Method and apparatus for forming composite parts from multilayer pre-preg composite charges
By using vacuum pipelines inside and outside the capsule in an atmospheric pressure chamber for degassing, and by expanding and compressing the multi-layer prepreg composite material in the capsule, the problem of complex and time-consuming degassing in composite material manufacturing is solved, achieving efficient degassing and cost reduction.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- THE BOEING CO
- Filing Date
- 2021-09-29
- Publication Date
- 2026-08-04
AI Technical Summary
In the manufacturing process of composite materials, the degassing step is complex and time-consuming, resulting in high manufacturing costs, especially in large and complex geometries.
The pressure is reduced in an atmospheric pressure chamber, and degassing is performed using independent vacuum lines inside and outside the capsule. Then, the multi-layer prepreg composite material is compressed and cured between the molding tools by expanding the capsule. No additional equipment is required for the degassing process.
It improves degassing efficiency, simplifies the process, reduces manufacturing costs, and shortens processing time.
Smart Images
Figure CN114290710B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a method and apparatus for forming composite parts from multilayer prepreg composite materials. Background Technology
[0002] Composite materials are becoming increasingly popular for manufacturing aircraft components and other lightweight structures. Composite materials possess excellent strength and stiffness properties and are lighter than, for example, metals. However, the manufacture of composite structures remains considerably more expensive than, for example, metallic structures. Manufacturing costs are particularly significant for large composite structures and those with complex geometries. The main factors contributing to these high manufacturing costs are equipment complexity and processing time. For example, the processing of composite materials often involves degassing, i.e., removing moisture, volatiles, and / or gases trapped within these materials. Degassing typically increases manufacturing cycle time and requires the use of specialized equipment (e.g., autoclaves). Summary of the Invention
[0003] Therefore, devices and methods designed to at least solve the above problems would be practical.
[0004] The following is a non-exhaustive list of examples of the topics disclosed in this article.
[0005] This document discloses a method for forming a composite part from a multilayer prepreg composite material. The method includes: reducing the pressure inside a bladder located in a chamber at atmospheric pressure to below atmospheric pressure. The method further includes: placing a multilayer prepreg composite material having a first shape in the chamber and reducing the pressure inside the chamber to below atmospheric pressure. While maintaining the pressure inside the chamber below atmospheric pressure, the method includes inflating the bladder within the chamber by increasing the pressure inside the bladder to atmospheric pressure, such that the multilayer prepreg composite material is compressed between the bladder and a molding tool located inside the chamber, and the multilayer prepreg composite material is configured by the molding tool into a second shape different from the first shape. The method also includes curing the multilayer prepreg composite material having the second shape.
[0006] The operational sequence presented above allows for degassing of the multilayer prepreg composite material prior to its formation. Specifically, degassing is performed while at least a portion of the multilayer prepreg composite material is exposed. At this stage, the multilayer prepreg composite material has not yet been compressed between the capsule and the forming tool. Once the multilayer prepreg composite material is compressed between the capsule and the forming tool, degassing efficiency decreases as the air passages become blocked by the capsule and the forming tool. It should be noted that degassing continues even while the multilayer prepreg composite material is compressed between the capsule and the forming tool, at which point degassing efficiency is low. More efficient degassing is initiated and continued (e.g., for a period of time) before the multilayer prepreg composite material is compressed between the capsule and the forming tool. Furthermore, this degassing is performed without additional equipment. Both the capsule and the chamber are equipped with independent vacuum lines, which allows for independent reduction of pressure inside the capsule and the chamber. Attached Figure Description
[0007] Referring now to the accompanying drawings, which are not necessarily drawn to scale, and in which the same labels are used throughout multiple drawings to refer to the same or similar parts. In the accompanying drawings:
[0008] Figure 1A and Figure 1B The common is a block diagram of a method for forming composite parts from multilayer prepreg composite materials according to one or more examples of the subject matter disclosed herein;
[0009] Figure 2 This is a schematic cross-sectional view of a sac located inside a cavity, representing one or more examples of the subject matter disclosed herein, illustrating the arrangement according to... Figure 1A and Figure 1B The steps to reduce the pressure inside the cyst;
[0010] Figure 3A This is a schematic cross-sectional view of a chamber according to one or more examples of the subject matter disclosed herein, illustrating the... Figure 1A and Figure 1B The steps to reduce the pressure inside the chamber;
[0011] Figure 3B This is one or more examples based on the subject matter disclosed in this article. Figure 3A A schematic enlarged cross-sectional view of the chamber, showing the different components of the chamber;
[0012] Figure 3C This is a schematic cross-sectional view of a chamber according to one or more examples of the subject matter disclosed herein, illustrating the... Figure 1A and Figure 1B The steps to reduce the pressure inside the chamber;
[0013] Figure 3D This is one or more examples based on the subject matter disclosed in this article. Figure 3C A schematic enlarged cross-sectional view of the chamber, showing the different components of the chamber;
[0014] Figure 3E This is a schematic cross-sectional view of a chamber according to one or more examples of the subject matter disclosed herein, illustrating the... Figure 1A and Figure 1B The steps to reduce the pressure inside the chamber;
[0015] Figure 3F This is one or more examples based on the subject matter disclosed in this article. Figure 3E A schematic enlarged cross-sectional view of the chamber, showing the different components of the chamber;
[0016] Figure 4A and Figure 4B These are two schematic cross-sectional views of a chamber representing one or more examples of the subject matter disclosed herein, illustrating the following: Figure 1A and Figure 1B The method involves inflating the cyst within the cavity;
[0017] Figure 4C This is one or more examples based on the subject matter disclosed in this article. Figure 4B A schematic enlarged cross-sectional view of the chamber, showing examples of different heaters;
[0018] Figure 4D and Figure 4E These are two schematic cross-sectional views of a chamber representing one or more examples of the subject matter disclosed herein, illustrating the following: Figure 1A and Figure 1B The method involves inflating the cyst within the cavity;
[0019] Figure 4F This is a schematic cross-sectional view of a chamber according to one or more examples of the subject matter disclosed herein, illustrating the... Figure 1A and Figure 1B The method for curing multilayer prepreg composite materials;
[0020] Figure 5 It is a block diagram of an apparatus for forming composite parts from multilayer prepreg composite materials, based on one or more examples of the subject matter disclosed herein;
[0021] Figure 6 It is a block diagram of aircraft production and service methods;
[0022] Figure 7 This is a schematic illustration of an aircraft. Detailed Implementation
[0023] The above reference Figure 5Solid lines (if any) connecting various elements and / or components may represent mechanical, electrical, fluid, optical, electromagnetic, and other connections and / or combinations thereof. As used herein, “connection” means both direct and indirect association. For example, component A may be directly associated with component B, or indirectly associated with it (e.g., via another component C). It will be understood that not all relationships between the various disclosed elements must be represented. Therefore, connections other than those depicted in the block diagram may also exist. Dashed lines (if any) connecting various elements and / or components indicate connections with similar functions and purposes to those represented by solid lines; however, connections represented by dashed lines may be provided selectively, or may relate to alternative examples of the subject matter disclosed herein. Similarly, elements and / or components (if any) represented by dashed lines indicate alternative examples of the subject matter disclosed herein. One or more elements shown in solid and / or dashed lines may be omitted from a particular example without departing from the scope of the subject matter disclosed herein. Environmental elements (if any) are represented by dashed lines. For clarity, hypothetical (imaginary) elements may also be shown. Those skilled in the art will understand that Figure 5 Some of the features shown can be combined in various ways without including Figure 5 Other features described in the accompanying drawings and / or disclosures, even if such combinations or such combinations are not explicitly shown herein. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features shown and described herein.
