 142 undergoes a chemical reaction and / or deformation under the application of heat, light, or both to form a composite part 190. The formed composite part 190 has a molding surface that matches the molding surface of the tool assembly (e.g., the build-up layer 116).

[0045] In other embodiments, work part 192 is placed on build-up surface 116 of tool assembly 102 by build-up apparatus 104, mechanically, or by hand. Work part 192 is then trimmed (e.g., cut, machined, bent, etc.) into composite part 190. Work part 192 may be formed by one or more steps of the above-described process for creating composite part 190.

[0046] In some embodiments, the components 112, 114 of the tool assembly 102 are made of a thermoplastic polymer material (e.g., an acrylonitrile butadiene styrene (ABS) material or a carbon-filled ABS material), a thermosetting polymer material, or another polymer material. The components 112, 114 of the tool assembly 102 can be constructed using an additive manufacturing process (such as filament fabrication, fused deposition modeling, plastic jet printing, 3D printing, powder bed machining, selective thermal sintering, stereolithography, selective laser melting, selective laser sintering, etc.).

[0047] In some such embodiments, as described with reference to Figures 6 to 8As depicted, the components 112, 114 of the tool assembly 102 are joined with one or more fasteners 118, adhesives, or a combination thereof. The adhesive is configured to help maintain vacuum integrity, and the fasteners 118 are configured to support movement of the tool assembly 102 due to thermal expansion of the tool assembly 102 and / or the setting of adhesive materials. As an illustrative example, the tool assembly 102 includes a fastener 118 that extends through a first joint portion 122 and a second joint portion 124.

[0048] Thus, composite part manufacturing system 100 can enable manufacturing of large composite parts 190 using tool assembly 102. Specifically, composite part manufacturing system 100 can enable manufacturing of large composite parts 190 using tool assembly 102 that is formed from components 112, 114 that have been additively manufactured. Because tool assembly 102 reduces cost and manufacturing time, manufacturing of composite parts reduces cost and design time, as compared to metal single-component tools. Additionally, by using tool assembly 102 that includes joint portions 122, 124, composite part manufacturing system 100 can form larger composite parts, as compared to forming smaller composite parts using smaller tool assemblies joined by butt joints.

[0049] Figure 2 is a diagram illustrating an isometric view of an example of tool assembly 102 . Figure 2 The diagram of FIG. 1 illustrates the tool assembly 102 along a vertical axis 252, a longitudinal axis 254, and a horizontal axis 256. Figure 2 As illustrated, the tool assembly 102 includes the first component 112 , the second component 114 , and the third component 202 . Figure 2 A diagram of a longitudinally aligned tool assembly 102 is illustrated, wherein components 112, 114, 202 are disposed along a longitudinal axis 254. In other embodiments, the tool assembly 102 can be peripherally aligned, such as aligned around a center of a circle along at least a portion of a periphery of the circle. In certain embodiments, the tool assembly 102 includes one or more peripherally aligned components, one or more longitudinally aligned components, or a combination thereof.

[0050] like Figure 2 As shown, the build-up surface 116 is formed by or corresponds to the top surface 136 of the component 112, 114, 202. In other embodiments, the build-up surface 116 includes one or more other surfaces of the component 112, 114, 202, such as a side surface, a bottom surface, a cutout surface (e.g., a surface of the cutout 212), or a combination thereof.

[0051] In some embodiments, one or more of components 112, 114, 202 include cutouts 212. Cutouts 212 are configured to reduce the weight and volume of tool assembly 102, provide a portion of bulk surface 116, trim composite part 190, or a combination thereof. Additionally, cutouts 212 may enable transportation of tool assembly 102 and its components 112, 114, 202. For example, a forklift fork may be inserted through one or more of cutouts 212 to lift, move, manipulate, and assemble tool assembly 102. Additionally or alternatively, one or more components 112, 114, 202 of tool assembly 102 include ribs or brackets (not shown) that enable movement or manipulation of tool assembly 102 or its components 112, 114, 202. For example, the ribs or brackets may form a channel or guide for the forks of a forklift or a lifting device of another moving equipment.

[0052] As reference Figure 3 As described and illustrated, components 112, 114, 202 are composed of components such as Figure 1 The joint portions 122 and 124 are joined. Figure 2 Also depicted is section line AA oriented along a longitudinal axis 254 through the components 112 , 114 , 202 . 9A to 9O The joints of components 112, 114, 202 (such as Figure 1 Other examples of the joint portions 122, 124).

[0053] Figure 3 It is an example Figure 2 FIG. 1 is an isometric view of the tool assembly 102 taken along section line AA, depicting the joints 302 , 304 of the tool assembly. Figure 3 An example joint scheme of the tool assembly 102 is illustrated. Figure 3 As shown, the tool assembly 102 includes a first component 112 having a female connector, a second component 114 having two male connectors, and a third component 202 having a female connector. In other embodiments, the tool assembly 102 may include one or more components having a male connector, a female connector, two male connectors, two female connectors, a male and female connector, or a combination thereof. As further described in Figure 4 As illustrated and described, the first joint 302 is formed by the first component 112 and the second component 114 , and the second joint 304 is formed by the second component 114 and the third component 202 .

[0054] In some embodiments, the joint 302, 304 extends along the width of the component 112, 114, 202 on the transverse axis 256. In other embodiments, the component 112, 114, 202 includes one or more segments of the joint 302, 304 along the transverse axis 256. For example, the components 112, 114, 202 are joined by one or more segments of the joint 302, 304 and segments of one or more other joints (e.g., butt joints) placed between the segments of the joint 302, 304 along the transverse axis 256.

[0055] Figure 4 It is an example Figure 3 Another diagram of an expanded isometric view of a section of the tool assembly 102 is shown, depicting the joints 302, 304 of the tool assembly. Figure 4 As illustrated, the second component 114 includes a third joint portion 422, and the third component 202 includes a fourth joint portion 424. The third joint portion 442 of the second component 114 is configured to engage with the fourth joint portion 424 of the third component 202 of the tool assembly 102. Thus, Figure 4 Depicted are a first joint 302 formed by first and second joint portions 122 , 124 of first and second components 112 , 114 , and a second joint 304 formed by third and fourth joint portions 422 , 424 of second component 114 and third component 202 .

[0056] In some embodiments, the third joint portion 442 has a shape similar to the first joint portion 122 or the second joint portion 124. Figure 4 The illustrated embodiment illustrates that the third connector portion 442 has a shape similar to that of the second connector portion 124 (eg, a male connector portion shape), and the fourth connector portion 444 has a shape similar to that of the first connector portion 122 (eg, a female connector portion shape).

[0057] like Figure 4 As shown, the male connector (i.e., the second connector 124 and the third connector 422) include tabs 402 (e.g., protrusions) that are embedded in recesses of the female connector (i.e., the first connector 122 and the fourth connector 424). Figure 4 and Figure 5 For example, the faces of the connector portions 122, 124, 422, 424 may include angled faces (e.g., Figure 5 interlocking surfaces 132, 134, 516, 536). An angled surface (e.g., Figure 5 The interlocking surfaces 132, 134, 516, 536) may help the joints 302, 304 accommodate thermal expansion of the components 112, 114, 202 better than horizontal or vertical surfaces.

[0058] The thermal expansion of a component is based on or governed by some characteristics of the component, such as material composition, structure (e.g., microstructure such as wood grain or fiber structure), and size. For linear thermal expansion (e.g., thermal expansion along a specific axis), the thermal expansion of a component depends on the length of the component along the specific axis and a specific thermal expansion coefficient along the specific axis, which depends on the material and structure. To illustrate, for the first component 112, because the length of the first component 112 on the longitudinal axis 254 is greater than the thickness of the first component 112 on the vertical axis 252 and because the thermal expansion coefficient along the longitudinal axis 254 is greater than the thermal expansion coefficient along the vertical axis 252, the thermal expansion along the longitudinal axis 254 is much greater than the thermal expansion along the vertical axis 252 (e.g., 100 times greater). In a particular embodiment, because the fibers of the material are oriented with the longitudinal axis 254, the material of the first component 112 has a thermal expansion coefficient on the longitudinal axis 254 that is, for example, 10 times greater than the vertical axis 252. Thermal expansion along the lateral axis 256 is generally parallel to the orientation of the joints 302 , 304 , and thus, thermal expansion along the lateral axis 256 affects the joints 302 , 304 by a smaller amount than thermal expansion along the vertical or longitudinal axes 252 , 254 .

[0059] For conventional joints, this difference in thermal expansion between the axes 252, 254 may cause Figure 1 For example, the joint portions 122, 124 may deflect along the vertical axis 252 (e.g., as Figure 4 exemplified upward) and deform the volume surface. Figure 4 In the illustrated embodiment, the geometry of the tab 402 allows the tab 402 to remain in place or as Figure 4 The illustrated downward deflection thereby maintains the build-up layer 116. Additionally, fasteners or adhesives may be added to keep the tabs 402 in place or resist deflection about the vertical axis 252, which maintains the geometry of the build-up layer 116.

[0060] Figure 5 It is an example Figure 2 FIG. 1 is an exploded view of the joint portions 122 , 124 of the first component 112 and the second component 114 of the tool assembly 102 . The exploded view is a cross-section of the first joint portion 122 and the second joint portion 124 .

