Equipment and methods for processing composite structures

Abstract

This disclosure relates to an apparatus and method for processing a composite structure. The apparatus for processing the composite structure includes a first processing tool and a second processing tool, movable between an open position and a closed position, wherein in the open position the first and second processing tools are separated from each other, and in the closed position the first and second processing tools are configured to seal to each other. In the closed position, the first and second processing tools are configured to seal to a mandrel tool located between the first and second processing tools and supporting the composite structure. In the closed position, the first processing tool, the second processing tool, and the mandrel tool form a container configured to apply at least one of pressure and heat to the composite structure.

Description

Technical Field

[0001] This disclosure generally relates to the manufacture of composite materials, and more specifically, to apparatus and methods for processing composite structures. Background Technology

[0002] Composite components are typically processed in autoclaves that apply heat and pressure to the component or in ovens that apply heat to the component. However, conventional autoclave and oven processing techniques have several drawbacks, particularly when processing large composite components such as aircraft structures. For example, conventional autoclaves and ovens require significant floor space in manufacturing facilities, increasing costs. Furthermore, conventional autoclaves and ovens require time for heating and cooling between processing cycles, increasing cycle time and costs. Conventional autoclaves and ovens often also require manual installation and removal of vacuum hoses and temperature sensors between cycles, further increasing cycle time and costs. Additionally, conventional processing techniques typically require the application of consumable materials (e.g., bagging), further increasing costs and cycle times. Moreover, conventional processing techniques often require large quantities of heated gas, further increasing processing costs, equipment costs, and cycle times. Therefore, those skilled in the art continue to conduct research and development in the field of composite processing, and devices and methods designed to address the aforementioned problems will find utility.

[0003] The Chinese translation of the abstract of DE102017107908A1 describes: "This invention relates to a molding tool 1 for producing fiber composite parts, particularly using FRP laminates. The molding tool 1 has: a lower mold shell 2 having a molding surface 22 for inserting a semi-finished fiber product 4; and an upper mold shell 3 forming a cavity 5 with the lower mold shell 2 in the closed state of the molding tool 1, in which pressures P1 and P2 can be adjusted to impregnate the inserted semi-finished fiber product 4 with a matrix material. Furthermore, the FRP laminate includes at least one pressure chamber 6 or 7 located on the lower mold shell 2 and / or the upper mold shell 3, the pressures P3 and P4 in the pressure chambers 6 or 7 being adjustable such that the pressure difference between the pressures P3 and P4 in the pressure chambers 6 or 7 and the pressures P1 and P2 in the cavity 5 is less than the pressure difference between the ambient pressure of the mold 1 and the pressures P1 and P2 in the cavity 5."

[0004] US 2456513A relates to molding hollow articles in a mold cavity while simultaneously heat-treating plastic materials between rigid and flexible mold elements.

[0005] The abstract of US2010 / 155984A1 describes a "method for manufacturing a composite part." A temporary removal layer can be placed on an internal mold line tool. A composite material can be laid on the internal mold line tool for the composite part. The internal mold line tool can be positioned together with the composite part within an external mold line tool. The composite part and the temporary removal layer can be transferred from the internal mold line tool to the external mold line tool. After transferring the composite part and the temporary removal layer to the external mold line tool, the internal mold line tool and the temporary removal layer can be removed from the interior of the external mold line tool. Summary of the Invention

[0006] The following is a non-exhaustive list of examples of subjects that may or may not be protected under the subject matter of this disclosure.

[0007] In one example, the disclosed apparatus for processing a composite structure includes a first processing tool and a second processing tool movable between an open position and a closed position. In the open position, the first and second processing tools are separated from each other, and in the closed position, the first and second processing tools are configured to seal to each other. In the closed position, the first and second processing tools are configured to seal to a mandrel tool located between the first and second processing tools and supporting the composite structure. In the closed position, the first processing tool, the second processing tool, and the mandrel tool form a container configured to apply at least one of pressure and heat to the composite structure.

[0008] In another example, the disclosed apparatus for processing a composite structure includes a mandrel tool configured to support the composite structure during processing. The apparatus includes a tool assembly movable relative to the mandrel tool between an open position and a closed position. The apparatus includes an interface seal configured to seal the tool assembly and the mandrel tool together to form a container surrounding the composite structure in the closed position.

[0009] In another example, the disclosed apparatus for processing a composite structure includes a tool assembly configured to form a sealed container with a mandrel tool and configured to apply at least one of pressure and heat to the composite structure supported by the mandrel tool.

[0010] In one example, the disclosed method for processing a composite structure includes the following steps: (1) positioning a first processing tool of a tool assembly and a second processing tool of a tool assembly from an open position (where the first processing tool and the second processing tool are separated) to a closed position, wherein the first processing tool and the second processing tool are sealed to each other and to a mandrel tool supporting the composite structure to form a container surrounding the composite structure; and (2) processing the composite structure.

[0011] In another example, the disclosed method for processing a composite structure includes the following steps: (1) sealing a first processing tool to a mandrel tool supporting the composite structure; (2) sealing a second processing tool to the first processing tool and the mandrel tool; and (3) forming a container surrounding the composite structure using the first processing tool, the second processing tool, and the mandrel tool.

[0012] In another example, the disclosed method for processing a composite structure includes the following steps: (1) positioning a mandrel tool supporting the composite structure on a second processing tool; (2) sealing a first processing tool to the second processing tool and the mandrel tool; and (3) forming a container surrounding the composite structure using the first processing tool, the second processing tool, and the mandrel tool.

[0013] Other examples of the disclosed systems, apparatus, and methods will become apparent from the following detailed description, accompanying drawings, and appended claims. Attached Figure Description

[0014] Figure 1 This is a schematic perspective view of an example of a device for processing composite structures;

[0015] Figure 2 This is a schematic perspective view of an example of the equipment;

[0016] Figure 3 This is a schematic end view of an example device;

[0017] Figure 4 This is a schematic end view of an example device;

[0018] Figure 5 This is a schematic cross-sectional end view of an example of the device;

[0019] Figure 6 This is a schematic cross-sectional end view of an example of the device;

[0020] Figure 7 This is a schematic end view of an example device;

[0021] Figure 8 This is a schematic end view of an example device;

[0022] Figure 9 This is a schematic cross-sectional end view of an example of the device;

[0023] Figure 10 This is a schematic cross-sectional end view of an example of the device;

[0024] Figure 11 This is a schematic cross-sectional end view of an example of the device;

[0025] Figure 12 This is a schematic perspective view of an example of the first processing tool of the equipment;

[0026] Figure 13 This is a schematic perspective view of an example of the second processing tool of the device;

[0027] Figure 14 This is a schematic 3D diagram of an example of the first processing tool;

[0028] Figure 15 yes Figure 14 A schematic perspective view of an example of the sealing interface of the first processing tool;

[0029] Figure 16 This is a schematic perspective view of examples of the first and second processing tools;

[0030] Figure 17 yes Figure 16 A schematic perspective view of an example of the sealing interface of the second processing tool;

[0031] Figure 18 A schematic cross-sectional view of an example of a first processing tool and a second processing tool;

[0032] Figure 19 A schematic perspective view of an example of a first processing tool;

[0033] Figure 20 A schematic cross-sectional perspective view of an example of a first processing tool;

[0034] Figure 21 This is a schematic perspective view of a part of the mandrel tool of the equipment;

[0035] Figure 22 This is a schematic block diagram illustrating an example of the device;

[0036] Figure 23 This is a schematic block diagram illustrating an example of the device;

[0037] Figure 24 This is a schematic block diagram illustrating an example of the device;

[0038] Figure 25This is a flowchart illustrating an example of a method for handling complex structures;

[0039] Figure 26 It is a flowchart of aircraft manufacturing and maintenance methods; and

[0040] Figure 27 This is a schematic block diagram of an example aircraft. Detailed Implementation

[0041] The following detailed description refers to the accompanying drawings, which illustrate specific examples of the features described herein. Other examples with different structures and operations do not depart from the scope of this disclosure. In different drawings, the same reference numerals may refer to the same features, elements, or parts.

[0042] The following are illustrative, non-exhaustive examples of the subject matter according to this disclosure, which may, but are not necessarily, claimed. References to “example” herein mean that one or more features, structures, elements, components, characteristics, and / or operating steps described in connection with that example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to this disclosure. Therefore, the phrases “example,” “another example,” “one or more examples,” and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, the subject matter characterizing any example may, but does not necessarily include the subject matter characterizing any other example. Moreover, the subject matter characterizing any example may, but does not necessarily, combine with the subject matter characterizing any other example.

[0043] This disclosure recognizes that current techniques for manufacturing large composite structures primarily employ a serial flow to process the composite structure. For example, current autoclave processing typically involves a series of operations performed along the processing flow path, including: (1) bagging; (2) transferring the mandrel supporting the composite structure from a transport trolley to an autoclave-compatible trolley for curing; (3) installing a vacuum hose between the autoclave and the mandrel; (4) performing at least one time-consuming leak check on the system; (5) heating and cooling the autoclave; (6) removing the mandrel from the autoclave; (7) removing the vacuum hose; (8) transferring the mandrel back to the transport trolley; and (9) unbagging. Conventional processing techniques typically require very large quantities of heated gas (e.g., air), which increases processing costs and the equipment costs required for the autoclave, such as the structure that reacts with internal pressure and large quantities of gas. This disclosure also recognizes that this method imposes limitations on the cycle time and cost reduction associated with composite processing.

[0044] Overall reference Figures 1 to 24As an example, this disclosure relates to an apparatus 100 for processing a composite structure 102. The apparatus 100 is configured to perform any of a variety of composite processing operations. In one or more examples, the apparatus 100 is configured to compact the composite structure 102 by applying a compaction pressure within a sealed container 114. In one or more examples, the apparatus 100 is configured to debulk the composite structure 102 by applying a combination of low to moderate compaction heat and low to moderate compaction pressure within the sealed container 114. In one or more examples, the apparatus 100 is configured to cure the composite structure 102 by applying a combination of moderate to high curing heat and moderate to high curing pressure within the sealed container 114. Therefore, the apparatus 100 performs the function of a pressurizer or oven without the disadvantages associated with using conventional pressurizer and oven processing techniques.

[0045] refer to Figure 1 and Figure 2 In one or more examples, device 100 includes tool component 164. In one or more examples, tool component 164 includes a first processing tool 104. In one or more examples, tool component 164 also includes a second processing tool 106.

[0046] In one or more examples, device 100 also includes a mandrel tool 112. Mandrel tool 112 is configured to, for example, support composite structure 102 during laying and processing. Mandrel tool 112 may generally be referred to as a laying mandrel.