[0024] The above reference Figure 1A , Figure 1B and Figure 6 In this text, boxes may represent operations and / or parts thereof, and the lines connecting the various boxes do not imply any particular order or dependency of the operations or their parts. Boxes represented by dashed lines indicate alternative operations and / or parts thereof. Dashed lines connecting the various boxes (if any) indicate alternative dependencies of operations or their parts. It will be understood that not all dependencies between the various exposed operations must be represented. Figure 1A , Figure 1B and Figure 6 The accompanying disclosures describing the methods described herein should not be construed as necessarily determining the order in which the operations are performed. Rather, while an exemplary order is indicated, it will be understood that the order of operations may be modified where appropriate. Thus, some operations may be performed in a different order or simultaneously. Furthermore, those skilled in the art will understand that not all of the described operations need to be performed.
[0025] In the following description, numerous specific details are set forth to provide a thorough understanding of the disclosed concepts, which can be practiced without some or all of these details. In other instances, details of known apparatuses and / or processes have been omitted to avoid unnecessarily obscuring this disclosure. Although some concepts will be described in conjunction with specific examples, it will be understood that these examples are not intended to be limiting.
[0026] Unless otherwise indicated, the terms “first,” “second,” etc., used herein are used merely as labels and are not intended to impose any order, position, or hierarchy on the items referred to by these terms. Furthermore, references to items such as “second” do not require or preclude the existence of items such as “first” or lower-numbered items and / or items such as “third” or higher-numbered items.
[0027] In this document, the reference to "one or more examples" means that one or more features, structures, or characteristics described in connection with an example are included in at least one implementation. The phrase "one or more examples" in various places in the specification may or may not refer to the same example.
[0028] As used herein, a system, device, structure, article, element, component, or hardware "configured to" perform a specified function is indeed capable of performing the specified function without any modification, and not merely potentially capable of performing the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed to perform the specified function. As used herein, "configured to" means an existing characteristic of the system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "suitable" and / or "operable to" perform that function.
[0029] Below are illustrative non-exhaustive examples of the topics disclosed in this article.
[0030] General reference Figure 1A and Figure 1B Especially for example Figures 2 to 4DFor illustrative purposes only and not as a limitation, the following section describes Example 1 of the subject matter disclosed herein. According to Example 1, a method 500 of forming a composite part 195 from a multilayer prepreg composite pack 190 includes (block 510) reducing the pressure inside a bladder 140 located in a chamber 100 at atmospheric pressure to below atmospheric pressure. Method 500 also includes (block 520) placing the multilayer prepreg composite pack 190 having a first shape in the chamber 100. Method 500 further includes (block 530) reducing the pressure inside the chamber 100 to below atmospheric pressure. Method 500 further includes (box 540) inflating the bladder 140 within the chamber 100 by increasing the pressure inside the bladder 140 to atmospheric pressure while maintaining the pressure inside the chamber 100 below atmospheric pressure, such that the multilayer prepreg composite material 190 is compressed between the bladder 140 and a molding tool 130 located inside the chamber 100, and the multilayer prepreg composite material 190 is configured by the molding tool 130 into a second shape different from the first shape. Method 500 further includes (box 550) curing the multilayer prepreg composite material 190 having the second shape.
[0031] The above-described sequence of operations allows for degassing of the multilayer prepreg composite 190 prior to its formation. Specifically, degassing is performed while at least a portion of the multilayer prepreg composite 190 (e.g., the portion facing the forming tool 130) is exposed. At this stage, the multilayer prepreg composite 190 is not yet compressed between the bladder 140 and the forming tool 130, and there is no restriction on the airflow exiting the multilayer prepreg composite 190. Once the multilayer prepreg composite 190 is compressed between the bladder 140 and the forming tool 130, degassing efficiency decreases as the airflow path is at least partially blocked by the bladder 140 and the forming tool 130. It should be noted that degassing continues even while the multilayer prepreg composite 190 is compressed between the bladder 140 and the forming tool 130, despite the reduced efficiency of this stage due to the aforementioned airflow path restrictions. However, degassing begins and continues before the multilayer prepreg composite charge 190 is compressed between the capsule 140 and the forming tool 130. At this stage, degassing efficiency is higher due to the absence of the aforementioned gas path limitations. Furthermore, degassing is performed without additional equipment. In some examples, both the capsule 140 and the chamber 100 are equipped with independent vacuum lines, which allows for independent pressure reduction within both the capsule 140 and the chamber 100.
[0032] Initially, chamber 100 is at atmospheric pressure; for example, chamber 100 is open and ready to receive multilayer prepreg composite material 190. Bud 140 is positioned inside chamber 100 and is at least initially exposed to the atmosphere. When the pressure inside bud 140 is reduced to below atmospheric pressure, the atmospheric pressure inside chamber 100 and outside bud 140 compresses bud 140, which may also be referred to as flattening of bud 140. In some examples, bud 140 is formed of a flexible material, which allows bud 140 to change shape and be flattened based on the pressure difference between the inside and outside of bud 140.
[0033] While the capsule 140 is being flattened, the multilayer prepreg composite material 190 is placed into the chamber 100. At this stage, the multilayer prepreg composite material 190 has a first shape (e.g., a substantially flat shape). In some examples, the multilayer prepreg composite material 190 is placed above the capsule 140. This processing stage is shown in... Figure 2 In this stage, chamber 100 is opened, thereby providing an entrance to the interior of chamber 100 for, for example, placement of multilayer prepreg composite charge 190.
[0034] Method 500 then continues to reduce the pressure inside chamber 100 to below atmospheric pressure. Chamber 100 is sealed at this stage, for example, as... Figure 3A As shown. For example, the pressure inside chamber 100 is reduced by connecting the interior of chamber 100 to a vacuum source. It should be noted that bladder 140 is maintained below atmospheric pressure during this stage. In some examples, the pressure inside bladder 140 and the pressure inside chamber 100 are the same during this stage, for example, both are fluidly connected to the same vacuum source. In other examples, the pressure inside bladder 140 is lower than the pressure inside chamber 100 to ensure that the bladder remains flat.
[0035] At this stage, the multilayer prepreg composite 190 is exposed to the environment inside chamber 100 (below atmospheric pressure). Simultaneously, the multilayer prepreg composite 190 is at least partially exposed (e.g., not in contact with other components besides bladder 140). Furthermore, bladder 140 is not yet compressed of the multilayer prepreg composite 190. This combination of factors allows for efficient degassing of the multilayer prepreg composite 190, which may be referred to as initial degassing or pre-compression degassing. This initial degassing is performed over a period of time, depending on various factors such as the thickness of the multilayer prepreg composite 190, the material properties of the multilayer prepreg composite 190 (e.g., porosity, density, elasticity), the desired level of degassing, etc. In some examples, the duration of this initial degassing is between one minute and one hour, or more specifically, between five minutes and thirty minutes.