[0061] The first joint portion 122 of the first component 112 includes a top surface 136a, intermediate surfaces 514, 518, a vertical edge surface 520, a bottom surface 522, a first interlocking surface 132, and a third interlocking surface 516. Figure 5As shown, the top surface 136a of the first component 112 is also a portion of the laminate surface 116. In some embodiments, the vertical edge surface 520 includes a notch 592. In some such embodiments, a portion of the vertical edge surface 520 contacts the second joint portion 124, such as Figure 5 The portion of the vertical edge surface 520 below the notch 592 is illustrated.

[0062] The top surface 136a and the first interlocking surface 132 form an obtuse corner 552 (e.g., an obtuse edge). The first interlocking surface 132 and the first intermediate surface 514 form an obtuse corner 554. The first intermediate surface 514 and the third interlocking surface 516 form an obtuse corner 556. The third interlocking surface 516 and the second intermediate surface 518 form another obtuse corner 558. The second intermediate surface 518 and the vertical edge surface 520 form a substantially right angle corner 560. The vertical edge surface 520 and the bottom surface 522 form a substantially right angle corner 560.

[0063] The second joint portion 124 of the second component 114 includes a top surface 136b, intermediate surfaces 534, 538, a vertical edge surface 540, a bottom surface 542, a second interlocking surface 134 and a fourth interlocking surface 536. Figure 5 As an example, the top surface 136 b of the second component 114 is also a part of the build-up surface 116 .

[0064] The top surface 136b and the second interlocking surface 134 form an obtuse corner 572. The second interlocking surface 134 and the first intermediate surface 534 form an obtuse corner 574. The second intermediate surface 538 and the fourth interlocking surface 536 form an obtuse corner 576. The fourth interlocking surface 536 and the second intermediate surface 538 form an obtuse corner 578. The second intermediate surface 538 and the vertical edge surface 540 form a substantially right angle corner 580. The vertical edge surface 520 and the bottom surface 522 form another substantially right angle corner 560.

[0065] In some embodiments, the interlocking surfaces 132, 134, 516, 536 are relative to Figure 2 The longitudinal axis 254 of the tool assembly 102 is oriented at a 45 degree angle. By orienting the interlocking surfaces 132, 134, 516, 536 as opposing surfaces at 45 degree angles or 135 degree angles, the joint 304 becomes self-locking. These 45 degree or 235 degree angles of opposing surfaces help mitigate cracks in the bonds (e.g., bond lines) of the joint 304 that occur from thermal stresses encountered by the tool assembly 102 during curing. By mitigating these cracks in the bond lines, the tool assembly 102 is able to Figure 1 Maintaining vacuum integrity (eg, maintaining an applied vacuum pressure) during fabrication of composite part 190 .

[0066] In some embodiments, the interlocking surfaces 132, 134, 516, 536, top surfaces 136a, 136b, intermediate surfaces 514, 518, 534, 538, or vertical edge surfaces 520, 540 of the joint portion 122 form rounded (e.g., rounded) or chamfered corners 590. Thus, one or more of the acute corners 527 or the obtuse corners 552, 554, 556, 574, 576 are rounded or chamfered corners 590. Figure 5 As an example, the obtuse corners 554, 556, 574, 576 are rounded (e.g., chamfered) corners 590. Such rounded or chamfered corners 590 can reduce localized stress and strain maxima, and therefore, can reduce damage or cracking of the joint portions 122, 124. For example, rounded (e.g., chamfered) or chamfered corners and edges are less likely to cause localized stress and strain maxima, and therefore, less likely to cause damage or cracking, as compared to sharp corners (e.g., acute corners and / or non-rounded or chamfered corners) or right-angled edges and corners.

[0067] The first joint portion 122 and the second joint portion 124 further include tangs 582, 584, respectively. The tangs 582, 584 are configured to contact each other to form a joint. For example, the tangs 582, 584 contact each other via the vertical edge surfaces 520, 540 below the notch 592. Figure 6 As shown, the tangs 582, 584 form a trapezoidal shape when joined. Figure 7 and Figure 8 As depicted, tangs 582, 584 provide space for fasteners.

[0068] Figure 6 It is an example Figure 2 FIG. 1 is a diagram of a cross-sectional front view of a tool assembly 102 depicting a joint of the tool assembly. Figure 6 The gaps 602-606 formed by the joint portions 122, 124 of the first component 112 and the second component 114 are illustrated. Figure 6 As illustrated, the interlocking surfaces 132 , 134 and the interlocking surfaces 516 , 536 are in contact and interlock.

[0069] like Figure 6 For example, when the first joint portion 122 and the second joint portion 124 are engaged (for example, tightly fitted), Figure 5 The surfaces 514, 534 form a first gap 602 (eg, the first gap is disposed between and defined by the two surfaces), Figure 5 The surfaces 518, 538 form a second gap 604 (eg, the second gap is disposed between and defined by the two surfaces), and are Figure 5The vertical edge surfaces 520, 540 form a third gap 606 (eg, the third gap is disposed between and defined by the two surfaces). Figure 6 As shown, the third gap 606 ends at the notch 592. Figure 6 As illustrated by the dashed rectangle in FIG. 6 , the ends of the gap 606 and the notch 592 may define the upper portions of the tangs 582 , 584 .

[0070] exist Figure 6 In the embodiment, the second gap 604 and the third gap 606 are connected. In other embodiments or under certain conditions such as thermal expansion, the second gap 604 and the third gap 606 are not connected. For example, Figure 5 One or more of the surfaces 518, 520, 538, 540 is close to Figure 5 The corners 560 and 576 of Figure 5 contact with a portion of another one of the surfaces 518, 520, 538, 540. Figure 6 Section line BB through first gap 602 is also depicted.

[0071] In some embodiments, the joint 302 includes an adhesive material 612 configured to form a bond (e.g., a bond line) between the faces of the joint 302. In a specific embodiment, the adhesive material 612 is applied to at least a portion of one of the first or second joint portions 122, 124. For example, the adhesive material 612 is applied to a specific portion of the first joint portion 122 and the second joint portion 124, such as the faces of the first joint portion 122 and the second joint portion 124 corresponding to the gaps 602-606. In this embodiment, the gaps 602-606 define bond lines, which are areas where the faces of the first joint portion 122 and the second joint portion 124 are bonded by the adhesive material 612. The bond lines help enable the joint 302 to maintain vacuum integrity. For example, the gaps 602-606 in the joint 302 provide space for the adhesive material 612 and prohibit the movement of the adhesive material 612 to maintain the vacuum integrity of the joint 302. In addition, the gaps 602-606 provide space for the thermal expansion of the material of the tool assembly 102.

[0072] The adhesive material 612 may include a thermosetting polyimide, a benzoxazine resin, a bismaleimide, a thermosetting polyurethane, an epoxy resin, a phenolic resin, or a vinyl ester. The adhesive material 612 may include or correspond to a paste adhesive or an adhesive film. The adhesive film may have a higher heat resistance (e.g., being able to withstand high temperatures without deformation or reduction in adhesive strength) than a paste adhesive, but may be more difficult to assemble.

[0073] Figure 7 It is an example Figure 11, a cross-sectional view of another example of a tool assembly 102 including a first example of a fastener 118. More specifically, the first example of the fastener 118 is a fastener assembly 702. Figure 7 As shown, the fastener assembly 702 includes a bolt 712, a washer 714, a spring 716, and a nut 718. In other embodiments, the spring 716 may be replaced with other biasing members, such as a spring washer, a Belleview washer, and the like.

[0074] The fastener assembly 702 is at least partially positioned in a clearance hole (not shown) that passes through the tangs 582, 584 of the first and second connector portions 122, 124. Figure 7 As illustrated, the fastener assembly 702 is oriented generally parallel to the build surface 116 and the top surfaces 136a, 136b of the first component 112 and the second component 114. Figure 7 , the fastener assembly 702 is at least partially positioned in a countersunk bore (eg, a recess). Figure 7 As shown, the fastener assembly 702 extends through the tangs 582, 584 of the first connector portion 122 and the second connector portion 124. In some embodiments, along Figure 2 The transverse axis 256 of the embodiment of the present invention positions the plurality of fastener assemblies 702 through the tangs 582 , 584 to engage the first component 112 and the second component 114 .

[0075] When in a high temperature environment, such as when curing a composite part or when heated, the spring 716 enables the fastener assembly 702 to maintain a holding force that engages the first component 112 and the second component 114 while allowing for thermal expansion of the first component 112 and the second component 114. Specifically, the spring 716 can deform (e.g., expand and compress) so that the fastener assembly 702 provides a holding force over varying lengths or stages of thermal expansion. In addition, the fastener assembly 702 is configured to relieve stress and strain on the tool assembly 102 when the tool assembly 102 is moved or handled. In addition, the fastener assembly 702 helps maintain the vacuum integrity of the tool assembly 102.

[0076] Figure 8 It is an example Figure 1 A second example of a fastener 118 Figure 6 102. More specifically, the second example of the fastener 118 is the second fastener assembly 802. Figure 8As shown, the second fastener assembly 802 includes a screw 812, a washer 714, and a spring 716. In other embodiments, the second fastener assembly 802 includes a different biasing member instead of the spring 706. Alternatively, the second fastener assembly 802 includes or corresponds to a single-sided fastener. In this embodiment, the second component 114 includes a threaded segment or a cap nut.