[0047] In one or more examples, the spindle tool 112 is movable relative to the tool assembly 164. In one or more examples, the tool assembly 164 is movable relative to the spindle tool 112. In one or more examples, the tool assembly 164 is movable relative to the spindle tool 112, and the spindle tool 112 is movable relative to the tool assembly 164.

[0048] In one or more examples, tool assembly 164 and mandrel tool 112 are configured to form a sealed container 114 ( Figure 2 In one or more examples, such as Figure 1 and Figure 2 As shown, via interface seal 180 ( Figure 1 A portion of ) along the first interface 124 ( Figure 2 The first processing tool 104 and the second processing tool 106 are sealed together, via another portion of the interface seal 180 along the second interface 126. Figure 1 A portion of the periphery surrounding the opposite ends of the mandrel tool 112 seals the end of the first processing tool 104 and, via another portion of the interface seal 180, along the third interface 132. Figure 1The other portion surrounding the opposite end of the mandrel tool 112 seals the end of the second processing tool 106 to form a container 114. Figure 2 ).

[0049] Therefore, the disclosed device 100 allows the end 214 of the mandrel tool 112 to extend beyond the tool assembly 164 and be located outside the container 114. The disclosed device 100 also allows the processing trolley 184, which supports the mandrel tool 112 during processing, to be located outside the container 114 during processing. Positioning a portion of the mandrel tool 112 and the processing trolley 184 outside the container 114 advantageously reduces the required size of the container 114, reduces the internal volume of the container 114, and reduces the time and energy required to process the composite structure 102.

[0050] In one or more examples, tool component 164 can be opened at location 108 ( Figure 1 ) and closing position 110 ( Figure 2 The tool assembly 164 moves between the first processing tool 104 and the second processing tool 106 in the open position 108. In the open position 108, the first processing tool 104 and the second processing tool 106 of the tool assembly 164 are positioned such that the mandrel tool 112 supporting the composite structure 102 can be appropriately positioned between the first processing tool 104 and the second processing tool 106 for processing. In the closed position 110, the first processing tool 104 and the second processing tool 106 of the tool assembly 164 are positioned such that the tool assembly 164 and the mandrel tool 112 are hermetically sealed together to form a container 114.

[0051] Container 114 surrounds composite structure 102 during processing. Container 114 is formed by the outer surface 210 of mandrel tool 112. Figure 1 The first processing tool 104 and the second processing tool 106 are formed. When the tool assembly 164 is in the closed position 110 ( Figure 2 When, via the interface seal 180 ( Figure 1 The sealed container 114 has an interface seal 180 in direct contact with the outer surface 210 of the opposite end 214 of the mandrel tool 112, the first processing tool 104, and the second processing tool 106. In other words, the mandrel tool 112, the first processing tool 104, and the second processing tool 106 form the periphery of the container 114 along the interface seal 180. With the container 114 surrounding and sealing the composite structure 102, the tool assembly 164 is configured to apply at least one of pressure and heat to the composite structure 102 supported by the mandrel tool 112.

[0052] Therefore, compared to conventional autoclaves, the disclosed device 100 advantageously reduces the amount of gas 118 located within and confined by the container 114. Figure 5 , Figure 6and Figures 9 to 11 The volume of the gas, such as a heated and / or pressurized gas, reduces the processing costs and cycle times associated with handling composite materials, as well as the cost of the structure required for tool assembly 164 to respond to internal pressure. For example, in conventional autoclaves, the outer walls and doors of the autoclave form a pressure vessel that needs to be large enough to accommodate a mandrel supporting the composite and the entire processing trolley used to support the mandrel during composite material processing. In contrast, the disclosed device 100 utilizes a mandrel tool 112 to form the structural component of container 114. Thus, the mandrel tool 112 serves to support the composite structure 102 ( Figure 1 (e.g., composite prefabricated) and has a dual function of forming part of a container 114 for handling composite structure 102.

[0053] In one or more examples, device 100 includes a heating system (“HS”) 116. Heating system 116 is configured to generate heat used during processing of composite structure 102. In one or more examples, heating system 116 heats gas 118 located within container 114. Figure 5 , Figure 6 and Figures 9 to 11 In one or more examples, the heating system 116 heats at least one of the first processing tool 104 and the second processing tool 106 of the tool assembly 164. In one or more examples, the heating system 116 heats the mandrel tool 112.

[0054] In one or more examples, device 100 includes a pressurization system (“PS”) 140. The pressurization system 140 is used to generate positive pressure for use during processing of the composite structure 102. The positive pressure acts on the composite structure 102 during processing. Figure 1 The pressurization system 140 applies compressive force to the gas 118 located within the container 114 to solidify the composite structure 102. In one or more examples, the pressurization system 140 applies compressive force to the gas 118 located within the container 114. Figure 5 , Figure 6 and Figures 9 to 11 Pressurization.

[0055] In one or more examples, device 100 includes a vacuum system (“VS”) 138. Vacuum system 138 is used to generate a negative pressure used during processing of composite structure 102. As described in more detail herein, vacuum system 138 is configured to evacuate the outer surface 210 of mandrel tool 112 from the conformal membrane (e.g., a first conformal membrane 136). Figure 6 , Figure 10 and Figure 11 ) and / or the second conformal membrane 146 ( Figure 6 )) or surrounding or enclosing the outer surface 212 of the composite structure 102 Figure 1 Compression bagging (e.g., compression bagging 162) Figure 5 and Figure 9 The gas between one of them.

[0056] In one or more examples, device 100 includes a combination of two or more of a heating system 116, a pressurization system 140, and a vacuum system 138 to generate a combination of heat, positive pressure, and negative pressure used during the processing of composite structure 102.

[0057] Therefore, in the various examples disclosed herein, tool assembly 164 opens to position mandrel tool 112 and closes to form container 114 surrounding composite structure 102 for processing composite structure 102 instead of conventional autoclave or oven processing techniques. Compared to conventional autoclave and oven processing techniques, apparatus 100 advantageously reduces the size of the processing equipment and improves cycle time and cost associated with processing composite structure 102. Apparatus 100 also advantageously provides increased production capacity, reduced cycle costs, and flexibility in facility layout.

[0058] General Reference Figures 1 to 11 In one or more examples, the first processing tool 104 and the second processing tool 106 can be in the open position 108 ( Figure 1 , Figure 3 and Figure 7 ) and closing position 110 ( Figure 2 , Figures 4 to 6 and Figures 7 to 11 The first processing tool 104 and the second processing tool 106 are separated from each other, allowing the mandrel tool 112 supporting the composite structure 102 to be properly positioned for processing, such as between the first processing tool 104 and the second processing tool 106. In the closed position 110, at least two of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 are configured to be hermetically sealed to each other to form a container 114 around the composite structure 102.

[0059] In one or more examples, container 114 is a sealed chamber that surrounds and encloses composite structure 102 for processing. Container 114 is configured to apply at least one of pressure and heat to composite structure 102.

[0060] In one or more examples, the first processing tool 104 may be movable relative to the second processing tool 106. In one or more examples, the second processing tool 106 may be movable relative to the first processing tool 104. In one or more examples, the first processing tool 104 and the second processing tool 106 may be movable relative to each other.

[0061] In one or more examples, the movement of the first processing tool 104 and / or the second processing tool 106 relative to each other and / or the mandrel tool 112 is automatically performed by using a drive mechanism, for example, computer-controlled, which is configured to move at least one of the first processing tool 104 and the second processing tool 106 in one or more directions between an open position 108 and a closed position 110.

[0062] As in Figure 3 and Figure 4 As best illustrated, in one or more examples, with the spindle tool 112 properly positioned relative to the tool assembly 164, at least one of the first processing tool 104 and the second processing tool 106 is in the open position 108 relative to each other and relative to the spindle tool 112. Figure 3 ) and closing position 110 ( Figure 4 They move linearly (e.g., roughly horizontally) between them.

[0063] In one or more examples, such as Figures 1 to 6 As shown, the mandrel tool 112 and the composite structure 102 have a closed cross-sectional shape (e.g., circular), for example, for forming a barrel-shaped composite product. The first processing tool 104 and the second processing tool 106 are suitably designed to adapt to the closed cross-sectional shape of the mandrel tool 112 and the composite structure 102 for processing.

[0064] As in Figure 7 and Figure 8 As best illustrated, in one or more examples, with the spindle tool 112 properly positioned relative to the tool assembly 164, the first processing tool 104 is in the open position 108 relative to the second processing tool 106 and relative to the spindle tool 112. Figure 7 ) and closing position 110 ( Figure 8 It pivots between them.

[0065] In one or more examples (not explicitly shown), with the spindle tool 112 properly positioned relative to the tool assembly 164, the first processing tool 104 moves linearly between an open position and a closed position (e.g., generally vertically or lowered) relative to the second processing tool 106 and relative to the spindle tool 112.

[0066] In one or more examples, such as Figures 7 to 11 As shown, the mandrel tool 112 and the composite structure 102 have an open cross-sectional shape (e.g., semi-circular), for example, for forming a semi-barrel-shaped composite product. The first processing tool 104 and the second processing tool 106 are suitably designed to adapt to the open cross-sectional shape of the mandrel tool 112 and the composite structure 102 for processing.

[0067] Typically, tool assembly 164 is configured to complement the shape of mandrel tool 112 and / or the shape of composite structure 102 supported by mandrel tool 112. The complementary shapes of tool assembly 164 and mandrel tool 112 facilitate a reduction in the size of the container 114 surrounding composite structure 102. For example, in conventional autoclave and oven processes, the entire mandrel supporting the composite and the entire processing trolley supporting the mandrel are located within the processing container of the autoclave or oven. The disclosed device 100 causes a portion of mandrel tool 112 (e.g., the opposite end 214 of mandrel tool 112) to be positioned within the container. Figure 1 The entire processing trolley 184 can be located outside the container 114, which significantly reduces the size of the container 114. Therefore, and as... Figures 3 to 11 As shown, the construction and / or shape of the first processing tool 104 and the second processing tool 106 may depend on the construction and / or shape of the mandrel tool 112 and / or the composite structure 102 (e.g., closed cross-sectional shape or open cross-sectional shape).

[0068] Additionally, in the closed position 110, the tool assembly 164 and the mandrel tool 112 may have a variety of sealing configurations, depending on the construction and / or shape of the mandrel tool 112 (e.g., closed cross-sectional shape or open cross-sectional shape), or depending on the construction and / or shape of the composite structure 102 supported by the mandrel tool 112 (e.g., closed cross-sectional shape or open cross-sectional shape).