[0036] Method 500 continues to inflate the sac 140 within the chamber 100. This stage is schematically shown in... Figures 4A to 4EThe expansion of bladder 140 is achieved by increasing the pressure inside bladder 140 to atmospheric pressure, for example, when bladder 140 is disconnected from a vacuum source and fluidly connected to the atmosphere. For example, bladder 140 includes a line extending from chamber 100 and connected to valve 186 (or more specifically, a three-way valve). One port of the three-way valve is open to the atmosphere. Furthermore, the bladder expansion operation is performed while maintaining the pressure inside chamber 100 below atmospheric pressure. A pressure inside bladder 140 higher than the pressure inside chamber 100 (and outside bladder 140) causes bladder 140 to expand.
[0037] During the capsule expansion operation, the multilayer prepreg composite charge 190 is compressed between the capsule 140 and the forming tool 130, for example as... Figures 4A to 4E The diagram is schematically shown. More specifically, the multilayer prepreg composite 190 is configured by the forming tool 130 into a second shape different from the first shape. In some examples, the forming tool 130 defines a second shape for the multilayer prepreg composite 190. Specifically, during the capsule inflation operation, the multilayer prepreg composite 190 conforms to the forming tool 130. It should be noted that during this operation, the pressure inside the chamber 100 remains below atmospheric pressure, thereby allowing further degassing of the multilayer prepreg composite 190. However, this subsequent degassing is less efficient than the initial degassing (before inflating the capsule 140 within the chamber 100 and compressing the multilayer prepreg composite 190). The degassing path is now limited by the compressing capsule 140 and the forming tool 130 of the multilayer prepreg composite 190.
[0038] Method 500 also includes curing the multilayer prepreg composite material 190 having a second shape. In some examples, during this curing operation, the multilayer prepreg composite material 190 is continuously compressed between the capsule 140 and the molding tool 130. Once the curing operation is complete, a composite part 195 is formed (from the multilayer prepreg composite material 190). Unlike the multilayer prepreg composite material 190, the composite part 195 is able to maintain its shape. Therefore, the composite part 195 no longer requires further support from the capsule 140 and the molding tool 130.
[0039] General reference Figure 1A and Figure 1B Especially for example Figures 3A to 3B For illustrative purposes only and not as a limitation, the following section describes Example 2 of the subject matter disclosed herein. According to Example 2, which covers Example 1 above, during the step of reducing the pressure inside chamber 100 to below atmospheric pressure (block 510), the multilayer prepreg composite charge 190 is separated from the forming tool 130 through gap 134.
[0040] The gap 134 ensures that the portion of the multilayer prepreg composite 190 facing the forming tool 130 remains exposed and available for degassing (or more specifically, initial degassing before compression of the multilayer prepreg composite 190). Once the forming tool 130 contacts the multilayer prepreg composite 190 and the multilayer prepreg composite 190 is compressed between the capsule 140 and the forming tool 130, the degassing path is more restricted and the degassing efficiency is lower than that of initial degassing.
[0041] In some examples, the gap 134 is at least one millimeter (or more specifically, at least five millimeters). On the one hand, a large gap is not necessary because gas can pass through the narrow path efficiently. However, a large gap ensures that deformation of the multilayer prepreg composite 190 does not cause contact between the forming tool 130 and the multilayer prepreg composite 190, thereby maintaining a continuous air path within the gap 134.
[0042] General reference Figure 1A and Figure 1B Especially for example Figure 2 , Figure 3A and Figure 3B For illustrative purposes only and not as a limitation, the following section describes Example 3 of the subject matter disclosed herein. According to Example 3, which covers Example 2 above, chamber 100 includes a chamber housing 110 and a chamber cover 120 coupled to and pivotable relative to the chamber housing 110. The steps of reducing the pressure inside chamber 100 to below atmospheric pressure (block 530) and inflating the bladder 140 within chamber 100 by increasing the pressure inside bladder 140 to atmospheric pressure while maintaining the pressure inside chamber 100 below atmospheric pressure (block 550) each include (block 532) providing a seal between chamber cover 120 and chamber housing 110. A molding tool 130 is attached to and supported by chamber cover 120.
[0043] Attaching the forming tool 130 to the chamber cover 120 eliminates the need for a separate support for the forming tool 130. Therefore, no additional or special tools are required to support and align the forming tool 130 within the chamber 100. Furthermore, the chamber cover 120 is pivotally coupled to the chamber housing 110, allowing opening and access to the chamber 100 while maintaining the relative orientation of the chamber cover 120 and the chamber housing 110. For example, the chamber cover 120 may be pivotally coupled to the chamber housing 110, such as... Figure 2 As shown. The molding tool 130, attached to and supported by the chamber cover 120, remains aligned with the chamber housing 110. In other words, when the chamber cover 120 is sealed relative to the chamber housing 110, the molding tool 130 occupies a designated position within the chamber housing 110 relative to the multilayer prepreg composite filler 190.
[0044] General reference Figure 1A and Figure 1B Especially for example Figure 3A and Figure 3B For illustrative purposes only and not as a limitation, the following section of this paragraph describes Example 4 of the subject matter disclosed herein. According to Example 4, which covers any one of Examples 1 to 3 above, method 500 further includes (box 538) heating the multilayer prepreg composite packing 190 before inflating the bladder 140 within the chamber 100.
[0045] Heating the multilayer prepreg composite material 190 before inflating the bladder 140 within the chamber 100 helps to degas the multilayer prepreg composite material 190, for example, by softening it and allowing trapped air bubbles to travel to its surface. Figure 3A and Figure 3B As shown, the forming tool 130 does not come into contact with the multilayer prepreg composite 190 at this stage, and the entire top surface of the multilayer prepreg composite 190 is exposed or covered by a permeable component, thereby allowing gas to escape from the multilayer prepreg composite 190.
[0046] In some examples, the temperature and duration to which the multilayer prepreg composite 190 is heated do not trigger or cause significant curing of the multilayer prepreg composite 190. For example, during this degassing and heating operation, the multilayer prepreg composite 190 is heated to between approximately 50% and 80% of its curing temperature.
[0047] General reference Figure 1A and Figure 1B Especially for example Figure 3A and Figure 3B For illustrative purposes only and not as a limitation, the following section of this paragraph describes Example 5 of the subject matter disclosed herein. According to Example 5, which covers Example 4 above, heating the multilayer prepreg composite charge 190 before inflating the bladder 140 within the chamber 100 (block 538) is performed after reducing the pressure inside the chamber 100 to below atmospheric pressure (block 530).