[0077] The second fastener assembly 802 is configured to engage the first component 112 and the second component 114. Figure 8 As shown, the first component 112 includes a countersunk bore 804, and the second fastener assembly 802 is inserted into the countersunk bore 804. The shank of the screw 812 passes through a clearance hole 806 of the first component 112 where the threads 811 of the screw 812 do not engage (i.e., contact) the first component 112. The threads 822 and the screw head of the far end of the screw 812 opposite the washer 714 engage (i.e., contact) the second component 114 in the guide hole 808. Although the screw 812 is in the Figure 8 804 is illustrated as fully threaded, but in other embodiments, a portion of the shank of the screw 812 is unthreaded (e.g., a partially threaded screw 812 or shank). In other embodiments, the first component 112 includes a countersunk hole or recess as an alternative to the countersunk hole 804.

[0078] Because the screw 812 of the second fastener assembly 802 is driven into the second component 114 (e.g., the top component of the joint 302), the second fastener assembly 802 secures (e.g., pushes) the components 112, 114 together, which stabilizes the joint 302. Because the threads 822 of the screw 812 pass through the clearance hole 806 of the first component 112, the second fastener assembly 802 enables the material of the tool assembly 102 to expand in a high temperature environment (e.g., causing the first component 112, the second component 114 and / or the gap 603 to expand and contract). The spring 716 enables thermal expansion of the tool assembly 102 and can inhibit the transfer of stress and strain caused by thermal expansion of the tool assembly 102 into the screw 812 itself. The second fastener assembly 802 helps maintain the vacuum integrity of the tool assembly 102. In some embodiments, along the centerline of the joint 302 (along the gap hole 806 between the first and second components 112, 114), the second fastener assembly 802 can be tightened. Figure 2 A plurality of second fastener assemblies 802 are placed along the transverse axis 256 .

[0079] 9A to 9O Each is a diagram illustrating an example of a joint portion of another joint used for the tool assembly 102 . 9A to 9O A cross-sectional view of a joint is illustrated. Fig. 9A and Fig. 9B Examples of lap joints are illustrated (eg, half-lap splice joints). Fig. 9A Examples include Figure 1 An example cross-section of a half-lap splice joint 910 of a third example of the fastener 118 (i.e., the third fastener assembly 902). Fig. 9A As illustrated, third fastener assembly 902 includes a bolt 712 , two washers 714 , and a nut 718 . Fig. 9B Examples include Figure 1 Another example cross-section of a half-lap splice joint 910 of a fourth example of the fastener 118 (i.e., the fourth fastener 904). Fig. 9B By way of example, the fourth fastener 904 includes or corresponds to a screw, such as Figure 8 Screw 812.

[0080] FIG. 9C to FIG. 9G An example of a tongue and groove joint 920 is illustrated. Fig. 9A and Fig. 9B Compared with lap joint 910, FIG. 9C to FIG. 9G The tongue and groove joint 920 has an insert or tongue 922 which is placed in Figure 1 The surface 116 and the joints 122 and 124 are Figure 5 The top surface 136a, 136b or Figure 5 Between the bottom surfaces 522 and 542. FIG. 9C to FIG. 9G For example, the tongue 922 is oriented Figure 1 The surface 116 of the accumulation layer and the top surfaces 136a, 136b of the first and second components are Figure 2 below or directly below the vertical axis 252.

[0081] Figures 9H to 9K A miter joint 930 (eg, a pointed miter joint) is illustrated. Figures 9H to 9K The miter joint 930 includes interlocking surfaces 132, 134 and a cusp 934 (eg, a blunt portion or feature that engages a matching shoulder in a mating component). The interlocking surfaces 132, 134 are angled relative to the top surfaces 136a, 136b.

[0082] Fig.9I and Figure 9J An example of a pointed miter joint 930 having a third fastener component 902 is illustrated. Figure 9H Compared with the pointed 934, Fig.9I The tip of 934a is Figure 2 larger or deeper on the vertical axis 252. Figure 9H and Figure 9K An example of a pointed miter joint 930 having a fourth fastener 904 is illustrated. Figure 9H and Fig.9I Compared with the pointed tips 934 and 934a, Figure 9J and Figure 9KThe top surfaces 136a, 136b correspond to the pointed tip 934b (e.g., Figure 9J and Figure 9K The illustrated upper tip 934 b ) has an angled surface 936 and forms an obtuse corner 937 or outer edge 938 with the angled surface 936 .

[0083] Figure 9L An example of a bevel lap joint 940 is illustrated (eg, a bevel lap splice joint). Fig. 9A and Fig. 9B Compared to the half-lap splice 910, the bevel lap splice 940 has an angled intermediate surface 942. The angled intermediate surface 942 includes a pair of complementary intermediate surfaces that are positioned at an angle relative to the surface 116 of the building.

[0084] Figure 9M Examples of combination joints 950 (e.g., bevel lap joints and miter joints) are illustrated. The combination joint 950 includes a miter joint 930 where the tip 934 is a bevel lap joint 940. Figure 9M As shown, the miter joint 930 begins at one end of the bevel lap joint 940. Figure 9L Compared with the bevel lap joint 940, Figure 9M The combined joint 950 includes an angled miter 952 that includes interlocking surfaces 132, 134. Figure 9M As shown, the combined joint 950 includes a fourth fastener 904 inserted into a countersunk hole 804 of the second joint portion 124 of the second component 114. In some embodiments, the second joint portion 124 includes a clearance hole 806, and the threads 822 of the third fastener component 902 do not contact the second joint portion 124 in the clearance hole 806. Figure 9M As shown, the fourth fastener 904 is oriented at an angle relative to the surface 116 and the top surfaces 136a, 136b of the first and second components 112, 114. The fourth fastener 904 is oriented generally orthogonal to the angled miter 952 and passes through the tangs 582, 584 of the first and second joint portions 122, 124.

[0085] Figure 9N An example of an angled chisel joint 960 (also known as a hook-shaped miter joint) is illustrated. Figure 9N Illustratively, the angled chime split joint 960 includes a fourth fastener 904 that is inserted into the countersunk hole 804 of the first joint portion 122. In some embodiments, the first joint portion 122 includes a clearance hole 806, and the threads 822 of the screw 812 do not contact the first joint portion 122 in the clearance hole 806.

[0086] like Figure 9NAs shown, the fourth fastener 904 and the countersunk bore 804 are oriented substantially orthogonal to the angled intermediate surface 944 and relative to Figure 1 The fourth fastener 904 and / or one or more additional fasteners (such as one of the fasteners 118, 904 or one of the fastener assemblies 702, 802, 902) may be disposed along the top surface 136a, 136b of the first component 112 and the second component 114. Additionally or alternatively, the fourth fastener 904 and / or one or more additional fasteners (such as one of the fasteners 118, 904 or one of the fastener assemblies 702, 802, 902) may be disposed along the top surface 136a, 136b of the first component 112 and the second component 114. Figure 2 The vertical axis 252 is substantially perpendicular to Figure 1 The interlocking surfaces 132, 134, 516, 536 disposed at an angle relative to the building surface 116 and the intermediate surfaces 514, 534 substantially parallel to the building surface 116 are shown. Figure 5 and Figure 6 Compared with the joint 302, Figure 9N The angled chimeric splice joint 960 includes vertical interlocking surfaces 962, 964 and angled intermediate surfaces 942, 944. The vertical interlocking surfaces 962, 964 each include a pair of complementary interlocking surfaces (eg, such as interlocking surfaces 132, 134) that are generally orthogonal to the building surface 116.

[0087] Fig.9O An example of an angled chiseled split joint 960 having interlocking surfaces 132, 134, 516, 536 positioned at an angle relative to the build surface 116 is illustrated. Fig.9O As shown, the first joint portion 122 of the angled joint 960 includes a countersunk hole 804 and a clearance hole 806, and the second joint portion 124 includes a pilot hole 808 for receiving a fastener such as the fourth fastener 904. Alternatively, the pilot hole 808 can be replaced with a threaded portion of a blind fastener (e.g., a cap nut) or configured to receive the threaded portion, so that the first joint portion 122 and the second joint portion 124 can be engaged with the blind fastener. Fig.9O For example, holes 804-806 are arranged along Figure 2 The vertical axis 252 is substantially perpendicular to Figure 1 The second angled intermediate surface 944 is oriented approximately perpendicular to the second angled intermediate surface 944 and relative to the first component 112 and the second component 114. In addition or alternatively, a fastener (such as one of the fasteners 118, 904 or one of the fastener assemblies 702, 802, 902) can be oriented approximately perpendicular to the second angled intermediate surface 944 and relative to the first component 112 and the second component 114. Figure 1 The surface 116 of the first component 112 and the top surface 136a, 136b of the second component 114 are angled. Figure 5 and Figure 6 Compared with the joint 302, Fig.9O The angled chimeric splice joint 960 includes angled intermediate surfaces 942 , 944 .