[0069] Figure 3 An example of a first configuration of the tool assembly 164 in the open position 108 is schematically shown, wherein the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106. Figure 3 The example of the device 100 shown depicts an end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 that supports the composite structure 102 and is supported by a processing trolley 184.

[0070] Figures 4 to 6 An example of a first configuration of the tool assembly 164 in the closed position 110 is schematically shown, wherein the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106 and is sealed with the first processing tool 104 and the second processing tool 106 to form a container 114. Figure 4 The example of the device 100 shown depicts an end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 that supports the composite structure 102 and is supported by a processing trolley 184. Figure 5 and Figure 6The example of device 100 shown depicts a cross-sectional end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 supported by a supporting composite structure 102 and a processing trolley 184. Figure 5 An example of a device 100 is depicted that utilizes a compression bag 162 that surrounds or encloses the outer surface 212 of the composite structure 102. Figure 6 An example of a device 100 is depicted using a first conformal membrane 136 and a second conformal membrane 146 that surround or enclose the outer surface 212 of the composite structure 102.

[0071] Figure 7 An example of a second configuration of the tool assembly 164 in the open position 108 is schematically shown, wherein the spindle tool 112 supporting the composite structure 102 is located on the second processing tool 106. Figure 7 The example shown depicts an end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 that supports the composite structure 102 and is supported by the second processing tool 106.

[0072] Figures 8 to 10 An example of a second configuration of the tool assembly 164 in the closed position 110 is schematically shown, wherein the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106 and is sealed with the first processing tool 104 and the second processing tool 106 to form a container 114. Figure 8 The example of the device 100 shown depicts an end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 that supports the composite structure 102 and is supported by the second processing tool 106. Figure 9 and Figure 10 The example of the device 100 shown depicts a cross-sectional end view of a first processing tool 104, a second processing tool 106, and a mandrel tool 112 that supports the composite structure 102 and is supported by the second processing tool 106. Figure 9 An example of a device 100 is depicted that utilizes a compression bag 162 surrounding the outer surface 212 of the composite structure 102. Figure 10 An example of a device 100 utilizing a first conformal membrane 136 surrounding the outer surface 212 of a composite structure 102 is depicted.

[0073] Figure 11 An example of a third configuration of the tool assembly 164 in the closed position is schematically shown, wherein the mandrel tool 112 supporting the composite structure 102 is sealed with the first processing tool 104 to form a container 114. Figure 11 The example shown depicts a cross-sectional end view of the first processing tool 104 and the mandrel tool 112 supporting the composite structure 102. Figure 11An example of a device 100 utilizing a first conformal membrane 136 surrounding or enclosing the outer surface 212 of a composite structure 102 is depicted. However, Figure 11 The configuration shown can alternatively or additionally utilize a compression bag 162 surrounding or enclosing the composite structure 102.

[0074] As will be apparent from this disclosure, device 100 is not limited to Figures 3 to 11 The construction shown is an example, and other constructions are also expected.

[0075] like Figures 4 to 6 As shown, in one or more examples, the mandrel tool 112 is located between the first processing tool 104 and the second processing tool 106. In the closed position 110, the first processing tool 104 and the second processing tool 106 are configured to seal via interface 180. Figure 1 A portion of the first processing tool 104 is hermetically sealed to each other along the first interface 124. In the closed position 110, the first processing tool 104 is configured to pass through another portion of the interface seal 180 ( Figure 1 The second processing tool 106 is hermetically sealed along the second interface 126 to the outer surface 210 of the end 214 of the mandrel tool 112. In the closed position 110, the second processing tool 106 is configured to pass through another part of the interface seal 180. Figure 1 It is hermetically sealed along the third interface 132 to the outer surface 210 of the end 214 of the mandrel tool 112.

[0076] refer to Figure 5 and Figure 6 In the closed position 110, the first processing tool 104 and the second processing tool 106 form a portion (e.g., the exterior) of the wall 216, which forms the outer shell or outer cover of the container 114, for example having a circular cross-sectional shape. In the closed position 110, the mandrel tool 112 forms another portion (e.g., the interior) of the wall 216, which forms the inner shell of the container 114, for example having a circular cross-sectional shape. This configuration is advantageous for processing materials with, for example,... Figures 1 to 6 The composite structure shown has a closed (e.g., circular) cross-sectional shape.

[0077] like Figures 8 to 10 As shown, in one or more examples, the mandrel tool 112 is positioned on or supported by the second processing tool 106. In the closed position 110, the first processing tool 104 and the second processing tool 106 are configured to hermetically seal each other along the first interface 124 via a portion of the interface seal 180. In the closed position 110, the first processing tool 104 is also configured to hermetically seal to the outer surface 210 of the end 214 of the mandrel tool 112 along the second interface 126 via another portion of the interface seal 180.

[0078] refer to Figure 9 and Figure 10 In the closed position 110, the first processing tool 104 and the second processing tool 106 form a portion (e.g., the exterior) of the wall 216 of the container 114, which has, for example, a semi-circular cross-sectional shape. In the closed position 110, the mandrel tool 112 forms another portion (e.g., the interior) of the wall 216 of the container 114, which also has, for example, a semi-circular cross-sectional shape. Figures 7 to 10 In the example shown, the second processing tool 106 may (but does not need to) be hermetically sealed with the mandrel tool 112. This configuration is advantageous for processing composite structures with open cross-sectional shapes (e.g., semi-circular) such as... Figures 7 to 10 (as shown), planar cross-sectional shape or other complex cross-sectional shape.

[0079] like Figure 11 As shown, in one or more examples, the mandrel tool 112 also functions as a processing tool. In the closed position 110, the first processing tool 104 is configured to hermetically seal to the mandrel tool 112 via a portion of the interface seal 180 along the second interface 126. In these examples, the container 114 is formed by the first processing tool 104 and the mandrel tool 112, without the need for a second processing tool 106. In other words, the mandrel tool 112 functions as a processing tool. In the closed position 110, the first processing tool 104 forms a portion of the wall 216 of the container 114, and the mandrel tool 112 forms another portion of the wall 216 of the container 114.

[0080] In the closed position 110, the first processing tool 104 is configured to hermetically seal to the mandrel tool 112 via the interface seal 180 along the second interface 126. In one or more examples, the mandrel tool 112 includes a pair of opposing mandrel flanges 238 extending outwardly along the length of the mandrel tool 112. In the closed position 110, the first processing tool 104 is configured to hermetically seal to the mandrel tool 112 via the interface seal 180 (… Figure 1 A portion of the first processing tool 104 is hermetically sealed along the second interface 126 to the mandrel flange 238, and another portion of the first processing tool 104 is hermetically sealed along the second interface 126 to the outer surface 210 of the end 214 of the mandrel tool 112 via the interface seal 180. Therefore, when the tool assembly 164 is in the closed position 110, the container 114 is sealed via the interface seal 180, which is in direct contact with the outer surface 210 of the opposite end 214 of the mandrel tool 112, the mandrel flange 238, and the first processing tool 104. In other words, the mandrel tool 112 and the first processing tool 104 form the periphery of the container 114 along the interface seal 180.

[0081] Reference Appendix Figure 1 and Figures 3 to 11 In one or more examples, the first processing tool 104 includes a first container wall 134 forming a portion of the wall 216 of the container 114. In one or more examples, the first processing tool 104 also includes a pair of opposing first container ends 194 forming a portion of the wall 216 of the container 114 (only one of the first container ends 194 is in...). Figure 3 , Figure 4 , Figure 7 and Figure 8 (As can be seen in the image). In one example, each of the first container ends 194 extends substantially perpendicularly from the first container wall 134. In these examples, the first container wall 134 and the first container ends 194 form a first portion of the wall 216 of the container 114.

[0082] Reference Appendix Figure 1 and Figures 3 to 6 In one or more examples, the second processing tool 106 includes a second container wall 144 forming a portion of the wall 216 of the container 114. In one or more examples, the second processing tool 106 also includes a pair of opposing second container ends 196 forming a portion of the wall 216 of the container 114 (only one of the second container ends 196 is in...) Figure 3 and Figure 4 (As can be seen in the image). In one example, each of the second container ends 196 extends substantially perpendicularly from the second container wall 144. In these examples, the second container wall 144 and the second container ends 196 form a second portion of the wall 216 of the container 114.

[0083] like Figure 5 and Figure 6 As shown, in one or more examples, in the closed position 110, the first container wall 134 and the second container wall 144 are connected via the interface seal 180. Figure 1 A portion of it is sealed at the first interface 124. For example... Figure 4 As shown, in the closed position 110, a portion of each of the first container ends 194 and a portion of each of the second container ends 196 are sealed at the first interface 124 via another portion of the interface seal 180. Figure 4 As shown, in the closed position 110, another portion of each of the first container ends 194 (one end of the first container end 194 in) Figure 4 (As can be seen in the image) and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the second interface 126 via another portion of the interface seal 180. (As shown in the image) Figure 4As shown, in the closed position 110, another portion of each of the second container ends 196 (one end of the second container end 196 in) Figure 4 (See in the image) and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the third interface 132 via another part of the interface seal 180.

[0084] Therefore, in one or more examples, with tool assembly 164 in the closed position 110, container 114 is formed by a first container wall 134, a first container end 194, a second container wall 144, a second container end 196, and a mandrel tool 112. Container 114 is connected via interface seal 180 ( Figure 1 The interface seal 180 is in direct contact with the outer surface 210 of the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the end 214 of the mandrel tool 112 along the first interface 124, the second interface 126, and the third interface 132.

[0085] refer to Figures 7 to 10 In one or more examples, the second processing tool 106 includes a second container wall 144 that forms part of the wall 216 of the container 114. In these examples, the second container wall 144 forms a second portion of the wall 216 of the container 114.

[0086] like Figure 9 and Figure 10 As shown, in one or more examples, in the closed position 110, the first container wall 134 and the second container wall 144 are sealed at the first interface 124 via a portion of the interface seal 180. Figure 8 As shown, in the closed position 110, a portion of each of the first container ends 194 (only one of the first container ends 194 is in) Figure 8 (As can be seen in the image) and the second container wall 144 is sealed at the first interface 124 via another portion of the interface seal 180. (See image) Figure 8 As shown, in the closed position 110, another portion of each end of the first container end 194 and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the second interface 126 via another portion of the interface seal 180.

[0087] Therefore, in one or more examples, with tool assembly 164 in the closed position 110, container 114 is formed by a first container wall 134, a first container end 194, a second container wall 144, and a mandrel tool 112. Container 114 is sealed via an interface seal 180, which is in direct contact with the outer surfaces 210 of the first container wall 134, the first container end 194, the second container wall 144, and the end 214 of the mandrel tool 112 along the first interface 124 and the second interface 126.