[0048] Heating the multilayer prepreg composite material 190 before inflating the sac 140 within the chamber 100 helps to degas the multilayer prepreg composite material 190. For example... Figure 3A and Figure 3BAs shown, the forming tool 130 does not contact the multilayer prepreg composite 190 at this stage, and the entire surface of the multilayer prepreg composite 190 is exposed or covered by a permeable component, allowing gas to escape from the multilayer prepreg composite 190. Furthermore, heating helps soften the multilayer prepreg composite 190, thereby enhancing degassing. Finally, heating helps to shape the multilayer prepreg composite 190, for example, also by softening it. However, heating is limited to avoid premature curing of the multilayer prepreg composite 190 (e.g., curing before molding). Specifically, the duration of heating at this stage is minimized by first reducing the pressure inside the chamber 100 to below atmospheric pressure before initiating heating.
[0049] In some examples, the temperature and duration to which the multilayer prepreg composite 190 is heated do not trigger or cause significant curing of the multilayer prepreg composite 190. For example, during this degassing and heating operation, the multilayer prepreg composite 190 is heated to between approximately 50% and 80% of its curing temperature.
[0050] General reference Figure 1A and Figure 1B Especially for example Figure 3A and Figure 3B For illustrative purposes only and not as a limitation, the following section of this paragraph describes Example 6 of the subject matter disclosed herein. According to Example 6, which covers Example 4 above, heating the multilayer prepreg composite filling 190 (block 538) and reducing the pressure inside the chamber 100 to below atmospheric pressure (block 530) are performed simultaneously before inflating the bladder 140 within the chamber 100.
[0051] Simultaneous heating of the multilayer prepreg composite 190 and reduction of the pressure inside the chamber 100 (to degas the multilayer prepreg composite 190) helps reduce the overall processing time. Furthermore, heating (at this stage) helps soften the multilayer prepreg composite 190, thereby enhancing initial degassing, and also facilitates the later shaping of the multilayer prepreg composite 190.
[0052] In some examples, heating the multilayer prepreg composite 190 and reducing the pressure begin simultaneously. Alternatively, heating the multilayer prepreg composite 190 and reducing the pressure are staggered but overlapped. For example, heating the multilayer prepreg composite 190 begins before reducing the pressure. Alternatively, reducing the pressure begins before heating the multilayer prepreg composite 190.
[0053] General reference Figure 1A and Figure 1B Especially for example Figure 3A and Figure 3BFor illustrative purposes only and not as a limitation, the following section describes Example 7 of the subject matter disclosed herein. According to Example 7, which covers any of Examples 4 through 6 above, heating the multilayer prepreg composite material 190 before inflating the bladder 140 within the chamber 100 (block 538) is performed using a heater 150. The bladder 140 is positioned between the heater 150 and the multilayer prepreg composite material 190.
[0054] Positioning the bladder 140 between the heater 150 and the multilayer prepreg composite charge 190 allows for separation of the heater 150 from the bladder 140, thus simplifying the overall design of the equipment. At this stage, the bladder 140 is flattened and heat is transferred through its two walls. One of these walls faces the heater 150, while the other faces the multilayer prepreg composite charge 190. The bladder 140 also functions as a radiator, effectively reducing the temperature gradient experienced by the multilayer prepreg composite charge 190.
[0055] In some examples, heater 150 is a separate component. For example, heater 150 is attached to chamber housing 110 and / or supported relative to chamber housing 110. Figure 3A A thermal insulator 170 is shown positioned between the chamber housing 110 and the heater 150. Various types of heaters 150 are included, such as resistance heaters, fluid-based heaters, etc.
[0056] General reference Figure 1A and Figure 1B Especially for example Figure 3C and Figure 3D For illustrative purposes only and not as a limitation, the following section describes Example 8 of the subject matter disclosed herein. According to Example 8, which covers any of Examples 4 to 7 above, heating the multilayer prepreg composite charge 190 before inflating the bladder 140 within the chamber 100 (box 538) is performed using a bladder surface heater 142 incorporated into the bladder 140.
[0057] Integrating the bladder surface heater 142 into the bladder 140 reduces the number of components. Furthermore, this integration allows the bladder surface heater 142 to be positioned close to the multilayer prepreg composite material 190 for efficient heating without requiring heat transfer through the walls of the bladder 140. In some examples, the bladder surface heater 142 faces the multilayer prepreg composite material 190. In some specific examples, the bladder surface heater 142 is in direct contact with the multilayer prepreg composite material 190. One example of the bladder surface heater 142 is a resistance heater.
[0058] General reference Figure 1A and Figure 1B Especially for example Figure 3E and Figure 3FFor illustrative purposes only and not as a limitation, the following section describes Example 9 of the subject matter disclosed herein. According to Example 9, which covers any of Examples 4 to 7 above, heating the multilayer prepreg composite material 190 before inflating the bladder 140 within the chamber 100 (box 538) is performed using a blanket heater 152 positioned between the bladder 140 and the multilayer prepreg composite material 190.
[0059] The blanket heater 152 is positioned adjacent to the multilayer prepreg composite pack 190 and engages with the multilayer prepreg composite pack 190 during certain operating steps to effectively heat it without requiring heat transfer through the walls of the bladder 140. Separating the blanket heater 152 from the bladder 140 allows for new designs between the blanket heater 152 and the bladder 140 that are not limited by the integration of these two components. In some examples, the blanket heater 152 faces the multilayer prepreg composite pack 190. In some specific examples, the blanket heater 152 is in direct contact with the multilayer prepreg composite pack 190. A direct example of the blanket heater 152 is a resistance heater.
[0060] General reference Figure 1A and Figure 1B Especially for example Figure 4B and Figure 4C For illustrative purposes only and not as a limitation, the following section describes Example 10 of the subject matter disclosed herein. According to Example 10, which covers Example 9 above, a cured multilayer prepreg composite 190 (box 550) includes (box 552) heating the multilayer prepreg composite 190 using a blanket heater 152 positioned between the multilayer prepreg composite 190 and the molding tool 130.
[0061] The blanket heater 152 provides localized direct heating to the multilayer prepreg composite charge 190 without heating other components, particularly large components such as the forming tool 130. This direct heating increases processing speed (e.g., by reaching the desired temperature faster) and saves energy (e.g., by heating fewer components). Furthermore, direct heating eliminates the need to cool components between processing cycles.
[0062] In some examples, the blanket heater 152 is in direct contact with the multilayer prepreg composite charge 190. In some examples, the blanket heater 152 is supported by a forming tool 130, for example, the blanket heater 152 wraps around the forming tool 130. Meanwhile, the heating element of the blanket heater 152 is thermally insulated from the forming tool 130. A direct example of the blanket heater 152 is a resistance heater.
[0063] General reference Figure 1A and Figure 1B Especially for example Figure 4A and Figure 4BFor illustrative purposes only and not as a limitation, the following section describes Example 11 of the subject matter disclosed herein. According to Example 11, which covers any one of Examples 1 to 10 above, inflating the sac 140 within the chamber 100 (box 540) includes fluidly connecting the sac 140 to the atmosphere (box 542).
[0064] Connecting the fluid in bladder 140 to the atmosphere requires no complex or additional equipment. Bladder 140 is simply exposed to the atmosphere, causing it to expand within chamber 100. It should be noted that the pressure inside chamber 100 is lower than atmospheric pressure, and pressure is applied to bladder 140 from within. For example, a line extending into bladder 140 may be connected to a three-way valve that connects the internal fluid of bladder 140 to the atmosphere (in immediate operation) or a vacuum source (in other operations).