[0088] In some embodiments, the angled chimeric splice connector 960 is as shown in FIG. Fig.9O The illustrated example includes gaps 602-606. The gaps 602-606 can be configured to receive adhesive material 612, keys, or wedges. For example, the gaps 604, 606 can include key holes and be configured to receive keys or wedges. Insertion of the key or wedge tightens the angled chiseled split joint 960.

[0089] FIG. 9A to FIG. 9N Depicted with a particular type of fastener, such as one of the third fastener assembly 902 or the fourth fastener 904. In other embodiments, other types of fasteners may be used with 9A to 9O The depicted examples are used together, such as one or more of fasteners 118, 904 or one or more of fastener assemblies 702, 802, 902. In some embodiments, 9A to 9O The joints 910-960 include one or more additional fasteners. For example, the example joints may include multiple fasteners of a certain type as illustrated and / or one or more additional fasteners of another type. Additionally or alternatively, 9A to 9O The connectors 910-960 also include Figure 6 of adhesive material 612. In some embodiments, 9A to 9O The corners or edges of the joint are rounded corners or chamfered corners.

[0090] Fig.10 1 is a diagram illustrating an example of a component (such as the first component 112) of a tool assembly 102 including an annular ring seal 1002 (e.g., a tubular seal or an O-ring seal). In some examples, the annular ring seal 1002 is cylindrical with an inlet and an opposing outlet. The annular ring seal 1002 is positioned between the first interlocking surface 132 and the second interlocking surface 134 ( Fig.10 Annular ring seal 1002 is configured to create or maintain an airtight seal between interlocking surfaces 132, 134. For example, engagement of first component 112 and second component 114 (e.g., joint portions 122, 124 thereof) compresses annular ring seal 1002 and creates or maintains a vacuum seal. Fig.10 As shown, the annular ring seal 1002 is positioned in the middle of the first interlocking surface 132 and extends along the first interlocking surface 132 on the lateral axis 256. In other embodiments, the annular ring seal 1002 can be positioned on the first interlocking surface 132 closer to or further away from the top of the tool assembly 102 (e.g., the build surface 116).

[0091] In some embodiments, one or both of the interlocking surfaces 132, 134 include a recess that accommodates the annular ring seal 1002. The recess is configured to enable the annular ring seal 1002 to be inserted or placed when the tool assembly 102 is disassembled, and to retain the annular ring seal 1002 when the tool assembly 102 is assembled.

[0092] In some embodiments, the annular ring seal 1002 serves as Figure 6 Alternatives to the adhesive material 612 are used, for example, when the tool assembly 102 is not exposed to significant processing (e.g., processing conditions that cause loads to create deflections greater than the adhesive material 612 or an adhesive bond formed therefrom can withstand).

[0093] In other embodiments, the annular ring seal 1002 is provided with Figure 6 The annular ring seal 1002 may be used together with the adhesive material 612. For example, the annular ring seal 1002 provides an additional seal or backup seal so that cracks in the adhesive bond formed by the adhesive material 612 do not result in leakage or loss of vacuum integrity. Such cracks in the adhesive bond may occur in large tools from handling or exposure to repeated curing processes.

[0094] Fig.10 A plurality of fastener assemblies 702 are illustrated coupling the first component 112 to the second component 114. Fig.10 The illustrated example of the tool assembly 102 does not illustrate a fastener (such as a fastener 250) extending through the first component 112 and the second component 114 on the vertical axis 252. Figure 8 802), but in other embodiments, such as with reference to Figure 8 As depicted, tool assembly 102 includes one or more fasteners extending through first component 112 and second component 114 on vertical axis 252. In addition, Fig.10 The components 112, 114, 202 of the tool assembly 102 may have joints (e.g., joints 122, 124) such as Figure 2 The illustrated cross axis 256 extends only along a portion of the width of the tool assembly 102 .

[0095] Fig.11 1 is a diagram illustrating an example of a tool assembly 102 including an annular ring seal 1002 (e.g., a tubular seal or an O-ring seal) and a support plate 1102. The support plate 1102 is configured to secure two adjacent components (e.g., a first component 112 and a second component 114) and to secure the two adjacent components using one or more fasteners (e.g., a first component 112 and a second component 114). Figure 1 The fastener 118) is fastened to the side 1012. Fig.11As shown, the support plate 1102 is coupled to the tool assembly 102 using two screws 812, one screw for each component 112, 114. In some embodiments, as shown in FIG. Fig.11 As illustrated, the support plate 1102 covers or protects the annular ring seal 1002. For illustration, the support plate 1102 covers and protects the inlet, outlet, both (i.e., "ends") of the annular ring seal 1002. In such an embodiment, the support plate 1102, together with the annular ring seal 1002, creates or maintains a vacuum seal. In a particular embodiment, the annular ring seal 1002 extends through the side 1012 of the tool assembly 102, such that fastening the support plate 1102 to the components 112, 114 compresses the annular ring seal 1002 and creates or maintains a vacuum seal.

[0096] Fig.12 1 is a diagram illustrating a specific example of components of a tool assembly 102 including an annular ring seal 1002 and a band 1202. Fig.12 In the illustrated example, annular ring seal 1002 extends in transverse axis 256 to side 1012 of first component 112 .

[0097] The strap 1202 (eg, wrap tape) is configured to secure the vacuum bag to the tool assembly 102 during curing and create a seal between the tool assembly 102 and the vacuum bag. A vacuum bag (not shown) surrounds the tool assembly 102 and includes a port to remove air to generate vacuum pressure.

[0098] Fig.13 1 is a diagram illustrating another example of a component of a tool assembly 102, such as the first component 112, including an annular ring seal 1002 and a band 1202. Fig.12 In the illustrated example, the annular ring seal 1002 extends to the top surface 136a (e.g., the build-up surface 116) of the first component 112 below the belt 1202 (e.g., between the belt 1202 and the top surface 136a). For example, the inlet or outlet of the annular ring seal 1002 is positioned toward the top surface 136a. Fig.13 In the illustrated embodiment, the annular ring seal 1002 extends on the vertical axis and the longitudinal axis 252, 254 near the side 1012. In other embodiments, the annular ring seal 1002 extends to the top surface 136a without extending on the longitudinal axis 254. For example, in a tool assembly 102 where the joint portion does not extend the entire width of the tool assembly 102 along the transverse axis 256, such as Figure 2 As illustrated, the annular ring seal 1002 curves upwardly at the vertical and lateral axes 252, 256 toward the end of the tool assembly 102. As another example, the annular ring seal 1002 has a 90 degree curve and extends upwardly along the vertical axis 252 near the end of the tool assembly 102.

[0099] As Fig.12 Compared with the illustrated structure, Fig.13 The illustrated configuration reduces vacuum loss from the area between the belt 1202 and the annular ring seal 1002. Alternatively, Fig.12 The configuration in reduces vacuum loss from the edge of the annular ring seal (eg, reduces vacuum leakage near the end of the annular ring seal 1002).

[0100] In some embodiments, Fig.12 and Fig.13 The tool assembly 102 also includes a support plate, such as Fig.11 In a particular embodiment, the support plate 1102 is coupled to the side 1012, and the annular ring seal 1002 extends to the top surface 136a and the band 1202 (i.e., does not extend to the support plate 1102). In another particular embodiment, the support plate 1102 is coupled to the top surface 136a, and the annular ring seal 1002 extends to the support plate 1102.

[0101] Fig.14 A specific example of a method 1400 for heating a tool assembly (such as tool assembly 102) is illustrated. As an illustrative, non-limiting example, the method 1400 may be performed by Figure 1 The tool assembly 102 may include a composite part manufacturing system 100, a lamination device 104, a curing device, or a combination thereof. Figures 3 to 8 as well as 9A to 9O One or more linkers described herein. Fig.14 , optional steps of method 1400 are illustrated as dashed boxes.

[0102] In some embodiments, method 1400 includes the following steps: At 1402, a first part of a tool assembly, a second part of a tool assembly, or both are formed by additive manufacturing. For example, the tool assembly may include or correspond to Figure 1 The first and second components may each include or correspond to Figure 1 The first component 112, the second component 114 or Figure 2 For illustration, the first component 112, the second component 114, or the third component 202 of the tool assembly 102 is as shown in FIG. Figure 1 Described can be formed or manufactured by an additive manufacturing process. Exemplary additive manufacturing processes include filament manufacturing, such as fused deposition modeling, plastic jet printing, 3D printing, powder bed processing, selective thermal sintering, stereolithography, selective laser melting, selective laser sintering, and the like.

[0103] The method 1400 includes the following steps: At 1404, a first component of a tool assembly is joined to a second component of a tool assembly via a first joint portion and a second joint portion. The first joint portion and the second joint portion may each include or correspond to Figure 1 The first joint portion 122 or the second joint portion 124. The first joint portion 122 and the second joint portion 124 can be joined 1404 by hand or by machinery. As another example, the joint portion can correspond to Figures 3 to 8 as well as 9A to 9O The joint part.