[0088] like Figure 11 As shown, in one or more examples, in the closed position 110, the first container wall 134 and the first container end 194 (in Figure 11 (Not visible in the middle) Seal the mandrel tool 112 at the second interface 126 via a portion of the interface seal 180 to form the container 114. In one or more examples, in the closed position 110, a portion of each of the first container wall 134 and the first container end 194 (in the middle) Figure 11 (Not visible in the middle) and the mandrel flange 238 are sealed at the second interface 126 via a portion of the interface seal 180. In the closed position 110, another portion of each of the first container ends 194 and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the second interface 126 via another portion of the interface seal 180.

[0089] Therefore, in one or more examples, with tool assembly 164 in the closed position 110, container 114 is formed by a first container wall 134 and mandrel tool 112. Container 114 is sealed via interface seal 180, which is in direct contact with the first container wall 134, the first container end 194, the mandrel flange 238, and the outer surface 210 of mandrel tool 112 along a second interface 126.

[0090] Figure 12 and Figure 13 An example of interface seal 180 is shown schematically. With tool assembly 164 in the closed position 110, interface seal 180 is configured to seal tool assembly 164 and mandrel tool 112 together to form a container 114 surrounding or enclosing composite structure 102. Figure 12 A first portion of the interface seal 180 associated with the first processing tool 104 is shown, and Figure 13 The second portion of the interface seal 180 associated with the second processing tool 106 is shown.

[0091] Reference Figure 12 , Figure 14 and Figure 15In one or more examples, the first processing tool 104 includes a first interface seal 122. The first interface seal 122 is an example of or forms part of an interface seal 180. In the closed position 110, the first interface seal 122 is configured to seal a first interface 124 between the first processing tool 104 and the second processing tool 106. In the closed position 110, the first interface seal 122 is also configured to seal a second interface 126 between the first processing tool 104 and the mandrel tool 112. For example, the first interface seal 122 extends along the periphery of the first container wall 134 and the first container end 194. The first interface seal 122 forms at least a portion of a seal between the first container wall 134 and the second container wall 144. The first interface seal 122 forms at least a portion of a seal between the first container end 194 and the second container end 196. The first interface seal 122 forms a seal between the first container end 194 and the outer surface 210 of the end 214 of the mandrel tool 112.

[0092] In one or more examples, the first processing tool 104 includes a first interface surface 120. In one or more examples, the first interface surface 120 forms the periphery of the first container wall 134. In one or more examples, the first interface surface 120 also forms the periphery of each of the first container ends 194. In one or more examples, a first interface seal 122 extends along the entire first interface surface 120. Typically, the first interface seal 122 is a reusable seal.

[0093] Reference Figure 13 , Figure 16 and Figure 17 In one or more examples, the second processing tool 106 includes a second interface seal 130. The second interface seal 130 is an example of or forms part of an interface seal 180. In the closed position 110, the second interface seal 130 is configured to seal a first interface 124 between the first processing tool 104 and the second processing tool 106. In the closed position 110, the second interface seal 130 is configured to seal a third interface 132 between the second processing tool 106 and the mandrel tool 112. For example, the second interface seal 130 extends along the periphery of the second container wall 144 and the second container end 196. The second interface seal 130 forms at least a portion of a seal between the first container wall 134 and the second container wall 144. The second interface seal 130 forms at least a portion of a seal between the first container end 194 and the second container end 196. The second interface seal 130 forms a seal between the second container end 196 and the outer surface 210 of the end 214 of the mandrel tool 112.

[0094] In one or more examples, the second processing tool 106 includes a second interface surface 128. In one or more examples, the second interface surface 128 forms the periphery of the second container wall 144. In one or more examples, the second interface surface 128 also forms the periphery of each of the second container ends 196. In one or more examples, a second interface seal 130 extends along the entire second interface surface 128. Typically, the second interface seal 130 is a reusable seal.

[0095] like Figure 15 and Figure 17 As shown, in one or more examples, the first interface seal 122 and the second interface seal 130 have complementary geometries. The complementary geometries of the first interface seal 122 and the second interface seal 130 are configured such that they can engage with each other in the closed position 110 to form an airtight seal. The complementary geometries are particularly advantageous at the three-way intersections of the first interface 124 between the first processing tool 104 and the second processing tool 106, the second interface 126 between the first processing tool 104 and the spindle tool 112, and the third interface 132 between the second processing tool 106 and the spindle tool 112.

[0096] refer to Figure 2 , Figure 4 and Figure 8 In one or more examples, tool assembly 164 is temporarily secured in closed position 110, wherein tool assembly 164 and mandrel tool 112 are sealed together to form container 114 during processing of composite structure 102. In one or more examples, tool assembly 164 includes at least one fastening device 236. Figure 2 As shown, at least the fastening device 236 includes or employs any suitable mechanism, such as a clamp, for firmly holding and securing the first processing tool 104 and the second processing tool 106 together to prevent movement or separation. Figure 4 As shown, at least the fastening device 236 includes or employs any suitable mechanism, such as a clamp, for holding and securing the first processing tool 104 and the mandrel tool 112 together to prevent movement or separation.

[0097] refer to Figure 6 , Figure 10 and Figure 12 In one or more examples, the device 100, such as the first processing tool 104, includes a first conformal membrane 136. In the closed position 110, the first conformal membrane 136 is configured to press against the composite structure 102, as... Figure 6 and Figure 10As shown. Typically, the first conformal membrane 136 is a reusable component of the device 100. In one or more examples, the first conformal membrane 136 compresses the composite structure 102 between the first conformal membrane 136 and the outer surface 210 of the mandrel tool 112. In one or more examples, the first conformal membrane 136 serves as an alternative to consumable vacuum bagging or compression bagging.

[0098] In one or more examples, in the closed position 110, the composite structure 102 is located between the mandrel tool 112 and the first conformal membrane 136. During processing, the first conformal membrane 136 applies pressure to the outer surface 212 of the composite structure 102 and compresses the composite structure 102 against the outer surface 210 of the mandrel tool 112. As will be further described herein, in one or more examples, the first conformal membrane 136 is pressed against the outer surface 212 of the composite structure 102 via at least one of a positive pressure applied by the pressure system 140 and / or a negative pressure applied by the vacuum system 138.

[0099] As in Figure 12 As best illustrated, in one or more examples, the first periphery 220 of the first conformal membrane 136 is coupled to and sealed to the first processing tool 104. In one or more examples, a portion of the first conformal membrane 136 (such as two opposing first periphery first sides 222 of the first conformal membrane 136) is coupled to and sealed to the first container wall 134 of the first processing tool 104. In one or more examples, another portion of the first conformal membrane 136 (such as two opposing first periphery second sides 224 of the first conformal membrane 136) is also coupled to and sealed to the first container end 194 of the first processing tool 104.

[0100] The first conformal membrane 136 is coupled to the first processing tool 104 by any suitable method or technique. In one or more examples, the first conformal membrane 136 is coupled and sealed (e.g., hermetic seal) to the first processing tool 104, for example, along the first periphery 220 by mechanical fasteners, chemical bonding (e.g., adhesives or other binders), or a combination of mechanical fasteners and chemical bonding.

[0101] refer to Figure 6 and Figure 13 In one or more examples, the device 100, such as the second processing tool 106, includes a second conformal membrane 146. In the closed position 110, the second conformal membrane 146 is configured to press against the composite structure 102, as... Figure 6As shown. Typically, the second conformal membrane 146 is a reusable component of device 100. In one or more examples, the second conformal membrane 146 compresses the composite structure 102 between the second conformal membrane 146 and the outer surface 210 of the mandrel tool 112. In one or more examples, the second conformal membrane 146 serves as an alternative to consumable vacuum bagging or compression bagging.

[0102] In one or more examples, in the closed position 110, the composite structure 102 is located between the mandrel tool 112 and the second conformal membrane 146. During processing, the second conformal membrane 146 applies pressure to the outer surface 212 of the composite structure 102 and compresses the composite structure 102 against the outer surface 210 of the mandrel tool 112. As will be further described herein, in one or more examples, the second conformal membrane 146 is pressed against the outer surface 212 of the composite structure 102 via at least one of a positive pressure applied by the pressure system 140 and / or a negative pressure applied by the vacuum system 138.

[0103] like Figure 13 As shown, in one or more examples, the second periphery 226 of the second conformal membrane 146 is coupled to and sealed to the second processing tool 106. In one or more examples, a portion of the second conformal membrane 146 (such as the two opposing second periphery first sides 228 of the second periphery 226 of the second conformal membrane 146) is coupled to and sealed to the second container wall 144 of the second processing tool 106. In one or more examples, another portion of the second conformal membrane 146 (such as the two opposing second periphery second sides 230 of the second periphery 226 of the second conformal membrane 146) is also coupled to and sealed to the second container end 196 of the second processing tool 106.

[0104] The second conformal membrane 146 is coupled to the second processing tool 106 by any suitable method or technique. In one or more examples, the second conformal membrane 146 is coupled and sealed (e.g., hermetic seal) to the second processing tool 106, for example, along the second periphery 226 by mechanical fasteners, chemical bonding (e.g., adhesives), or a combination of mechanical fasteners and chemical bonding.

[0105] In one or more examples, the first conformal membrane 136 and the second conformal membrane 146 comprise or are formed of a wide, flat, flexible element (e.g., a sheet) of an elastomeric material. The elastomeric material of the first conformal membrane 136 and the second conformal membrane 146 is impermeable and is therefore capable of applying mechanical pressure to the composite structure 102 during processing by applying positive and / or negative pressure.

[0106] In one or more examples, the first conformal membrane 136 and the second conformal membrane 146 are composed of an elastomer or combination of elastomers, such as, but not limited to, natural rubber, synthetic rubber, fluoropolymer elastomers (e.g., Viton®), silicone resin, ethylene propylene diene monomer (EPDM) rubber, etc. In one or more examples, the elastomer or combination of elastomers of the first conformal membrane 136 and the second conformal membrane 146 are reinforced by a reinforcing material (such as, but not limited to, glass fiber, carbon fiber, etc.).

[0107] The elastomer materials selected for the first conformal membrane 136 and the second conformal membrane 146 may depend on the processing cycle parameters (e.g., heat and pressure) used during the processing of the composite structure 102.