[0065] General reference Figure 1A and Figure 1B Especially for example Figure 4B and Figure 4C For illustrative purposes only and not as a limitation, the following section describes Example 12 of the subject matter disclosed herein. According to Example 12, which covers any one of Examples 1 to 11 above, curing a multilayer prepreg composite 190 (box 550) includes heating the multilayer prepreg composite 190 using a molding tool heater 132 incorporated into a molding tool 130 (box 554).
[0066] While the multilayer prepreg composite 190 is cured, it conforms to and is pressed into the molding tool 130, thereby ensuring good heat transfer between the multilayer prepreg composite 190 and the molding tool 130. The use of the molding tool 130 (or more specifically, the molding tool heater 132 incorporated into the molding tool 130) relies on this heat transfer between the multilayer prepreg composite 190 and the molding tool 130. Furthermore, in some examples, the molding tool 130 is preheated before contacting the multilayer prepreg composite 190. This preheating feature reduces the overall processing time by eliminating the heating period.
[0067] In some examples, the forming tool heater 132 is a resistance heater. However, other types of heaters are also within the scope of this disclosure. In some examples, the forming tool heater 132 is positioned adjacent to the surface of the forming tool 130 that contacts the multilayer prepreg composite charge 190. Furthermore, the forming tool heater 132 is uniformly distributed along this surface. For example, the forming tool heater 132 includes a plurality of heating elements, such as... Figure 4C As shown.
[0068] General reference Figure 1A and Figure 1B Especially for example Figure 4B , Figure 4C , Figure 4D and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 13 of the subject matter disclosed herein. According to Example 13, which covers any one of Examples 1 to 12 above, curing a multilayer prepreg composite 190 (box 550) includes heating the multilayer prepreg composite 190 using a capsule 140 (box 556).
[0069] While the multilayer prepreg composite 190 is cured, it conforms to the capsule 140 and is pressed together by the capsule 140, thereby ensuring good heat transfer between the multilayer prepreg composite 190 and the capsule 140. Furthermore, using the capsule 140 as a heat source eliminates the need to heat other components, especially large components such as the molding tool 130, thus increasing the overall processing speed.
[0070] In some examples, an integrated heater is used to heat the bladder 140. Alternatively, the bladder 140 is heated by supplying hot air into it. For example, the air is heated outside the bladder 140 and then introduced into it.
[0071] General reference Figure 1A and Figure 1B Especially for example Figure 4B and Figure 4C For illustrative purposes only and not as a limitation, the following section describes Example 14 of the subject matter disclosed herein. According to Example 14, which covers Example 13 above, heating the multilayer prepreg composite pack 190 using the bladder 140 (block 556) includes heating the multilayer prepreg composite pack 190 using a bladder surface heater 142 incorporated into the bladder 140 (block 557).
[0072] While the multilayer prepreg composite 190 is cured, it conforms to and is pressed into the capsule 140, ensuring good heat transfer between the multilayer prepreg composite 190 and the capsule 140. For example, a capsule surface heater 142 is positioned on the surface of the capsule 140 that contacts the multilayer prepreg composite 190. Furthermore, using the capsule 140 as a heat source eliminates the need to heat other components, particularly large parts such as the molding tool 130, thereby increasing overall processing speed.
[0073] In some examples, the capsule surface heater 142 is a resistance heater. However, other types of heaters are also within the scope of this disclosure. In some examples, the capsule surface heater 142 is integrated into the capsule 140, for example, forming the surface of the capsule 140.
[0074] General reference Figure 1A and Figure 1B Especially for example Figure 4D and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 15 of the subject matter disclosed herein. According to Example 15, which covers Example 13 above, heating the multilayer prepreg composite charge 190 using a bladder 140 (box 556) includes (box 558) introducing hot air into the bladder 140.
[0075] While the multilayer prepreg composite 190 is cured, it conforms to and is pressed into the capsule 140, thereby ensuring good heat transfer between the multilayer prepreg composite 190 and the capsule 140. Introducing hot air into the capsule 140 provides uniform heating of the capsule 140, and as a result of this heat transfer, also provides uniform heating of the multilayer prepreg composite 190. In some examples, the air is heated outside the capsule 140 and then introduced into the capsule 140.
[0076] General reference Figure 1A and Figure 1B Especially for example Figure 4D and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 16 of the subject matter disclosed herein. According to Example 16, which covers Example 15 above, after inflating the bladder 140 within chamber 100 by increasing the pressure inside the bladder 140 to atmospheric pressure (box 540), the bladder 140 includes a first bladder volume 148 and a second bladder volume 149, such that the molding tool 130 is positioned between the first bladder volume 148 and the second bladder volume 149. The step of introducing hot air into the bladder 140 (box 558) includes recirculating the hot air between the first bladder volume 148 and the second bladder volume 149 (box 559).
[0077] A closed-loop system is established by recirculating hot air between the first bladder volume 148 and the second bladder volume 149 of bladder 140, which is more energy efficient than a system that continuously draws more air from the environment. In addition, recirculating hot air between the first bladder volume 148 and the second bladder volume 149 ensures a uniform temperature distribution within bladder 140 and on the resulting multilayer prepreg composite material 190.
[0078] In some examples, additional air is supplied to or removed from bladder 140 based on the monitored pressure inside bladder 140. For example, the pressure inside bladder 140 is maintained at atmospheric pressure.
[0079] General reference Figure 1A and Figure 1B Especially for example Figure 4D and Figure 4EFor illustrative purposes only and not as a limitation, the following section describes Example 17 of the subject matter disclosed herein. According to Example 17, which covers Example 16 above, hot air is recirculated between the first bladder volume 148 and the second bladder volume 149 (block 559) using a thermal module 182 fluidly connected to the first bladder volume 148 and the second bladder volume 149.
[0080] The thermal module 182 ensures that the temperature of the hot air recirculated between the first bladder volume 148 and the second bladder volume 149 is at a set point. For example, as air passes through bladder 140 (e.g., the first bladder volume 148 or the second bladder volume 149), the air is cooled to heat the walls of bladder 140 and to provide heat to the multilayer prepreg composite filling 190. As the air leaves bladder 140, the thermal module 182 reheats the air back to the set point.
[0081] In some examples, the thermal module 182 is equipped with a heater (e.g., a resistance heater). Additionally, in some examples, the thermal module 182 is equipped with a blower to force hot air and recirculate it between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0082] General reference Figure 1A and Figure 1B Especially for example Figure 4D For illustrative purposes only and not as a limitation, the following section describes Example 18 of the subject matter disclosed herein. According to Example 18, which covers Example 17 above, a first sac volume 148 is fluidly connected to a second sac volume 149 via a conduit 185 outside the sac 140.
[0083] The conduit 185 fluidly connects the first bladder volume 148 to the second bladder volume 149 and ensures that hot air can be recirculated between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0084] In some examples, the catheter 185 protrudes into the respective first balloon volume 148 and second balloon volume 149. Furthermore, the catheter 185 extends outside the chamber 100 to avoid interfering with the balloon 140 and other components.