[0104] The method 1400 includes the following steps: At 1406, inserting a fastener through the first joint portion and the second joint portion of the tool assembly. For example, the fastener may include or correspond to Figure 1 Fasteners 118, Figure 7 The fastener assembly 702, Figure 8 9, or the fourth fastener 904 of FIG. 9. Inserting the fastener 118, 904 or the fastener assembly 702, 802, 902 through the first joint portion 122 and the second joint portion 124 can secure the first joint portion 122 and the second joint portion 124 together so that the first component 112 and the second component 114 can be moved as a single tool assembly 102 moves to form the stacking surface 116, or both. In addition, the first joint portion and the second joint portion can be joined by hand or by a machine 1404, and as shown in reference Figure 1 As depicted, the fastening or further fastening may be performed by inserting 1406 additional fasteners of the same or different type, applying an adhesive material 612 , or both.

[0105] In some embodiments, method 1400 further includes the following steps: At 1408, applying a composite material to a build-up surface of the tool assembly. The build-up surface is configured to support the formation of a composite part and has a shape that is complementary to the shape of the composite part. For example, as described in reference Figure 1As depicted, lamination device 104 applies 1408 composite material 142 to lamination layer 116 of tool assembly 102 in response to receiving commands from controller 110. For illustration, composite material 142 may be applied 1408 to lamination layer 116 using any suitable method for positioning composite material 142 on tool assembly 102. For example, the composite material 142 can be applied 1408 by: (a) hand lamination, which includes manually placing the composite material 142 on the build layer 116 by an individual, (b) robotically placing (e.g., pick and place) using a robot with a vacuum-assisted end effector as a laminating device 104 that places the composite material 142 on the build layer 116, (c) via automated fiber placement (AFP), in which a machine acting as a laminating device 104 places the composite material 142 on the build layer 116, particularly for composite materials having a width within a predetermined width range, (d) via automated tape laying (ATL), which is similar to AFP but is used when the composite material 142 is a tape material, or (e) any combination of two or more of (a)-(d).

[0106] The method 1400 also includes the step of applying heat to the tool assembly at 1410, wherein upon heating, the interlocking surfaces of the first joint portion and the second joint portion abut against each other. Figure 1 As described, the curing device 108 applies 1410 heat to the tool assembly 102 to further contact each other or interlock to tighten the interlocking surfaces 132, 134 against each other. Preferably, the composite material 142 is applied to the buildup surface 116 before applying 1410 heat to the tool assembly 102. The tool assembly 102 in the heated condition maintains vacuum integrity and as described with reference to Figure 1 The method described may be used to cure large composite parts such as composite part 190. In certain embodiments, upon or after applying 1410 heat, tool assembly 102 is Figure 2 The tab 402 expands longitudinally along the longitudinal axis 254 and the tab 402 deflects along the longitudinal axis 252 toward the bottom surface 522 (eg, downward).

[0107] In some embodiments, method 1400 includes the following steps: At 1412, a vacuum pressure is generated between the composite material and the laminate surface. Figure 1 As depicted, vacuum system 106 generates a vacuum pressure or condition between composite material 142 and build-up surface 116 of tool assembly 102 in response to receiving commands from controller 110. Fig.14 Illustratively, vacuum pressure is generated 1412 after heat is applied at 1410. In other embodiments, vacuum pressure is generated 1412 prior to or at least partially concurrently with applying heat to the tool assembly at 1410.

[0108] In some embodiments, the fastener inserted at 1406 includes or corresponds to a fastener device. The fastener device extends through the tangs of the first joint portion and the second joint portion, and the fastener device is configured to enable the tool assembly 102 to withstand thermal expansion and still maintain vacuum integrity. For example, the fastener device includes or corresponds to Figure 7 Fastener assembly 702 or Figure 8 The second fastener assembly 802. For illustration, as shown in FIG. Figure 7 As described, the fastener assembly 702 is arranged along Figure 2 The longitudinal axis 254 extends through Figure 5 In certain embodiments, the fastener 118 is generally parallel to the build face 116 for longitudinally aligned structures, or generally parallel to a local tangent to the build face 116 for peripherally aligned structures. In other embodiments, the fastener 118 is generally orthogonal to the build face 116 for longitudinally aligned structures, or generally orthogonal to a local tangent to the build face 116 for peripherally aligned structures. Alternatively, the fastener 118 is generally orthogonal to a particular interlocking face 132, 134 or intermediate face 534, 538 of the tool assembly 102.

[0109] In some embodiments, the joint formed by the first joint portion and the second joint portion includes one or more gaps defined by the surfaces of the first joint portion and the second joint portion. Figure 6 The description includes gaps 602-606. In some such embodiments, the joint includes an adhesive material placed in one or more gaps between the faces of the first joint portion and the second joint portion. The adhesive material is configured to maintain the vacuum integrity of the joint. For example, as described with reference to Figure 6 As depicted, one or more of the gaps 602 - 606 of the joints 302 , 304 include an adhesive material 612 on at least a portion of one of its faces.

[0110] In some embodiments, before joining the first component and the second component, method 1400 further includes the step of applying a paste adhesive or an adhesive film to at least a portion of the first joint portion of the first component. Figure 1 and Figure 6 Described, Figure 6 The adhesive material 612 may be applied to the surfaces corresponding to the gaps 602 - 606 of the joint portions 122 , 124 as a paste or a film.

[0111] In certain embodiments, the fastener does not pass through the interlocking surface or the angled interlocking surface. Figure 7 and Figure 8 Described, Figure 7The fastener assembly 702 and Figure 8 The second fastener component 802 does not extend through any of the interlocking surfaces 132 , 134 , 516 , 536 .

[0112] In some embodiments, the tool assembly further includes one or more second fasteners configured to couple the first component to the second component. Figure 8 As depicted, a particular tool assembly 102 includes a fastener assembly 702 and one or more second fastener assemblies 802. In some such embodiments, the fastener, one or more second fasteners, or a combination thereof, includes or corresponds to a spring-loaded device or a single-sided fastener configured to allow for thermal expansion of the tool assembly. For example, the fastener includes or corresponds to a spring 716 or a biasing member, Figure 7 The fastener assembly 702 and Figure 8 The second fastener assembly 802. In certain embodiments, the one or more second fasteners are substantially orthogonal to the fastener. For example, as shown in FIG. Figure 7 and Figure 8 As depicted, fastener assembly 702 is oriented along or parallel to longitudinal axis 254 , and one or more second fasteners are oriented along or parallel to perpendicular axis 252 .

[0113] The joints 122 and 124 correspond to Figure 5 In some embodiments of the joint portion and including obtuse angles 552, 554, 556, 574, 576 and acute angles 572, the obtuse angle is approximately 135 degrees, and the acute angle is approximately 45 degrees. For example, the angle is manufactured by adding or subtracting 5 degrees within the design tolerance. In this embodiment, the angle of the corner reduces the normal and shear stress of the joint 302, 304. In some embodiments, the corner includes or corresponds to a fillet corner, a chamfered corner or a combination thereof. This corner is smaller than the normal and shear stress of the joint 302, 304 (for example, to prevent or reduce the local maximum of stress).

[0114] In some embodiments, the first component includes a material having an anisotropic coefficient of thermal expansion. For example, the first component 112 may have a coefficient of thermal expansion that is 10 times greater in one axis (e.g., longitudinal axis 254) than in another axis (e.g., vertical axis 252). In some such embodiments, the first component includes a thermoplastic polymer material (e.g., ABS material or carbon-filled ABS material), a thermosetting polymer material, or another polymer material.

[0115] In some embodiments, the first joint portion of the first component further includes a third interlocking surface, a first intermediate surface, and a second intermediate surface. The first intermediate surface and each of the first and second interlocking surfaces form an obtuse angle. The second intermediate surface and the second interlocking surface form another obtuse angle. For example, as shown in FIG. Figure 5 As described, the first intermediate surface 514 and each of the first and third interlocking surfaces 132, 516 form an obtuse corner 554, 556, and the second intermediate surface 518 and the third interlocking surface 516 form another obtuse corner 558. In a particular embodiment, the second intermediate surface and the vertical edge surface form a substantially right angle corner. For example, as shown in reference Figure 5 As described, the second intermediate surface 518 and the vertical edge surface 520 form a substantially right angle corner 560. Additionally or alternatively, the second joint portion of the second component further includes a fourth interlocking surface, a first intermediate surface, and a second intermediate surface. Each of the first intermediate surface and the first and second interlocking surfaces forms an obtuse angle corner. The second intermediate surface and the second interlocking surface form another obtuse angle corner. For example, as described with reference to Figure 5 As depicted, the first intermediate surface 534 and each of the second and fourth interlocking surfaces 134 , 536 form an obtuse corner 574 , 576 , and the second intermediate surface 538 and the fourth interlocking surface 536 form another obtuse corner 578 .

[0116] In some embodiments, the second component further comprises a third joint portion. The third joint portion has a shape similar to the first joint portion or the second joint portion and is configured to engage with the fourth joint portion of the third component of the tool assembly. Figure 3 and Figure 4 As depicted, the second component 114 includes a third joint portion 422 that interlocks with a fourth joint portion 424 of the third component 202 .

[0117] Fig.15 A specific example of a method 1500 for applying a composite material to a tool assembly, such as tool assembly 102, is illustrated. As an illustrative, non-limiting example, method 1500 may be performed by Figure 1 The tool assembly 102 may include a composite part manufacturing system 100, a lamination device 104, a curing device, or a combination thereof. Figures 3 to 8 as well as 9A to 9O One or more linkers described herein. Fig.15 , optional steps of method 1500 are illustrated as dashed boxes.