[0108] like Figure 12 As shown, in one or more examples, device 100 (e.g., first processing tool 104) includes a first pad 142. In one or more examples, the first pad 142 is coupled to a first conformal membrane 136. In the closed position 110, the first pad 142 is configured to shape and / or smooth the outer surface 212 of the composite structure 102. For example, in the closed position 110, the first pad 142 is located between the first conformal membrane 136 and the outer surface 212 of the composite structure 102, and a portion of the composite structure 102 is located between the outer surface 210 of the mandrel tool 112 and the first pad 142. During processing, the first pad 142, together with the first conformal membrane 136, is pressed against a portion of the outer surface 212 of the composite structure 102 to shape and / or smooth the outer surface 212 of the composite structure 102.

[0109] The first pad 142 is attached to the first conformal membrane 136 by any suitable method or technique. In one or more examples, the first pad 142 is chemically bonded to the surface of the first conformal membrane 136 (e.g., via an adhesive or other binder).

[0110] like Figure 13 As illustrated, in one or more examples, device 100 (e.g., second processing tool 106) includes a second pad 148. In one or more examples, the second pad 148 is coupled to a second conformal membrane 146. In the closed position 110, the second pad 148 is configured to shape and / or smooth the outer surface 212 of the composite structure 102. For example, in the closed position 110, the second pad 148 is located between the second conformal membrane 146 and the outer surface 212 of the composite structure 102, and a portion of the composite structure 102 is located between the outer surface 210 of the mandrel tool 112 and the second pad 148. During processing, the second pad 148, together with the second conformal membrane 146, is pressed against a portion of the outer surface 212 of the composite structure 102 to shape and / or smooth the outer surface 212 of the composite structure 102.

[0111] The second pad 148 is attached to the second conformal membrane 146 by any suitable method or technique. In one or more examples, the second pad 148 is chemically bonded to the surface of the second conformal membrane 146 (e.g., via an adhesive or other binder).

[0112] Typically, the first pad 142 and the second pad 148 comprise or are formed of a wide, flat, flexible element (e.g., a sheet) that is substantially free of surface defects. The first pad 142 and the second pad 148 are used to come into close contact with the outer surface 212 of the composite structure 102 during processing operations to provide a smooth outer surface to the composite structure 102.

[0113] In one or more examples, the first pad 142 and the second pad 148 are made of fiber-reinforced polymer materials, such as, but not limited to, carbon fiber-reinforced polymers and carbon fiber-reinforced epoxy resins. As an example, the first pad 142 and the second pad 148 are made of carbon fiber-reinforced benzoxazine or carbon fiber-reinforced bismaleimide. In one or more examples, the first pad 142 and the second pad 148 are made of metallic materials, such as, but not limited to, aluminum. In one or more examples, the first pad 142 and the second pad 148 are made of metallic alloys, such as, but not limited to, nickel-iron alloys (e.g., Invar alloy).

[0114] In one or more examples, the first pad 142 and the second pad 148 have a thickness ranging from about 0.030 inches (0.76 mm) to about 0.125 inches (3.17 mm).

[0115] In one or more examples, the outer surfaces of the first pad 142 and the second pad 148 (e.g., the surfaces configured to contact the outer surface 212 of the composite structure 102) have surface roughness values ​​between approximately 32 Ra and approximately 63 Ra.

[0116] The materials and / or thicknesses selected for the first pad 142 and the second pad 148 may depend on the processing cycle parameters (e.g., heat and pressure) used during the processing of the composite structure 102.

[0117] refer to Figure 1 , Figure 2 , Figure 5 , Figures 9 to 11 , Figure 14 and Figure 16In one or more examples, device 100 includes a heating system 116. Heating system 116 is configured to heat the composite structure 102 supported on a mandrel tool 112 during processing. In one or more examples, heating system 116 is configured to heat the composite structure 102 to a temperature sufficient to compact the composite structure 102 and maintain the composite structure 102 at a compaction temperature duration. The compaction process typically includes both temperature and pressure components, as compressive pressure removes voids and facilitates consolidation during compaction. In one or more examples, heating system 116 is configured to heat the composite structure 102 to a temperature sufficient to cure the composite structure 102 and maintain the composite structure 102 at a curing temperature duration. The curing process typically includes both temperature and pressure components, as compressive pressure removes voids and facilitates consolidation during curing.

[0118] In one or more examples, the heating system 116 is configured to heat gas 118 located within (e.g., constrained by) container 114. Figure 5 , Figure 6 and Figures 9 to 11 For example, heating system 116 is in thermal communication with gas 118. In these examples, heat is transferred from heated gas 118 to composite structure 102.

[0119] In one or more examples, the heating system 116 is configured to heat the tool assembly 164. For example, the heating system 116 is coupled to and / or in thermal communication with at least one of the first processing tool 104, the second processing tool 106, the first conformal membrane 136, and / or the second conformal membrane 146. In these examples, heat is transferred from the heated tool assembly 164 to the composite structure 102.

[0120] In one or more examples, the heating system 116 is configured to heat the mandrel tool 112. For example, the heating system 116 is coupled to and / or in thermal communication with the mandrel tool 112. In these examples, heat is transferred from the mandrel tool 112 to the composite structure 102.

[0121] In one or more examples, the heating system 116 is configured to heat at least one or a combination of two or more of the first processing tool 104, the second processing tool 106, the gas 118 located in the container 114, and the mandrel tool 112, such that the composite structure 102 reaches and maintains the desired processing temperature.

[0122] The heating system 116 includes or takes the form of any suitably arranged heating device and / or heating element, which is configured to heat components associated with the heating equipment. In one or more examples, the heating system 116 includes at least one electric heater (e.g., a resistance heat source) configured to generate electrical heat. In one or more examples, the heating system 116 includes at least one gas heater (e.g., a gas heat source) configured to generate gaseous heat. In one or more examples, the heating system 116 includes a combination of an electric heater and a gas heater.

[0123] In one or more examples, at least one heating element (such as a resistance heating element) of the heating system 116 is coupled to and in thermal communication with the first processing tool 104 (such as the first container wall 134 and the first container end 194).

[0124] In one or more examples, at least one heating element (such as a resistance heating element) of the heating system 116 is coupled to and in thermal communication with at least one of the first conformal membrane 136 and / or the first pad 142. Positioning the heating element of the heating system 116 on the first conformal membrane 136 and / or the first pad 142 facilitates efficient heat transfer to the composite structure 102. Furthermore, positioning the heating element of the heating system 116 on the first conformal membrane 136 and / or the first pad 142 allows for selective heating of different regions or portions of the composite structure 102. For example, thicker portions of the composite structure 102 may be heated more than thinner portions of the composite structure 102.

[0125] In one or more examples, a heating system 116, such as an electric heater, is coupled to and in thermal communication with a second processing tool 106 (such as a second container wall 144 and / or a second container end 196).

[0126] In one or more examples, at least one heating element (such as a resistance heating element) of the heating system 116 is coupled to and in thermal communication with at least one of the second conformal membrane 146 and / or the second pad 148. Positioning the heating element of the heating system 116 on the second conformal membrane 146 and / or the second pad 148 can facilitate efficient heat transfer to the composite structure 102. Additionally, positioning the heating element of the heating system 116 on the second conformal membrane 146 and / or the second pad 148 allows for selective heating of different regions or portions of the composite structure 102. For example, a thicker portion of the composite structure 102 can be heated more than a thinner portion of the composite structure 102.

[0127] In one or more examples, at least one heating element (such as a resistance heating element) of the heating system 116 is coupled to and in thermal communication with the mandrel tool 112.

[0128] In one or more examples, at least one heating element of the heating system 116 (such as an electric heat exchanger or a gas heat exchanger) is positioned in thermal communication with the gas 118 to heat the gas 118 located within the container 114. In one or more examples, the heating system 116 heats the gas 118 before it is introduced into the container 114 (e.g., preheating the gas). In one or more examples, the heating system 116 heats the gas 118 after it is introduced into the container 114 (e.g., postheating the gas).

[0129] Still refer to Figure 1 , Figure 2 , Figure 5 , Figures 9 to 11 , Figure 14 and Figure 16 In one or more examples, device 100 includes a pressurization system 140. The pressurization system 140 is coupled to and in communication with tool assembly 164 (such as at least one of the first processing tool 104 and the second processing tool 106). In the closed position 110, with tool assembly 164 and mandrel tool 112 sealed together, the pressurization system 140 is configured to pressurize gas 118 located within container 114 (… Figure 5 , Figure 6 and Figures 9 to 11 Pressurization. In these examples, device 100 uses positive pressure to process composite structure 102.

[0130] As in Figure 5 and Figure 9As shown, in one or more examples, device 100 uses positive pressure applied to composite structure 102 by pressurized gas 118 to process (e.g., compress, compact, or cure) composite structure 102, such as compressing composite structure 102 against the outer surface 210 of mandrel tool 112.

[0131] As in Figure 5 and Figure 9 As shown, in one or more examples, in the closed position 110, a pressurizing system 140 pressurizes a gas 118 located between (constrained by) the first container wall 134, the first container end 194, and the mandrel tool 112. The pressurized gas 118 applies positive pressure to the composite structure 102 to compress a portion of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0132] like Figure 5 As shown, in one or more examples, in the closed position 110, a pressurizing system 140 pressurizes a gas 118 located between (constrained by) the second container wall 144, the second container end 196, and the mandrel tool 112. The pressurized gas 118 applies positive pressure to the composite structure 102 to compress a portion of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0133] In one or more examples, in the closed position 110, gas 118 is constrained by the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112. In the closed position 110, the pressurization system 140 is configured to pressurize the gas 118 located between the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112 (e.g., constrained by the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112) to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0134] In one or more examples, pressurized gas 118 applies positive pressure directly to the outer surface 212 of composite structure 102 to compress it. In one or more examples, the distance between the first container wall 134 and the outer surface 212 of composite structure 102 is relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during processing of composite structure 102. In one or more examples, the distance between the second container wall 144 and the outer surface 212 of composite structure 102 is relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during processing of composite structure 102.

[0135] In one or more examples, such as Figure 5 and Figure 9 As shown, pressurized gas 118 applies positive pressure directly to the compression bag 162 surrounding or enclosing the composite structure 102, and the compression bag 162 is then pressed against the outer surface 212 of the composite structure 102 to compress the composite structure 102 between the compression bag 162 and the mandrel tool 112. In one or more examples, the distance between the first container wall 134 and the compression bag 162 surrounding or enclosing the composite structure 102 is relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during the processing of the composite structure 102. In one or more examples, the distance between the first container wall 134 and the compression bag 162 surrounding or enclosing the composite structure 102 is relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during the processing of the composite structure 102.