[0085] General reference Figure 1A and Figure 1B Especially for example Figure 4A For illustrative purposes only and not as a limitation, the following section describes Example 19 of the subject matter disclosed herein. According to Example 19, which covers Examples 17 or 18 above, a first sac volume 148 is fluidly connected to a second sac volume 149 via a channel 141 inside the sac 140.
[0086] Channel 141 fluidly connects the first capsule volume 148 to the second capsule volume 149 and ensures that hot air can be recirculated between the first capsule volume 148 and the second capsule volume 149 of the capsule 140. Furthermore, channel 141 heats the portion of the capsule 140 extending between the first capsule volume 148 and the second capsule volume 149, thereby ensuring that all surfaces of the multilayer prepreg composite filler 190 are heated.
[0087] In some examples, the height of channel 141 is the same as the gap between the multilayer prepreg composite charge 190 and the forming tool 130. Therefore, the height of channel 141 is determined by the design of the forming tool 130. In some examples, the height of channel 141 varies along the length (X direction) of the chamber to ensure uniform flow of hot air through channel 141.
[0088] General reference Figure 1A and Figure 1B Especially for example Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 20 of the subject matter disclosed herein. According to Example 20, which covers Example 16 above, the recirculation of hot air between the first bladder volume 148 and the second bladder volume 149 (block 559) is performed using a thermal module 182 fluidly connected to the first bladder volume 148 and the second bladder volume 149, and a second thermal module 183 fluidly connected to the first bladder volume 148 and the second bladder volume 149.
[0089] Thermal modules 182 and 183 ensure that the temperature of the hot air recirculated between the first capsule volume 148 and the second capsule volume 149 is at a set point. For example, as air passes through capsule 140 (e.g., the first capsule volume 148 or the second capsule volume 149), the air is cooled to heat the walls of capsule 140 and provide heat to the multilayer prepreg composite filling 190. As air leaves the first capsule volume 148, the second thermal module 183 reheats the air back to the set point before reintroducing it into the second capsule volume 149. Similarly, as air leaves the second capsule volume 149, thermal module 182 reheats the air back to the set point before reintroducing it into the first capsule volume 148.
[0090] In some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a heater (e.g., a resistance heater). Furthermore, in some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a blower to force hot air and recirculate the hot air between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0091] General reference Figure 1A and Figure 1B Especially for example Figure 4A and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 21 of the subject matter disclosed herein. According to Example 21, which covers any one of Examples 16 to 19 above, the introduction of hot air into sac 140 (box 558) includes distributing the hot air within sac 140 via a first sac conduit 144 positioned inside a first sac volume 148 and via a second sac conduit 146 positioned inside a second sac volume 149 (box 560).
[0092] The first bladder conduit 144 and the second bladder conduit 146 control the distribution of hot air within the bladder 140, thereby reducing the overall heating and energy consumption of the tool. In some examples, each of the first bladder conduit 144 and the second bladder conduit 146 is a perforated tube.
[0093] General reference Figure 1A and Figure 1B Especially for example Figure 4A and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 22 of the subject matter disclosed herein. According to Example 22, which covers Example 21 above, hot air is directed by a first bladder conduit 144 and a second bladder conduit 146 toward a multilayer prepreg composite charge 190.
[0094] The first bladder conduit 144 and the second bladder conduit 146 control the distribution of hot air within the bladder 140, thereby reducing the overall heating and energy consumption of the tool. In some examples, each of the first bladder conduit 144 and the second bladder conduit 146 is a perforated tube that directs hot air toward the multilayer prepreg composite 190 for curing the multilayer prepreg composite 190.
[0095] General reference Figure 1A and Figure 1B Especially for example Figure 4A and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 23 of the subject matter disclosed herein. According to Example 23, which covers Example 22 above, when hot air is distributed within the capsule 140, the first capsule 144 includes a first capsule opening 145 and the second capsule 146 includes a second capsule opening 147 only in those corresponding portions of the first capsule duct 144 and the second capsule duct 146 facing the multilayer prepreg composite filler 190.
[0096] The first bladder conduit 144 and the second bladder conduit 146 control the distribution of hot air within the bladder 140, thereby reducing the overall heating and energy consumption of the tool. In some examples, each of the first bladder conduit 144 and the second bladder conduit 146 is a perforated tube. Specifically, the perforation of the first bladder conduit 144 is indicated by the first bladder conduit opening 145. The perforation of the second bladder conduit 146 is indicated by the second bladder conduit opening 147.
[0097] General reference Figure 1A and Figure 1B Especially for example Figure 4A and Figure 4F For illustrative purposes only and not as a limitation, the following section describes Example 24 of the subject matter disclosed herein. According to Example 24, which covers any one of Examples 21 to 23 above, reducing the pressure inside the sac 140 to below atmospheric pressure (box 530) includes flattening the first sac duct 144 and the second sac duct 146 (box 536).
[0098] Flattening the first balloon catheter 144 and the second balloon catheter 146 ensures that the first balloon catheter 144 and the second balloon catheter 146 do not interfere with the operation of the balloon 140 when the multilayer prepreg composite material 190 is placed in the chamber 100. In some examples, the balloon 140 is substantially flat when the multilayer prepreg composite material 190 is placed in the chamber 100.
[0099] General reference Figure 1A and Figure 1B Especially for example Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 25 of the subject matter disclosed herein. According to Example 25, which covers any one of Examples 21 to 24 above, distributing hot air within a sac 140 by means of a first sac conduit 144 located within a first sac volume 148 and a second sac conduit 146 located within a second sac volume 149 (block 560) includes supplying hot air to the first sac conduit 144 using a thermal module 182 and supplying hot air to the second sac conduit 146 using a second thermal module 183 (block 562).
[0100] Thermal modules 182 and 183 ensure that the temperature of the hot air recirculated between the first capsule volume 148 and the second capsule volume 149 is at a set point. For example, as air passes through capsule 140 (e.g., the first capsule volume 148 or the second capsule volume 149), the air is cooled to heat the walls of capsule 140 and provide heat to the multilayer prepreg composite filling 190. As air leaves the first capsule volume 148, the second thermal module 183 reheats the air back to the set point before reintroducing it into the second capsule volume 149. Similarly, as air leaves the second capsule volume 149, thermal module 182 reheats the air back to the set point before reintroducing it into the first capsule volume 148.
[0101] In some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a heater (e.g., a resistance heater). Furthermore, in some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a blower to force hot air and recirculate the hot air between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0102] General reference Figure 1A and Figure 1B Especially for example Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 26 of the subject matter disclosed herein. According to Example 26, which covers Example 25 above, distributing hot air within the bladder 140 via a first bladder conduit 144 positioned inside a first bladder volume 148 and a second bladder conduit 146 positioned inside a second bladder volume 149 (box 560) also includes recirculating the hot air from the first bladder volume 148 to the second thermal module 183 and recirculating the hot air from the second bladder volume 149 to the thermal module 182 (box 564).