[0118] In some embodiments, as described in Fig.14As described, method 1500 includes: at 1402, forming a first part 112 of a tool assembly 102, a second part 114 of a tool assembly 102, or both by additive manufacturing. In a particular embodiment, forming 1402 includes: forming a first joint portion 122 of the first part 112 of the tool assembly 102 using an additive manufacturing process. The first joint portion 122 includes a top surface 136a and at least a first interlocking surface 132. Forming 1402 also includes forming a second joint portion 124 of the second part 114 of the tool assembly 102 using an additive manufacturing process. The second joint portion 124 includes a top surface 136b and at least a second interlocking surface 134 that is complementary to the first interlocking surface 132.

[0119] In some embodiments, forming 1402 the first joint portion 122 includes forming an obtuse corner 552 between the first interlocking surface 132 and the top surface 136 of the first joint portion 122 using an additive manufacturing process. Additionally, forming the second joint portion 124 includes forming an obtuse corner 572 between the second interlocking surface 134 and the top surface 136b of the second joint portion 124 using an additive manufacturing process.

[0120] In some embodiments, forming 1402 further comprises forming the tangs 582, 584 of the first joint portion and the second joint portion using an additive manufacturing process. In some embodiments, forming 1402 the first joint portion 122 and the second joint portion 124 using an additive manufacturing process comprises forming the first component and the second component using at least one of a filament manufacturing process, a plastic jet printing process, a three-dimensional printing process, a powder bed machining process, a selective thermal sintering process, a fused deposition modeling process, a stereolithography process, a selective laser sintering process, or a selective laser melting process.

[0121] The method 1500 includes the following steps: At 1404, the first part 112 of the tool assembly 102 is joined to the second part 114 of the tool assembly 102 via the first joint part 122 and the second joint part 124, wherein the tool assembly 102 includes a build-up surface 116. The first joint part and the second joint part can be joined 1404 by hand or by a machine, and can be as described in reference Figure 1 As described, the joint is joined 1404 using a joint portion along with applying fasteners, adhesives, or both. As another example, the joint portion may correspond to 9A to 9O The joint part.

[0122] Method 1500 includes the following steps: At 1408, composite material 142 is applied to buildup layer 116. Buildup layer 116 is configured to support the formation of composite part 190 and has a shape that is complementary to the shape of composite part 190. In some embodiments, applying composite material 142 to buildup layer 116 includes depositing or placing composite material 142 manually or by an automated device. For example, composite material 142 can be applied to buildup layer 116 as described in reference to Figure 1 The composite material 142 is described as being deposited or placed by the lamination device 104 to form the composite part 190. Alternatively, the composite material 142 deposited or placed onto the lamination layer 116 defines or corresponds to a working part (eg, an unfinished composite part), such as Figure 1 The working part 192. In this embodiment, as shown in FIG. Figure 1 As depicted, method 1500 also includes the following step: at 1136 a , trimming work part 192 to generate composite part 190 .

[0123] In some embodiments, method 1500 further includes the step of generating a vacuum pressure between composite material 142 and laminate surface 116 at 1412. For example, as described in reference Figure 1 As depicted, vacuum system 106 generates a vacuum pressure or condition between composite material 142 and build-up surface 116 of tool assembly 102 in response to receiving commands from controller 110 .

[0124] In some embodiments, method 1500 further includes the step of applying heat and / or light at 1410a to cure composite material 142 and form composite part 190. For example, as described in reference Figure 1 As depicted, curing device 108 applies 1410a heat and / or light to composite material 142 to cure composite material 142 and form composite part 190. Fig.15 By way of example, heat may be applied 1410a to the tool assembly 102, optionally after generating vacuum pressure at 1412. In other embodiments, heat and / or light are applied 1410a to the tool assembly without generating vacuum pressure at 1412, before generating vacuum pressure at 1412, or at least partially simultaneously with generating vacuum pressure at 1412.

[0125] In some embodiments, the tool assembly 102 further includes an adhesive material 612 for adhering the first component to the second component. Figure 6 As described, a paste adhesive or adhesive film is applied to the intermediate surface 514 , 534 of the tool assembly 102 .

[0126] In some embodiments, tool assembly 102 of method 1400 or 1500 is an additively manufactured tool assembly, e.g., one or more of its components 112, 114, 202 are made by an additive manufacturing process such as filament manufacturing, such as fused deposition modeling, plastic jet printing, 3D printing, powder bed machining, selective heat sintering, selective laser sintering, stereolithography, selective laser melting, etc. Because tool assembly 102 reduces cost and manufacturing time, using tool assembly 102 to manufacture composite part 190 reduces cost and manufacturing time, such as compared to using metal tools and tool assemblies. Additionally, by using tool assembly 102 that includes one or more of the joints described herein, smaller composite parts can be formed, such as compared to using smaller tool assemblies joined by butt joints. Figure 1 Composite part manufacturing system 100 may form larger composite parts.

[0127] Fig.14 Method 1400 and / or Fig.15 The method 1500 may be initiated or controlled by an application specific integrated circuit (ASIC), a processing unit such as a central processing unit (CPU), a controller, another hardware device, a firmware device, a field programmable gate array (FPGA) device, or any combination thereof. As an example, Fig.14 Method 1400 and / or Fig.15 Method 1500 may be initiated or controlled by one or more processors, such as one or more processors included in or coupled to controller 110 of composite part manufacturing system 100. In some embodiments, Fig.14 or Fig.15 One or more operations in one of the methods may be combined with Fig.14 or Fig.15 In addition, referring to Fig.14 or Fig.15 One or more operations described in the method may be optional, may be performed in a different order than shown or described, or both. Fig.14 or Fig.15 Two or more operations described in a method may be performed at least partially concurrently.

[0128] Reference Fig.16 and Fig.17 , in Fig.16 The vehicle manufacturing and maintenance method 1600 illustrated by the flowchart and the Fig.17 Examples of the present disclosure are described in the context of a vehicle 1702 illustrated in the block diagram of FIG. Fig.16 Vehicle manufacturing and maintenance method 1600 The vehicle (such as Fig.17The vehicle 1702 may include an airplane, an airship, a rocket, a satellite, a submarine, a ship, a motor vehicle, or another vehicle, as illustrative, non-limiting examples. The vehicle 1702 may be manned or unmanned (e.g., a drone or an unmanned aerial vehicle (UAV)).

[0129] Reference Fig.16 A flow chart of an illustrative example of a method of composite part manufacturing and maintenance is shown and designated 1600. During pre-production, the exemplary method 1600 includes the following steps: At 1602, a vehicle is specified and designed, such as with reference to Fig.17 During the designation and design of the vehicle 1702, the method 1600 may include the following steps: designating a vehicle such as Figure 1 The method 1600 includes material procurement at 1604. For example, the method 1600 may include procuring materials for the vehicle 1702 (e.g., Figure 1 Design and manufacture of tool assembly 102).

[0130] During production, method 1600 includes the following steps: at 1606, manufacturing components and subassemblies, and at 1608, integrating systems of vehicle 1702. Method 1600 may include manufacturing components and subassemblies of vehicle 1702 (e.g., manufacturing Figure 1 Composite parts 190) and system integration (e.g. Figure 1 The composite part 190 is coupled to one or more components of the vehicle 1702. For example, at 1606, Figure 1 The system 100 may implement Fig.14 Method 1400 and / or Fig.15 The method 1500 is used to manufacture a composite part 190 which is then assembled at 1608 to manufacture a vehicle 1702 .

[0131] At 1610, method 1600 includes certification and delivery of vehicle 1702, and delivery of vehicle 1702 for use at 1612. Certification and delivery may include certification by inspection or nondestructive testing. Figure 1 While being serviced by the customer, aircraft 1702 may be dispatched for routine maintenance and servicing, which may also include modification, reconfiguration, refurbishment, etc. At 1614, method 1600 includes the step of performing maintenance and servicing on vehicle 1702. Method 1600 may include the step of performing maintenance and servicing on composite part 190. For example, maintenance and servicing of a communication system may include replacing composite part 190 or repairing a face of composite part 190.

[0132] The various processes of method 1600 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, without limitation, any number of vehicle manufacturers and main system subcontractors; a third party may include, without limitation, any number of sellers, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a maintenance organization, etc.

[0133] Reference Fig.17 , illustrates a block diagram of an exemplary embodiment of a vehicle 1702, the vehicle including a vehicle assembly (such as Figure 1 For purposes of illustration, vehicle 1702 may include an aircraft, as an illustrative, non-limiting example. Vehicle 1702 may be comprised of Fig.16 The method 1600 is performed by at least a portion of the method 1600. Fig.17 As shown, vehicle 1702 (e.g., an aircraft) may include airframe 1718, interior 190, composite part 190, and plurality of systems 1720. In other embodiments, airframe 1718 includes or corresponds to composite part 190. For example, composite part 190 may include or correspond to a wing, a section of a wing, a section of a fuselage, or other components of airframe 1718. Plurality of systems 1720 may include one or more of propulsion system 1724, electrical system 1726, environmental system 1728, hydraulic system 1730, or communication system 1732. Composite part 190 is formed or manufactured using tool assembly 102. Composite part 190 may be formed or manufactured by Figure 1 For example, the composite part 190 may be manufactured by the composite part manufacturing system 100. Fig.14 and Fig.15 One or more steps of methods 1400 and 1500 and / or references Figure 1 Describe the manufacturing process.