[0136] In one or more examples, such as Figure 6 , Figure 10 and Figure 11 As shown, pressurized gas 118 applies positive pressure directly to the first conformal membrane 136, which is then pressed against the outer surface 212 of the composite structure 102 to compress the composite structure 102 between the first conformal membrane 136 and the mandrel tool 112. In these examples, the pressurized gas 118 is constrained by the first container wall 134, the first container end 194, and the first conformal membrane 136. In one or more examples, the distances between the first container wall 134 and the outer surface 212 of the composite structure 102, the distances between the first container wall 134 and the first conformal membrane 136, and / or the distances between the first conformal membrane 136 and the outer surface 212 of the composite structure 102 are relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during the processing of the composite structure 102.

[0137] In one or more examples, such as Figure 6As shown, pressurized gas 118 applies positive pressure directly to the second conformal membrane 146, and the second conformal membrane 146 is then pressed against the outer surface 212 of the composite structure 102 (e.g., via or without compression bag 162) to compress the composite structure 102 between the second conformal membrane 146 and the mandrel tool 112. In these examples, pressurized gas 118 is constrained by the second container wall 144, the second container end 196, and the second conformal membrane 146. In one or more examples, the distance between the second container wall 144 and the outer surface 212 of the composite structure 102, the distance between the second container wall 144 and the second conformal membrane 146, and / or the distance between the second conformal membrane 146 and the outer surface 212 of the composite structure 102 is relatively small (e.g., a few inches or less), which creates a relatively small volume that needs to be pressurized during the processing of the composite structure 102.

[0138] In one or more examples, in the closed position 110, one of the first processing tool 104 or the second processing tool 106 is in communication with the pressurization system 140, and the first processing tool 104 and the second processing tool 106 are in fluid communication with each other, such that the pressurization system 140 is configured to pressurize gas 118 constrained by the first container wall 134, the first container end 194, the second container wall 144, the second container end 196 and the mandrel tool 112 (e.g., located between the first container wall 134, the first container end 194, the second container wall 144, the second container end 196 and the mandrel tool).

[0139] In one or more examples, each of the first processing tool 104 and the second processing tool 106 is coupled to and communicates with the pressurization system 140, such that the pressurization system 140 is configured to pressurize gas 118 constrained (e.g., located between the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112).

[0140] In one or more examples, device 100 includes more than one pressurization system 140, wherein a dedicated pressurization system 140 is coupled to and in communication with each of the first processing tool 104 and the second processing tool 106. In these examples, the first pressurization system is associated with the first processing tool 104 and configured to pressurize gas 118 constrained by a first container wall 134, a first container end 194, and a mandrel tool 112 (e.g., located between the first container wall 134, the first container end 194, and the mandrel tool 112). The second pressurization system is associated with the second processing tool 106 and configured to pressurize gas 118 constrained by a second container wall 144, a second container end 196, and a mandrel tool 112 (e.g., located between the second container wall 144, the second container end 196, and the mandrel tool 112).

[0141] like Figure 6 , Figure 10 and Figure 11 As shown, in one or more examples, device 100 uses positive pressure applied by pressurized gas 118 to at least one of the first conformal membrane 136 and the second conformal membrane 146 to press the first conformal membrane 136 and the second conformal membrane 146 against the composite structure 102 and process the composite structure 102, such as by compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0142] As in Figure 6 , Figure 10 and Figure 11 As shown, in one or more examples, in the closed position 110, the pressurization system 140 is configured to apply positive pressure between the first container wall 134 and the first conformal membrane 136. For example, a first periphery 220 of the first conformal membrane 136 is connected to and sealed to the first container wall 134 and the first container end 194. Gas 118 constrained by the first container wall 134, the first container end 194, and the first conformal membrane 136 (e.g., located between the first container wall 134, the first container end 194, and the first conformal membrane 136) is pressurized using the pressurization system 140. The pressurized gas 118 applies positive pressure between the first container wall 134 and the first conformal membrane 136 to press the first conformal membrane 136 against the composite structure 102 and compress the composite structure 102 against the mandrel tool 112. Therefore, in these examples, the first conformal membrane 136 is used as an alternative to consumable compression bagging or vacuum bagging, which is typically used in compounding processes.

[0143] like Figure 6As shown, in one or more examples, in the closed position 110, the pressurization system 140 is configured to apply positive pressure between the second container wall 144 and the second conformal membrane 146. For example, the second periphery 226 of the second conformal membrane 146 is connected to and sealed to the second container wall 144 and the second container end 196. The second container wall 144, the second container end 196 (…) Figure 3 and Figure 4 The gas 118 constrained by the second conformal membrane 146 (e.g., located between the second container wall 144, the second container end 196, and the second conformal membrane 146) is pressurized using a pressurization system 140. The pressurized gas 118 applies positive pressure between the second container wall 144 and the second conformal membrane 146 to press the second conformal membrane 146 against the composite structure 102 and against the mandrel tool 112 to compress the composite structure 102. Therefore, in these examples, the second conformal membrane 146 serves as an alternative to consumable compression bagging or vacuum bagging typically used in composite processes.

[0144] In one or more examples, in the closed position 110, the tool assembly 164 is configured such that the pressurization system 140 is configured to simultaneously pressurize gas 118 constrained by the first container wall 134, the first container end 194 and the first conformal membrane 136 (e.g., between the first container wall 134, the first container end 194 and the first conformal membrane 136) and gas 118 constrained by the second container wall 144, the second container end 196 and the second conformal membrane 146 (e.g., between the second container wall 144, the second container end 196 and the second conformal membrane 146) against the outer surface 210 of the mandrel tool 112 to compress the composite structure 102.

[0145] In one or more examples, in the closed position 110, one of the first processing tool 104 or the second processing tool 106 is coupled to and in communication with the pressurization system 140 (e.g., fluid communication). The first processing tool 104 and the second processing tool 106 are in fluid communication with each other, such that the pressurization system 140 is configured to simultaneously pressurize gas 118 constrained (e.g., located between the first container wall 134, the first container end 194, and the first conformal membrane 136) and gas 118 constrained (e.g., between the second container wall 144, the second container end 196, and the second conformal membrane 146).

[0146] In another of these examples, each of the first processing tool 104 and the second processing tool 106 is coupled to and in communication with the pressurization system 140 (e.g., fluid communication), such that the pressurization system 140 is configured to independently pressurize gas 118 constrained by the first container wall 134, the first container end 194 and the first conformal membrane 136 (e.g., located between the first container wall 134, the first container end 194 and the first conformal membrane 136), and independently pressurize gas 118 constrained by the second container wall 144, the second container end 196 and the second conformal membrane 146 (e.g., located between the second container wall 144, the second container end 196 and the second conformal membrane 146).

[0147] In one or more examples, device 100 includes more than one pressurization system 140, wherein a dedicated pressurization system 140 is coupled to and in communication with each of the first processing tool 104 and the second processing tool 106. In these examples, the first pressurization system is associated with the first processing tool 104 and configured to pressurize gas 118 constrained (e.g., located between the first container wall 134, the first container end 194, and the first conformal membrane 136) by the first container wall 134, the first container end 194, and the first conformal membrane 136. The second pressurization system is associated with the second processing tool 106 and configured to pressurize gas 118 constrained (e.g., located between the second container wall 144, the second container end 196, and the second conformal membrane 146) by the second container wall 144, the second container end 196, and the second conformal membrane 146.

[0148] The pressurization system 140 includes any one or a combination of various types of systems configured to control the pressure inside the sealed container 114.

[0149] In one or more examples, the pressurization system 140 is configured to utilize liquid nitrogen, which is allowed to change into a gaseous state when introduced into the sealed container 114. The expansion of the nitrogen increases the pressure within the sealed container 114.

[0150] In one or more examples, the pressurization system 140 includes a compressor or pump coupled to a first processing tool 104 and a second processing tool 106 and in fluid communication with the internal volume of the container 114. The operation of the compressor or pump is configured to selectively control the pressure within the sealed container 114.

[0151] In one or more examples, the pressurization of the sealed container 114 is controlled by increasing the temperature of the gas 118 located within the sealed container 114. Increasing the temperature of the gas 118 within the sealed container 114 causes the gas 118 to expand, which results in an increase in pressure within the sealed container 114. In one or more examples, as described above, the temperature of the gas 118 is controlled via a heating system 116.

[0152] refer to Figure 12 , Figure 13 and Figure 18 In one or more examples, in the closed position 110, the tool assembly 164 is configured to transfer gas 118, such as pressurized and / or heated gas, between the first processing tool 104 and the second processing tool 106. For example, in the closed position 110, the tool assembly 164 is configured to provide a path for transferring gas 118 between the first processing tool 104 and the second processing tool 106. These examples are advantageous when the first conformal membrane 136 and the second conformal membrane 146 are respectively coupled to the first processing tool 104 and the second processing tool 106, and are used to compress the composite structure 102 against the mandrel tool 112.

[0153] like Figure 12 and Figure 18 As shown, in one or more examples, the first processing tool 104 includes a first partition 150. The first partition 150 is coupled to and extends from the first container wall 134. In one or more examples, the first processing tool 104 includes more than one first partition 150. In one or more examples, as... Figure 12 As shown, the first processing tool 104 includes two first partitions 150. Each first partition 150 extends along a portion of the first interface surface 120 configured to interface with or contact the second processing tool 106. Figure 18 Only one first partition 150 is shown in the image.

[0154] like Figure 13 and Figure 18 As shown, in one or more examples, the second processing tool 106 includes a second partition 154. The second partition 154 is coupled to and extends from the second container wall 144. In one or more examples, the second processing tool 106 includes more than one second partition 154. In one or more examples, as... Figure 13 As shown, the second processing tool 106 includes two second partitions 154. Each second partition 154 extends along a portion of the second interface surface 128 configured to interface with or contact the first processing tool 104. Figure 18 Only one second partition 154 is shown in the image.

[0155] refer to Figure 18In one or more examples, the first partition 150 includes a first hole 152. In one or more examples, such as Figure 12 As shown, the first partition 150 includes a plurality of first holes 152. In one or more examples, the second partition 154 includes a second opening 156. In one or more examples, as... Figure 13 As shown, the second partition 154 includes a plurality of second holes 156.

[0156] like Figure 18 As shown, in the closed position 110, the first partition 150 and the second partition 154 are in contact with each other, such that the first hole 152 or a plurality of first holes 152 ( Figure 12 ) and second hole 156 or more second holes 156 ( Figure 13 They are aligned with each other so that gas 118 passes between the first processing tool 104 and the second processing tool 106, for example, in the direction of arrow 198.