[0103] Thermal modules 182 and 183 ensure that the temperature of the hot air recirculated between the first capsule volume 148 and the second capsule volume 149 is at a set point. For example, as air passes through capsule 140 (e.g., the first capsule volume 148 or the second capsule volume 149), the air is cooled to heat the walls of capsule 140 and provide heat to the multilayer prepreg composite filling 190. As air leaves the first capsule volume 148, the second thermal module 183 reheats the air back to the set point before reintroducing it into the second capsule volume 149. Similarly, as air leaves the second capsule volume 149, thermal module 182 reheats the air back to the set point before reintroducing it into the first capsule volume 148.
[0104] In some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a heater (e.g., a resistance heater). Furthermore, in some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a blower to force hot air and recirculate the hot air between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0105] General reference Figure 1A and Figure 1B Especially for example Figure 4B For illustrative purposes only and not as a limitation, the following section describes Example 27 of the subject matter disclosed herein. According to Example 27, which covers Example 26 above, method 500 further includes cooling the multilayer prepreg composite 190 (block 570) after curing the multilayer prepreg composite 190 (block 550).
[0106] Cooling the multilayer prepreg composite 190 ensures that, for example, the multilayer prepreg composite 190 retains its second shape after the pouch 140 no longer supports it. In some examples, the multilayer prepreg composite 190 is cooled while being compressed between the pouch 140 and the molding tool 130. More specifically, the multilayer prepreg composite 190 is still configured into its second shape by the molding tool 130 while being cooled.
[0107] General reference Figure 1A and Figure 1B Especially for example Figure 4D and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 28 of the subject matter disclosed herein. According to Example 28, which covers Example 27 above, the cooling multilayer prepreg composite charge 190 (box 570) includes allowing cold air to flow into the bladder 140 (box 572).
[0108] Introducing cold air into the bladder 140 ensures uniform cooling of the bladder 140 and consequently, uniform cooling of the multilayer prepreg composite 190. Uniform cooling of the multilayer prepreg composite 190 helps alleviate thermal stress and prevent deformation. In some examples, the temperature of the cold air introduced into the bladder 140 is gradually decreased to ensure gradual cooling.
[0109] General reference Figure 1A and Figure 1B Especially for example Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 29 of the subject matter disclosed herein. According to Example 29, which covers Example 28 above, the inflow of cold air into bladder 140 (block 572) is performed using thermal module 182 and second thermal module 183.
[0110] Thermal modules 182 and 183 ensure that the temperature of the cold air introduced into bladder 140 is at a set point (e.g., a gradually decreasing set point). For example, the air is heated as it passes through bladder 140, cooling the walls of bladder 140 and the multilayer prepreg composite filling 190. As the air leaves the first bladder volume 148, the second thermal module 183 cools the air back to the set point before reintroducing it into the second bladder volume 149. Similarly, as the air leaves the second bladder volume 149, the thermal module 182 cools the air back to the set point before reintroducing it into the first bladder volume 148.
[0111] In some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a cooler. Furthermore, in some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a blower to recirculate cool air between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0112] General reference Figure 1A and Figure 1B Especially for example Figure 3A , Figure 3B , Figure 3C and Figure 3D For illustrative purposes only and not as a limitation, the following section describes Example 30 of the subject matter disclosed herein. According to Example 30, which covers any one of Examples 1 to 29 above, method 500 further includes placing the multilayer prepreg composite charge 190 between the porous membranes 160 (block 512) before placing the multilayer prepreg composite charge 190 into the chamber 100 (block 520).
[0113] The porous diaphragm 160 prevents the multilayer prepreg composite 190 from sticking to other components while allowing degassing of the multilayer prepreg composite 190. Specifically, when the pressure inside chamber 100 drops below atmospheric pressure, the porous diaphragm 160 allows gas to escape from the multilayer prepreg composite 190. In some examples, one porous diaphragm 160 is positioned between the multilayer prepreg composite 190 and the capsule 140. In one or more examples, another porous diaphragm 160 is positioned between the multilayer prepreg composite 190 and the forming tool 130.
[0114] General reference Figure 1A and Figure 1B Especially for example Figure 4B For illustrative purposes only and not as a limitation, the following section describes example 31 of the subject matter disclosed herein. According to example 31, which covers any one of examples 1 to 25 above, method 500 further includes cooling the multilayer prepreg composite 190 (box 570) after curing the multilayer prepreg composite 190.
[0115] Cooling the multilayer prepreg composite 190 ensures that, for example, the multilayer prepreg composite 190 retains its second shape after the pouch 140 no longer supports it. In some examples, the multilayer prepreg composite 190 is cooled while being compressed between the pouch 140 and the molding tool 130. More specifically, the multilayer prepreg composite 190 is still configured into its second shape by the molding tool 130 while being cooled.
[0116] General reference Figure 1A and Figure 1B Especially for example Figure 4D and Figure 4E For illustrative purposes only and not as a limitation, the following section describes Example 32 of the subject matter disclosed herein. According to Example 32, which covers Example 31 above, the cooling multilayer prepreg composite charge 190 (box 570) includes allowing cold air to flow into the bladder 140 (box 572).
[0117] Introducing cold air into the bladder 140 ensures uniform cooling of the bladder 140 and consequently, uniform cooling of the multilayer prepreg composite 190. Uniform cooling of the multilayer prepreg composite 190 helps alleviate thermal stress and prevent deformation. In some examples, the temperature of the cold air introduced into the bladder 140 is gradually decreased to ensure gradual cooling.
[0118] General reference Figure 1A and Figure 1B Especially for example Figure 4F For illustrative purposes only and not as a limitation, the following section describes example 33 of the subject matter disclosed herein. According to example 33, which covers example 32 above, the flow of cold air into bladder 140 (block 572) is performed using a thermal module 182 fluidly connected to bladder 140.
[0119] Thermal modules 182 and 183 ensure that the temperature of the cold air introduced into bladder 140 is at a set point (e.g., a gradually decreasing set point). For example, the air is heated as it passes through bladder 140, cooling the walls of bladder 140 and the multilayer prepreg composite filling 190. As the air leaves the first bladder volume 148, the second thermal module 183 cools the air back to the set point before reintroducing it into the second bladder volume 149. Similarly, as the air leaves the second bladder volume 149, the thermal module 182 cools the air back to the set point before reintroducing it into the first bladder volume 148.
[0120] In some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a cooler. Furthermore, in some examples, each of the thermal module 182 and the second thermal module 183 is equipped with a blower to recirculate cool air between the first bladder volume 148 and the second bladder volume 149 of the bladder 140.
[0121] General reference Figure 1A and Figure 1B Especially for example Figure 5 For illustrative purposes only and not as a limitation, the following section describes Example 34 of the subject matter disclosed herein. According to Example 34, which covers any one of Examples 1 to 33 above, chamber 100 is configured for forming composite part 195 from multilayer prepreg composite charge 190 using the steps of method 500.
[0122] Chamber 100 allows for a specific sequence of operations involving degassing the multilayer prepreg composite 190 prior to its formation. Specifically, degassing is performed while at least a portion of the multilayer prepreg composite 190 is exposed. At this stage, the multilayer prepreg composite 190 is not yet compressed between the bladder 140 and the forming tool 130. Once the multilayer prepreg composite 190 is compressed between the bladder 140 and the forming tool 130, degassing efficiency decreases as the air passages become blocked by the bladder 140 and the forming tool 130.