[0134] The devices and methods included herein can be found in Fig.16 1600 . For example, components or subassemblies corresponding to production process 1608 can be manufactured in a manner similar to components or subassemblies produced while vehicle 1702 is in operation (at 1612 , for example and without limitation). Moreover, one or more apparatus embodiments, method embodiments, or a combination thereof can be used during a production phase (e.g., phases 1602-1610 of method 1600 ), for example, by significantly speeding up assembly of vehicle 1702 or reducing its cost. Similarly, one or more apparatus embodiments, method embodiments, or a combination thereof can be used for maintenance and servicing at 1614 while vehicle 1702 is in operation (at 1612 , for example and without limitation).

[0135] The present disclosure also includes the following non-exhaustive list of examples that may or may not be claimed:

[0136] 1. A tool assembly 102, the tool assembly comprising:

[0137] a first component 112 having a first joint portion 122 including a top surface 136a and at least a first interlocking surface 132;

[0138] A second component 114 having a second joint portion 124 configured to interlock with the first joint portion 122, the second joint portion 124 including a top surface 136b and at least a second interlocking surface 134 complementary to the first interlocking surface 132; and

[0139] The fastener 118, 702, 802, 902, 904 extends through the first joint portion 122 and the second joint portion 124,

[0140] The first interlocking surface 132 and the top surface 136a of the first joint portion 122 form an obtuse corner 552, and the second interlocking surface 134 and the top surface 136b of the second joint portion 124 form an acute corner 572, and

[0141] Therein, the first interlocking surface 132 is configured to contact the second interlocking surface 134 to inhibit relative movement between the first component 112 and the second component 114 along the longitudinal axis 254 of the tool assembly 102 .

[0142] 2. The tool assembly 102 of Example 1, wherein the fastener 118 , 904 extends through the tangs 582 , 584 of the first joint portion 122 and the second joint portion 124 .

[0143] 3. The tool assembly 102 of examples 1 or 2, further comprising one or more second fasteners 702 , 802 configured to couple the first component 112 to the second component 114 .

[0144] 4. The tool assembly 102 of any of Examples 1 to 3, wherein the fastener 118 , 904 comprises a spring loaded device or a blind fastener configured to allow for thermal expansion of the tool assembly 102 .

[0145] 5. The tool assembly 102 of any of Examples 1 to 4, wherein the obtuse corner 552 is approximately 135 degrees and the acute corner 572 is approximately 45 degrees.

[0146] 6. The tool assembly of any of Examples 1 to 5, wherein the first component 112 comprises a material having an anisotropic coefficient of thermal expansion.

[0147] 7. The tool assembly of any one of Examples 1 to 6, wherein the joint formed by the first joint portion 122 and the second joint portion 124 includes one or more gaps 602, 604, 606 defined by surfaces of the first joint portion 122 and the second joint portion 124, and also includes an adhesive material 612 placed in the one or more gaps 602, 604, 606, and the adhesive material 612 is constructed to maintain the vacuum integrity of the joint.

[0148] 8. A tool assembly 102, the tool assembly comprising:

[0149] A first component 112 having a top surface 136a and a first joint portion 122 including at least a first interlocking surface 132; and

[0150] The second component 114 has a second joint portion 124 configured to interlock with the first joint portion 122, the second joint portion 124 including a top surface 136b and at least a second interlocking surface 134 complementary to the first interlocking surface 132,

[0151] The first interlocking surface 132 and the top surface 136a of the first component 112 form an obtuse corner 552, and the second interlocking surface 134 and the top surface 136b of the second joint portion 124 form an acute corner 572, and

[0152] Therein, the first interlocking surface 132 is configured to contact the second interlocking surface 134 to inhibit relative movement between the first component 112 and the second component 114 along the longitudinal axis 254 of the tool assembly 102 .

[0153] 9. The tool assembly 102 of example 8, wherein the first component 112 comprises a thermoplastic polymer material, a thermosetting polymer material, or another polymer material.

[0154] 10. The tool assembly 102 of examples 8 or 9, wherein the sharp corner 572, the sharp corner 552, or both comprise rounded corners or chamfered corners.

[0155] 11. The tool assembly 102 of any one of Examples 8 to 10, wherein the first component 112 further includes a third interlocking surface 516 and a first intermediate surface 514, wherein the first intermediate surface 514 and the first interlocking surface 132 form an obtuse corner 554, and wherein the first intermediate surface 514 and the third interlocking surface 516 form an obtuse corner 556.

[0156] 12. The tool assembly 102 of any one of Examples 8 to 11, wherein the second component 114 further comprises a third joint portion 422 having a shape similar to the first joint portion 122 or the second joint portion 124 and configured to engage with the fourth joint portion 424 of the third component 202 of the tool assembly 102 .

[0157] 13. The tool assembly 102 of any of Examples 8 to 12, further comprising an adhesive material 614 adhering the first component 112 to the second component 114, an annular ring seal 1002 positioned between the first interlocking surface 132 and the second interlocking surface 134, or a combination thereof.

[0158] 14. A method of heating a tool assembly 102, the method comprising the following steps:

[0159] Joining the first component 112 of the tool assembly 102 with the second component 114 of the tool assembly 102 via the first joint portion 122 and the second joint portion 124;

[0160] inserting the fastener 118 , 904 through the first fitting portion 122 and the second fitting portion 124 of the tool assembly 102 ; and

[0161] Heat is applied to the tool assembly 102 , wherein upon heating, the interlocking surfaces of the first joint portion 122 and the second joint portion 124 abut against each other.

[0162] 15. The method of example 14, wherein inserting the fastener 118, 904 comprises:

[0163] Inserting the fastener 118 , 904 through the tangs 582 , 584 of the first and second joint portions 122 , 124 ; and

[0164] The fasteners 118 , 904 are secured to the first joint portion 122 and the second joint portion 124 .

[0165] 16. The method of example 14 or 15, further comprising the following steps:

[0166] Applying composite material 142 to buildup layer 116 of tool assembly 102 prior to applying heat to tool assembly 102, buildup layer 116 being configured to support formation of composite part 190 and having the shape of composite part 190; and

[0167] A vacuum pressure is created between the composite material 142 and the build layer 116 .

[0168] 17. A method of applying a composite material 142 to a tool assembly 102, the method comprising the steps of:

[0169] Joining the first component 112 of the tool assembly 102 with the second component 114 of the tool assembly 102 via the first joint portion 122 and the second joint portion 124, wherein the tool assembly 102 includes the build-up layer 116; and

[0170] Composite material 142 is applied to buildup layer 116 , which is configured to support the formation of composite part 190 and has a shape that is complementary to the shape of composite part 190 .

[0171] 18. The method of Example 17 further comprises the following step: forming a vacuum pressure between the composite material 142 and the build-up layer 116 .

[0172] 19. The method of example 17 or 18 further includes the following step: applying heat or light to the composite material 142 to cure the composite material 142 .

[0173] 20. The method of any of Examples 17 to 19, wherein the composite material 142 applied to the build-up layer 116 defines a work part 192, and the method further comprises the step of trimming the work part 192 to produce the composite part 190.

[0174] 21. A method of manufacturing a tool assembly 102, the method comprising the following steps:

[0175] forming a first joint portion 122 of the first component 112 of the tool assembly 102 using an additive manufacturing process, the first joint portion 122 including a top surface 136a and at least a first interlocking surface 132; and

[0176] The second joint portion 124 of the second component 114 of the tool assembly 102 is formed using an additive manufacturing process and includes a top surface 136 b and at least a second interlocking surface 134 that is complementary to the first interlocking surface 132 .

[0177] 22. The method of Example 21, wherein:

[0178] forming the first joint portion 122 includes forming an obtuse corner 552 between the first interlocking surface 132 and the top surface 136a of the first joint portion 122 using an additive manufacturing process; and

[0179] Forming the second joint portion 124 includes forming an obtuse corner 572 between the second interlocking surface 134 and the top surface 136 b of the second joint portion 124 using an additive manufacturing process.

[0180] 23. The method of example 21 or 22, further comprising the following steps:

[0181] The tangs 582 , 584 of the first and second joint portions 122 , 124 are formed using an additive manufacturing process.

[0182] 24. The method of any one of Examples 21 to 23, wherein forming the first joint portion 122 and the second joint portion 124 using an additive manufacturing process includes forming the first component 112 and the second component 114 using at least one of a filament manufacturing process, a plastic jet printing process, a three-dimensional printing process, a powder bed processing process, a selective thermal sintering process, a fused deposition modeling process, a stereolithography process, a selective laser sintering process, or a selective laser melting process.

[0183] The illustration of the examples described herein is intended to provide a general understanding of the structure of the various embodiments. The illustration is not intended to serve as a complete description of all elements and features of the equipment and systems using the structures or methods described herein. Many other embodiments may be apparent to those skilled in the art when consulting this disclosure. Other embodiments may be used and derived from this disclosure so that structural and logical replacements and changes may be made without departing from the scope of this disclosure. For example, the method operations may be performed in a different order than shown in the accompanying drawings, or one or more method operations may be omitted. Therefore, this disclosure and the accompanying drawings are considered to be illustrative, rather than restrictive.