[0157] like Figure 18 As shown, in one or more examples, gas 118 moves from a first portion 114-1 of container 114, formed by a first processing tool 104 and a mandrel tool 112, to a second portion 114-2 of container 114, formed by a second processing tool 106 and a mandrel tool 112, through aligned first holes 152 and second holes 156 (e.g., in the direction of arrow 198). In some examples, such as in those examples where the first partition 150 and the second partition 154 are entirely positioned between the first processing tool 104 and the second processing tool 106 along the first interface 124, as... Figure 12 and Figure 13 As shown, gas 118 can circulate through container 114, such as passing around composite structure 102 between first processing tool 104 and second processing tool 106. In other words, by combining, the alignment of first partition 150 and second partition 154 with associated first orifice 152 and second orifice 156 acts as a manifold configured to share the supply of gas 118 between first processing tool 104 and second processing tool 106.

[0158] like Figure 18As shown, in one or more examples, the first partition 150 includes a first hole seal 200 extending around the periphery of the first hole 152. In one or more examples, alternatively or otherwise, the second partition 154 includes a second hole seal 202 extending around the periphery of the second hole 156. In the closed position 110, the first hole seal 200 and / or the second hole seal 202 form a seal between the first partition 150 and the second partition 154 around the aligned first hole 152 and second hole 156 to allow gas 118 to pass through. The first hole seal 200 and / or the second hole seal 202 prevent gas 118 from entering the space between the first conformal membrane 136, the second conformal membrane 146, and the composite structure 102.

[0159] Figure 19 and Figure 20 An example of a portion of a first processing tool 104, including a first septum 150 and a first conformal membrane 136, is schematically shown. Although not explicitly shown, an example of an equivalent portion of a second processing tool 106, including a second septum 154 and a second conformal membrane 146, is also shown. Figure 19 and Figure 20 The same applies to China.

[0160] refer to Figures 18 to 20 In one or more examples, the first conformal membrane 136 is coupled to the first partition 150. In one or more examples, the first conformal membrane 136 is sealed to the first partition 150. In one or more examples, opposing first peripheral first sides 222 of the first conformal membrane 136 are coupled to and sealed to the first partition 150 (in... Figures 18 to 20 Only one first periphery, first side 222 of the first conformal membrane 136 and the first partition 150 are shown in the image.

[0161] In one or more examples, the first partition 150 supports the first conformal membrane 136. In the closed position 110, the first partition 150 positions the first conformal membrane 136 closer to the surface of the composite structure 102 than the first container wall 134. The first processing tool 104 may have any number (e.g., one or more) of first partitions 150, which are coupled to the first container wall 134 and support the first conformal membrane 136 at any number of locations.

[0162] In one or more examples, the second conformal membrane 146 is coupled to the second partition 154. In one or more examples, the second conformal membrane 146 is sealed to the second partition 154. In one or more examples, the opposing second peripheral first side 228 of the second conformal membrane 146 is coupled to and sealed to the second partition 154 (in... Figure 18 Only one second periphery first side 228 of the second conformal membrane 146 is shown in the diagram.

[0163] In one or more examples, the second partition 154 supports the second conformal membrane 146. In the closed position 110, the second partition 154 positions the second conformal membrane 146 closer to the surface of the composite structure 102 than the second container wall 144. The second processing tool 106 may have any number (e.g., one or more) of second partitions 154, which are coupled to the second container wall 144 and support the second conformal membrane 146 at any number of locations.

[0164] refer to Figure 1 , Figure 2 , Figure 5 , Figures 9 to 11 , Figure 14 and Figure 16 In one or more examples, device 100 includes a vacuum system 138. In one or more examples, the vacuum system 138 is integrated with the outer surface 210 of the mandrel tool 112 and the compression bag 162. Figure 5 and Figure 9 The container is in fluid communication with the mandrel tool 112. In one or more examples, the vacuum system 138 is in fluid communication with the outer surface 210 and the first conformal membrane 136 formed on the mandrel tool 112. Figure 6 , Figure 10 and Figure 11 The flux between the mandrel tool 112 and the first conformal film 136 and the second conformal film 146 is formed on the outer surface 210 of the mandrel tool 112. Figure 6 The volumetric fluid communication between the two components is as follows: In other words, in the closed position 110, with the tool assembly 164 and the spindle tool 112 sealed together, the vacuum system 138 is configured to provide fluid communication within the container 114, for example, within the compression bag 162. Figure 5 and Figure 9 ), First conformal membrane 136 ( Figure 6 , Figure 10 and Figure 11 ), or the first conformal membrane 136 and the second conformal membrane 146 ( Figure 6 A vacuum is applied between one of the components and the mandrel tool 112. In these examples, the device 100 uses negative pressure to process the composite structure 102.

[0165] like Figure 6 , Figure 10 and Figure 11As shown, in one or more examples, the vacuum system 138 is configured to apply a vacuum between the first conformal membrane 136 and the mandrel tool 112. The vacuum applies a negative pressure to evacuate the gas between the first conformal membrane 136 and the outer surface 210 of the mandrel tool 112. Evacuating the gas between the first conformal membrane 136 and the outer surface 210 of the mandrel tool 112 facilitates the formation of a higher pressure outside the first conformal membrane 136, thereby pushing the first conformal membrane 136 against the outer surface 212 of the composite structure 102 and causing compression of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0166] like Figure 6 As shown, in one or more examples, the vacuum system 138 is configured to apply a vacuum between the second conformal membrane 146 and the mandrel tool 112. The vacuum applies a negative pressure to evacuate the gas between the second conformal membrane 146 and the outer surface 210 of the mandrel tool 112. Evacuating the gas between the second conformal membrane 146 and the outer surface 210 of the mandrel tool 112 facilitates the formation of a higher pressure outside the second conformal membrane 146, thereby pushing the first conformal membrane 136 against the outer surface 212 of the composite structure 102 and causing compression of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0167] In one or more examples, vacuum system 138 includes one or more vacuum pumps. In one or more examples, vacuum system 138 is coupled to mandrel tool 112. In one or more examples, vacuum system 138 is coupled to tool assembly 164, such as at least one of first processing tool 104 and / or second processing tool 106. In one or more examples, vacuum system 138 is coupled to tool assembly 164 and mandrel tool 112.

[0168] refer to Figure 1 , Figure 2 , Figure 14 , Figure 15 and Figure 21 In one or more examples, the vacuum system 138 is connected to the spindle tool 112 via a spindle manifold 206. For example... Figure 21 As shown, in one or more examples, the spindle tool 112 includes a plurality of vacuum holes 240 formed through the outer surface 210 of the spindle tool 112. Typically, the vacuum holes 240 are positioned toward the end of the spindle tool 112, extending beyond the peripheral boundary of the composite structure 102 supported on the spindle tool 112. The vacuum holes 240 are in fluid communication with the spindle manifold 206 via a plurality of spindle vacuum lines 242.

[0169] refer to Figure 1 , Figure 2 , Figure 14 , Figure 15 and Figure 20In one or more examples, the vacuum system 138 is coupled to the tool assembly 164, such as the first processing tool 104 and / or the second processing tool 106, via the tool manifold 204. Figure 20 As shown, in one or more examples, tool assembly 164 (such as first processing tool 104 and / or second processing tool 106) includes components located on or coupled to first conformal membrane 136 and / or second conformal membrane 146. Figure 20 At least one vacuum connector 246 (not shown). The vacuum connector 246 is in fluid communication with the tool manifold 204 via a plurality of tool vacuum lines 244. It is connected to the first conformal membrane 136 (…). Figure 20 The associated vacuum connector 246 is in volumetric fluid communication with the outer surface 212 of the first conformal membrane 136 and the mandrel tool 112. It is also in communication with the second conformal membrane 146. Figure 20 (Not shown in the image) The associated vacuum connector 246 is in volumetric fluid communication with the outer surface 212 of the second conformal membrane 146 and the mandrel tool 112.

[0170] like Figure 5 and Figure 9 As shown, in one or more examples, device 100 includes a compression bag 162. The compression bag 162 is configured to surround or enclose a composite structure 102 supported by a mandrel tool 112. Typically, the compression bag 162 is a consumable. In one or more examples, the compression bag 162 is hermetically sealed to the outer surface 210 of the mandrel tool 112 surrounding the composite structure 102. In one or more examples, the compression bag 162 is applied to the composite structure 102 before the tool assembly 164 is closed and sealed to the mandrel tool 112 to surround or enclose the composite structure 102 to form a container 114.

[0171] In one or more examples, the pressurization system 140 is configured to apply positive pressure between the first container wall 134 and the compression bag 162. Figure 5 and Figure 9 In one or more examples, the pressurization system 140 is configured to apply positive pressure between the second container wall 144 and the compression bag 162. Figure 5 In these examples, the compression bag 162 is pressed (e.g., pushed) against the outer surface 212 of the composite structure 102 by pressurized gas 118 located within the container 114, so as to compress the composite structure 102 between the compression bag 162 and the outer surface 210 of the mandrel tool 112.

[0172] In one or more examples, the compression bag 162 protects the composite structure 102 from interaction with the gas 118 located within the container 114. In one or more examples, the gas 118 is air. In one or more examples, the gas 118 is an inert gas, such as nitrogen.

[0173] In one or more examples, the vacuum system 138 is configured to apply a vacuum between the mandrel tool 112 and the compression bag 162. In these examples, the periphery of the compression bag 162 extends beyond the vacuum hole 240 formed in the mandrel tool 112. Figure 21 The position of the compressed bag 162 is connected to and sealed to the outer surface 210 of the mandrel tool 112. A vacuum is applied to evacuate the gas between the compressed bag 162 and the outer surface 210 of the mandrel tool 112. Evacuating the gas between the compressed bag 162 and the outer surface 210 of the mandrel tool 112 promotes the formation of higher pressure outside the compressed bag 162, thus pushing the compressed bag 162 against the outer surface 212 of the composite structure 102, and causing the composite structure 102 to be compressed against the outer surface 210 of the mandrel tool 112.

[0174] Although Figure 11 The example configuration of the tool assembly 164 shown illustrates the use of the first conformal membrane 136, but in other examples of this configuration of the tool assembly 164, the compression bag 162 is sealed to the mandrel tool 112 and surrounds or encloses the composite structure 102.

[0175] In various examples, the first conformal membrane 136 and / or the second conformal membrane 146 replace the compression bag 162 or serve a substantially similar purpose as the compression bag 162. In these examples, the device 100 advantageously reduces the use of consumable materials such as the compression bag 162. In other examples, the device 100 uses both the compression bag 162 and the first conformal membrane 136 and / or the second conformal membrane 146.