[0123] When the pressure inside chamber 100 decreases to below atmospheric pressure, the multilayer prepreg composite 190 is exposed to the environment inside chamber 100, resulting in degassing of the multilayer prepreg composite 190. It should be noted that the multilayer prepreg composite 190 is initially placed in chamber 100 while chamber 100 is at atmospheric pressure. This degassing occurs over a period of time, depending on various factors such as the thickness of the multilayer prepreg composite 190, the material properties of the multilayer prepreg composite 190 (e.g., porosity, density, elasticity), the desired level of degassing, etc. In some examples, the duration of degassing ranges from one minute to one hour (or more specifically, from five minutes to thirty minutes).
[0124] Examples of the topics disclosed in this article can be found in, for example... Figure 6 The aircraft manufacturing and service method 900 shown, and as such Figure 7 The description is based on the background of the aircraft 902 shown. Prior to production, method 900 may include the specifications and design of the aircraft 902 (block 904) and the procurement of materials (as shown in block 906). During production, the manufacturing of components and sub-assemblies of the aircraft 902 (as shown in block 908) and system integration (as shown in block 910) may be carried out. Thereafter, the aircraft 902 may be certified and distributed (as shown in block 912) for service (as shown in block 914). During service, routine maintenance and upkeep may be scheduled for the aircraft 902 (as shown in block 916). Routine maintenance and upkeep may include modification, reconfiguration, retrofitting, etc., of one or more systems of the aircraft 902.
[0125] The various processes of Method 900 may be performed or completed 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 (but is not limited to) any number of aircraft manufacturers and main system subcontractors; a third party may include (but is not limited to) any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.
[0126] like Figure 7As shown, an aircraft 902 produced by method 900 may include a fuselage 918 having multiple advanced systems 920 and an interior 922. Examples of advanced systems 920 include one or more of a propulsion system 924, an electrical system 926, a hydraulic system 928, and an environmental system 930. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein can be applied to other industries, such as the automotive industry. Therefore, in addition to aircraft 902, the principles disclosed herein can be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, etc.
[0127] The equipment and methods shown or described herein may be employed during any one or more stages of method 900. For example, a component or subassembly corresponding to component and subassembly manufacturing (block 908) may be processed or manufactured in a manner similar to that of the component or subassembly produced when aircraft 902 is put into service (block 914). Additionally, one or more examples of equipment, methods, or combinations thereof may be used during the production stages shown in blocks 908 and 910 (e.g., by significantly accelerating the assembly of aircraft 902 or reducing the cost of aircraft 902). Similarly, one or more examples of equipment or method implementations or combinations thereof may (e.g., but not limited to) be used when aircraft 902 is put into service (block 914) and / or during maintenance and repair (block 916).
[0128] The various examples of devices and methods disclosed herein include a wide range of components, features, and functions. It should be understood that the various examples of devices and methods disclosed herein may include any combination of any components, features, and functions of any other examples of devices and methods disclosed herein.
[0129] With the help of the teachings presented in the above description and the related figures, those skilled in the art will conceive of many modifications to the examples set forth herein.
[0130] Therefore, it will be understood that the subject matter disclosed herein is not limited to the specific examples shown, and modifications and other examples are intended to be included within the scope of the appended claims. Furthermore, although the foregoing description and associated drawings illustrate examples of the subject matter disclosed herein in the context of certain illustrative combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided through alternative implementations without departing from the scope of the appended claims. Therefore, the reference numerals in parentheses in the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided herein.
[0131] Although the foregoing concepts have been described in some detail for clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. It should be noted that alternative ways of implementing these processes, systems, and devices exist. Therefore, this example is to be considered illustrative rather than restrictive.
Claims
1. A method (500) for forming a composite part (195) from a multilayer prepreg composite material (190), the method (500) comprising the following steps: The pressure inside the sac (140) located in the chamber (100) at atmospheric pressure is reduced to below atmospheric pressure; The multilayer prepreg composite material (190) having a first shape is placed in the chamber (100); Reduce the pressure inside the chamber (100) to below atmospheric pressure; While maintaining the pressure inside the chamber (100) below atmospheric pressure, the sac (140) inside the chamber (100) is inflated by increasing the pressure inside the sac (140) to atmospheric pressure, so that: The multilayer prepreg composite material (190) is compressed between the capsule (140) and the molding tool (130) located inside the chamber (100), and The multilayer prepreg composite material (190) is configured by the forming tool (130) into a second shape different from the first shape; as well as The multilayer prepreg composite material (190) having the second shape is cured. During the step of reducing the pressure inside the chamber (100) to below atmospheric pressure, the multilayer prepreg composite charge (190) is separated from the molding tool (130) through a gap (134).
2. The method (500) according to claim 1, wherein: The chamber (100) includes a chamber housing (110) and a chamber cover (120) connected to the chamber housing (110) and pivotable relative to the chamber housing (110); The steps of reducing the pressure inside the chamber (100) to below atmospheric pressure and increasing the pressure inside the bladder (140) to atmospheric pressure while maintaining the pressure inside the chamber (100) below atmospheric pressure to inflate the bladder (140) within the chamber (100) each include providing a seal between the chamber cap (120) and the chamber housing (110); and The forming tool (130) is attached to and supported by the chamber cover (120).
3. The method (500) according to any one of claims 1 to 2, further comprising the step of heating the multilayer prepreg composite material (190) prior to the step of inflating the capsule (140) within the chamber (100).
4. The method (500) of claim 3, wherein The step of heating the multilayer prepreg composite material (190) prior to the step of inflating the bladder (140) within the chamber (100) is performed after the step of reducing the pressure inside the chamber (100) to below atmospheric pressure.
5. The method (500) of claim 3, wherein, The steps of heating the multilayer prepreg composite material (190) before the step of inflating the bladder (140) within the chamber (100) and reducing the pressure inside the chamber (100) to below atmospheric pressure are performed simultaneously.
6. The method (500) according to claim 3, wherein: The step of heating the multilayer prepreg composite filling (190) prior to the step of inflating the bladder (140) within the chamber (100) is performed using a heater (150); and The capsule (140) is positioned between the heater (150) and the multilayer prepreg composite material (190).
7. The method (500) of claim 3, wherein The step of heating the multilayer prepreg composite material (190) prior to the step of inflating the bladder (140) within the chamber (100) is performed using a bladder surface heater (142) incorporated into the bladder (140).
8. The method (500) of claim 3, wherein, The step of heating the multilayer prepreg composite material (190) prior to the step of inflating the bladder (140) within the chamber (100) is performed using a blanket heater (152) positioned between the bladder (140) and the multilayer prepreg composite material (190).
9. The method (500) of claim 8, wherein, The step of curing the multilayer prepreg composite material (190) includes heating the multilayer prepreg composite material (190) using the blanket heater (152) positioned between the multilayer prepreg composite material (190) and the molding tool (130).