[0184] Moreover, although specific examples are illustrated and described herein, it should be understood that any subsequent structure designed to achieve the same or similar results may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or changes of the various embodiments. Combinations of the above embodiments and other embodiments not specifically described herein will be apparent to those skilled in the art upon reviewing the specification.

[0185] The abstract of the present disclosure is submitted with the following understanding: it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing specific embodiments, various features may be grouped together or described in a single embodiment for the purpose of streamlining the present disclosure. The above examples illustrate but do not limit the present disclosure. It should also be understood that a large number of modifications and changes are possible according to the principles of the present disclosure. As reflected in the attached claims, the claimed subject matter may be devoted to less than all the features of any one of the disclosed examples. Therefore, the scope of the present disclosure is defined by the attached claims and their equivalents.

Claims

1. A tool assembly (102), the tool assembly (102) comprising: A first component (112) having a first joint portion (122) including a top surface (136a) and at least a first interlocking surface (132); a second component (114) having a second joint portion (124) configured to interlock with the first joint portion (122), the second joint portion (124) including a top surface (136b) and at least a second interlocking surface (134) complementary to the first interlocking surface (132); and a fastener (118, 702, 802, 902, 904) extending through the first joint portion (122) and the second joint portion (124), wherein the first interlocking surface (132) and the top surface (136a) of the first joint portion (122) form an obtuse angle, and the second interlocking surface (134) and the top surface (136b) of the second joint portion (124) form an acute angle (572), and wherein the first interlocking surface (132) is configured to contact the second interlocking surface (134) to inhibit relative movement between the first component (112) and the second component (114) along a longitudinal axis (254) of the tool assembly (102), wherein the first component (112) further comprises a third interlocking surface (516) and a first intermediate surface (514), wherein the first intermediate surface (514) and the first interlocking surface (132) form an obtuse angle, and wherein the first intermediate surface (514) and the third interlocking surface (516) form an obtuse angle, The tool assembly (102) includes a deposition layer (116), The second joint portion (124) includes a tab which is embedded in a recess of the first joint portion (122), and the geometric structure of the tab enables the tab to be held in a suitable position or deflected downward, thereby maintaining the accumulation layer.

2. The tool assembly (102) according to claim 1, wherein: The fastener (118, 904) extends through the tangs (582, 584) of the first joint portion (122) and the second joint portion (124).

3. The tool assembly (102) of claim 1 or 2, further comprising one or more second fasteners (702, 802) configured to couple the first component (112) to the second component (114).

4. The tool assembly (102) according to claim 1 or 2, wherein: The fastener (118, 904) comprises a spring loaded device or a blind fastener configured to allow for thermal expansion of the tool assembly (102).

5. The tool assembly (102) according to claim 1 or 2, wherein: The obtuse corner is 135 degrees and the acute corner (572) is 45 degrees.

6. The tool assembly (102) according to claim 1 or 2, wherein: The first component (112) includes a material having an anisotropic coefficient of thermal expansion.

7. The tool assembly (102) according to claim 1 or 2, wherein: The joint formed by the first joint portion (122) and the second joint portion (124) includes one or more gaps (602, 604, 606) defined by surfaces of the first joint portion (122) and the second joint portion (124), and also includes an adhesive material (612) located in the one or more gaps (602, 604, 606), and the adhesive material (612) is configured to maintain the vacuum integrity of the joint.

8. The tool assembly (102) of claim 1, wherein: The first component (112) includes a thermoplastic polymer material, a thermosetting polymer material, or other polymer materials.

9. The tool assembly (102) according to claim 1 or 8, wherein: The second component (114) also includes a third joint portion (422), which has a shape similar to the first joint portion (122) or the second joint portion (124) and is configured to engage with the fourth joint portion (424) of the third component (202) of the tool assembly (102).

10. The tool assembly (102) according to claim 1 or 8, the tool assembly (102) further comprising: An adhesive material (612) that adheres the first component (112) to the second component (114), an annular ring seal (1002) between the first interlocking surface (132) and the second interlocking surface (134), or a combination thereof.

11. A method of heating a tool assembly (102), the method comprising the steps of: Joining the first component (112) of the tool assembly (102) and the second component (114) of the tool assembly (102) via a first joint portion (122) and a second joint portion (124); inserting a fastener (118, 904) through the first connector portion (122) and the second connector portion (124) of the tool assembly (102); applying a composite material (142) to a buildup layer (116) of the tool assembly (102), the buildup layer (116) being configured to support formation of a composite part (190) and having a shape complementary to the shape of the composite part (190); as well as applying heat to the tool assembly (102) and the composite material, wherein upon heating, the interlocking surfaces of the first joint portion (122) and the second joint portion (124) abut against each other, The second joint portion (124) includes a tab which is embedded in a recess of the first joint portion (122), and the geometric structure of the tab enables the tab to be held in a suitable position or deflected downward, thereby maintaining the accumulation layer.

12. The method according to claim 11, wherein: The step of inserting the fastener (118, 904) comprises: inserting the fastener (118, 904) through the tangs (582, 584) of the first joint portion (122) and the second joint portion (124); and The fastener (118, 904) is secured to the first joint portion (122) and the second joint portion (124).

13. The method according to claim 11 or 12, further comprising the following steps: A vacuum pressure is created between the composite material (142) and the laminate surface (116).

14. A method of applying a composite material (142) to a tool assembly (102), the method comprising the steps of: Joining a first component (112) of a tool assembly (102) to a second component (114) of the tool assembly (102) via a first joint portion (122) and a second joint portion (124), wherein the tool assembly (102) includes a build-up face (116), wherein the first joint portion includes at least a first interlocking surface, the first interlocking surface being configured to contact the second component in response to the first component being joined to the second component, wherein a fastener couples the first joint portion to the second joint portion, the fastener including a spring loading device, the spring loading device including a spring, wherein the spring is configured to compress along a first axis in response to thermal expansion of the tool assembly, wherein the first axis is parallel to a first surface defined by the build-up face, wherein a second axis is perpendicular to the first axis, and wherein the second axis intersects the build-up face, the first interlocking surface, and the fastener; and applying the composite material (142) to the buildup layer (116), the buildup layer (116) being configured to support formation of a composite part (190) and having a shape complementary to the shape of the composite part (190), wherein the composite material applied to the buildup layer defines a working part, The second joint portion (124) includes a tab which is embedded in a recess of the first joint portion (122), and the geometric structure of the tab enables the tab to be held in a suitable position or deflected downward, thereby maintaining the accumulation layer.

15. The method according to claim 14, further comprising the steps of: A vacuum pressure is created between the composite material (142) and the laminate surface (116).

16. The method according to claim 14 or 15, further comprising the following steps: Heat or light is applied to the composite material (142) to cure the composite material (142).

17. The method according to claim 14 or 15, further comprising the following steps: The work part is trimmed to produce the composite part (190).

18. A method of manufacturing a tool assembly (102), the method comprising the steps of: forming a first joint portion (122) of a first component (112) of the tool assembly (102) using an additive manufacturing process, the first joint portion (122) including a top surface (136a) and at least a first interlocking surface (132); forming a second joint portion (124) of a second component (114) of the tool assembly (102) using an additive manufacturing process, the second joint portion (124) comprising a top surface (136b) and at least a second interlocking surface (134) complementary to the first interlocking surface (132); joining the first component and the second component; inserting a fastener through the first and second fitting portions of the tool assembly, wherein the fastener includes a spring-loaded device, the spring-loaded device including a spring, wherein the spring is configured to compress along a first axis in response to thermal expansion of the tool assembly, wherein the first axis is parallel to a first surface defined by the top surface, wherein a second axis is perpendicular to the first axis, and wherein the second axis intersects the top surface, the first interlocking surface, and the fastener; and applying a composite material to the top surface, the top surface being configured to support formation of a composite part and having a shape complementary to a shape of the composite part, The tool assembly (102) includes a deposition layer (116), The second joint portion (124) includes a tab which is embedded in a recess of the first joint portion (122), and the geometric structure of the tab enables the tab to be held in a suitable position or deflected downward, thereby maintaining the accumulation layer.

19. The method according to claim 18, wherein: Forming the first joint portion (122) includes forming an obtuse angle corner between a first interlocking surface (132) and a top surface (136a) of the first joint portion (122) using an additive manufacturing process; and Forming the second joint portion (124) includes forming an obtuse angle corner between a second interlocking surface (134) and a top surface (136b) of the second joint portion (124) using an additive manufacturing process.

20. The method according to claim 18 or 19, further comprising the steps of: The tangs (582, 584) of the first joint portion (122) and the second joint portion (124) are formed using an additive manufacturing process.

21. The method according to claim 18 or 19, wherein: Forming the first joint portion (122) and the second joint portion (124) using an additive manufacturing process includes forming the first component (112) and the second component (114) using at least one of a filament manufacturing process, a plastic jet printing process, a three-dimensional printing process, a powder bed machining process, a selective thermal sintering process, a fused deposition modeling process, a stereolithography process, a selective laser sintering process, and a selective laser melting process.

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