[0176] refer to Figure 1 , Figure 2 , Figure 14 , Figure 16 and Figure 20 In one or more examples, the tool manifold 204 is located on or associated with the first processing tool 104. The tool manifold 204 enables the pressurization system 140, heating system 116, and / or vacuum system 138 to be connected to the tool assembly 164 (e.g., electrical connection, data connection, fluid connection, etc.). The tool manifold 204 advantageously allows the pressurization system 140, heating system 116, and vacuum system 138 to be operatively connected to the tool assembly 164 from outside the container 114.

[0177] In an example where the first processing tool 104 and the second processing tool 106 are fluidly connected to each other, such as in Figure 12 , Figure 13 and Figures 18 to 20 In the example shown, tool assembly 164 may use only one tool manifold 204 associated with either the first processing tool 104 or the second processing tool 106. In an example where the first processing tool 104 and the second processing tool 106 are not in fluid communication with each other, the tool assembly may use two tool manifolds 204 (only one tool manifold 204 is shown), each tool manifold 204 associated with a corresponding one of the first processing tool 104 and the second processing tool 106.

[0178] In one or more examples, tool manifold 204 is configured to route gas 118 heated by heating system 116 into container 114.

[0179] In one or more examples, tool manifold 204 is configured to route power to heating system 116 to heat at least one of first container wall 134, second container wall 144, first conformal membrane 136, second conformal membrane 146, first pad 142, and second pad 148.

[0180] In one or more examples, tool manifold 204 is configured to route gas 118 pressurized by pressurization system 140 to container 114.

[0181] refer to Figure 1 , Figure 2 , Figure 14 , Figure 16 and Figure 21 In one or more examples, the manifold 206 enables the vacuum system 138 and the heating system 116 to be connected to the manifold tool 112 (e.g., electrical connection, data connection, fluid connection, etc.). The manifold 206 advantageously enables the vacuum system 138 and the heating system 116 to be operatively connected to the manifold tool 112 outside the container 114.

[0182] In one or more examples, the manifold 206 is configured to route gas removed by the vacuum system 138 from between the compression bag 162 and the manifold tool 112 or from between the first conformal membrane 136 and / or the second conformal membrane 146 and the manifold tool 112.

[0183] In one or more examples, the manifold 206 is configured to route power to the heating system 116 to heat the manifold tool 112.

[0184] In one or more examples, the composite structure 102 may include a portion having a closed cross-sectional shape with an open interior. For example, the composite structure 102 may include a panel and a panel reinforcement (e.g., a hat stringer) coupled to the panel. In such an example, an inflatable airbag (not shown) is located between the interior of the opening formed by the closed cross-sectional shape of the panel and the reinforcement. In one or more examples, the mandrel manifold 206 is also configured to deliver pressurized gas (such as from the pressurization system 140) from the outside of the tool assembly 164 to the inflatable airbag. Typically, the inflatable airbag is located within the hollow space formed by the closed cross-sectional shape of the panel and the reinforcement (e.g., within the hat stringer) to prevent the reinforcement (e.g., the stringer) from being crushed during processing.

[0185] like Figure 2 As best shown, in one or more examples, in the closed position 110, a portion of the mandrel tool 112 is located outside the container 114. For example, opposite ends 214 of the mandrel tool 112 extend from the tool assembly 164 (e.g., beyond the first container end 194 and the second container end 196) and are located outside the container 114. This configuration allows the heating system 116 and / or the vacuum system 138, for example, to be connected to and disconnected from the mandrel manifold 206 while the mandrel tool 112 is located within the tool assembly 164 in the closed position 110.

[0186] Reference Figure 2 , Figure 4 and Figure 8 In one or more examples, device 100 includes a pair of end caps 158. Figure 2 , Figure 4 and Figure 8 In this configuration, only one end cap 158 is visible. End cap 158 is configured to seal the open end 232 of the mandrel tool 112. Figure 3 and Figure 7 ).exist Figure 3 and Figure 7 Only one of the open ends 232 of the mandrel tool 112 is visible. For example, the end cap 158 seals the open end 232 of the mandrel tool 112 and closes the internal volume 160 of the mandrel tool 112, so that the internal volume 160 can be pressurized during the processing of the composite structure 102.

[0187] In one or more examples, end cap 158 is configured to engage with and hermetically seal the open end 232 of spindle tool 112, which is located outside tool assembly 164. Sealing the open end 232 with end cap 158 closes and seals the internal volume 160 of spindle tool 112. With the internal volume 160 of spindle tool 112 sealed, it can be pressurized, for example, using pressurization system 140. Pressurizing the internal volume 160 of spindle tool 112 increases the structural integrity of spindle tool 112 to respond to positive pressure applied to spindle tool 112 by tool assembly 164 during processing.

[0188] In one or more examples, end cap 158 is coupled to or forms part of tool assembly 164. In one or more examples, end cap 158 is coupled to mandrel tool 112 or forms part of mandrel tool 112.

[0189] In one or more examples, the manifold 206 is configured to direct pressurized gas (such as from the pressurization system 140) into the internal volume 160 of the manifold tool 112.

[0190] As in Figure 1 and Figure 2 As best illustrated, in one or more examples, device 100 includes a processing trolley 184. The processing trolley 184 is configured to support the mandrel tool 112 during processing. In the closed position 110, the processing trolley 184 (e.g., the entire processing trolley 184) is located outside the container 114. Positioning the processing trolley 184 outside the container 114 formed by the tool assembly 164 and the mandrel tool 112 reduces the volume required to process the composite structure 102 and reduces the thermal mass heated during processing of the composite structure 102, thereby reducing cycle time and the energy required to process the composite structure 102.

[0191] Reference Figure 22 In one or more examples, the mandrel tool 112 is configured to shape the inner mold line 190 of the composite structure 102. In these examples, the tool assembly 164 (e.g., a first processing tool 104 or a combination of first processing tool 104 and second processing tool 106) is configured to shape the outer mold line 192 of the composite structure 102. In the examples, a first conformal membrane 136 or a first pad 142 shapes at least a portion of the outer mold line 192 of the composite structure 102. In the examples, the first conformal membrane 136 or the first pad 142 shapes a portion of the outer mold line 192 of the composite structure 102, and a second conformal membrane 146 or a second pad 148 shapes another portion of the outer mold line 192.

[0192] refer to Figure 23 In one or more examples, the mandrel tool 112 is configured to shape the outer mold line 192 of the composite structure 102. In these examples, the tool assembly 164 (e.g., a first processing tool 104 or a combination of first processing tool 104 and second processing tool 106) is configured to shape the inner mold line 190 of the composite structure 102. In examples, a first conformal membrane 136 or a first pad 142 shapes at least a portion of the inner mold line 190 of the composite structure 102. In examples, the first conformal membrane 136 or the first pad 142 shapes a portion of the inner mold line 190 of the composite structure 102, and a second conformal membrane 146 or a second pad 148 shapes another portion of the inner mold line 190.

[0193] As mentioned above and generally as in Figures 3 to 11 As shown, tool assembly 164 has a cross-sectional shape that is complementary to the cross-sectional shape of mandrel tool 112 and the composite structure 102 supported by mandrel tool 112. Compared to conventional autoclave or oven processing equipment, the cross-sectional shape of tool assembly 164, which is complementary to and substantially matches the cross-sectional shape of mandrel tool 112, advantageously reduces the size of the equipment required to fully process composite structure 102. This reduction in overall size beneficially improves the efficiency of equipment 100 and provides a smaller footprint for facility layout.

[0194] refer to Figure 24 In one or more examples, the first processing tool 104 includes a first open cross-sectional shape 168. In one or more examples, the first processing tool 104 (e.g., the first open cross-sectional shape 168) is complementary to a first portion of the mandrel tool 112 (such as a first half or first side of the mandrel tool 112). In one or more examples, the first container wall 134 includes a first non-planar member 174. The first non-planar member 174 of the first container wall 134 surrounds the first portion of the mandrel tool 112. Examples of this configuration are shown in... Figures 3 to 11 As shown in the image.

[0195] In one or more examples, the second processing tool 106 includes a second open cross-sectional shape 170. In one or more examples, the second processing tool 106 (e.g., the second open cross-sectional shape 170) is complementary to a second portion of the mandrel tool 112 (such as a second half or opposite second side of the mandrel tool 112). In one or more examples, the second container wall 144 includes a second non-planar member 178. The second non-planar member 178 of the second container wall 144 surrounds the second portion of the mandrel tool 112. Examples of this construction are shown in... Figures 3 to 6 As shown in the image.

[0196] In one or more examples, the second processing tool 106 includes a first planar cross-sectional shape 172. In one or more examples, the second processing tool 106 (e.g., the first planar cross-sectional shape 172) is complementary to a portion of the mandrel tool 112 (such as a second half or an opposite second side of the mandrel tool 112). In one or more examples, the second container wall 144 includes a planar member 176. The planar member 176 supports the mandrel tool 112. Examples of this construction are shown in... Figures 7 to 10 As shown in the image.

[0197] In one or more examples, the mandrel tool 112 includes a closed cross-sectional shape 182. A first open cross-sectional shape 168 of the first container wall 134 is complementary to a first portion of the closed cross-sectional shape 182 of the mandrel tool 112. A second open cross-sectional shape 170 of the second container wall 144 is complementary to a second portion of the closed cross-sectional shape 182 of the mandrel tool 112.

[0198] In one or more examples, the closed cross-sectional shape 182 of the mandrel tool 112 is circular, and the first open cross-sectional shape 168 of the first container wall 134 and the second open cross-sectional shape 170 of the second container wall 144 are each semi-circular. In this example, the circular cross-sectional shape of the mandrel tool 112 and the semi-circular cross-sectional shapes of the first container wall 134 and the second container wall 144 can be used to form a composite structure 102 with a circular cross-sectional shape, such as a cylindrical segment of an aircraft fuselage. An example of this construction is... Figures 3 to 6 As shown in the image.

[0199] In one or more examples, the mandrel tool 112 includes a third open cross-sectional shape 186. A first open cross-sectional shape 168 of the first container wall 134 is complementary to the third open cross-sectional shape 186 of the mandrel tool 112. A first planar cross-sectional shape 172 of the second container wall 144 is configured to support the mandrel tool 112 for processing. Examples of this configuration are shown in... Figures 7 to 10 As shown in the image.

[0200] In one or more examples, the mandrel tool 112 includes a second planar cross-sectional shape 188. A first open cross-sectional shape 168 of the first container wall 134 is complementary to a first portion of the second planar cross-sectional shape 188 of the mandrel tool 112 (such as a first surface of the mandrel tool 112). A first planar cross-sectional shape 172 of the second container wall 144 is complementary to a second portion of the second planar cross-sectional shape 188 of the mandrel tool 112 (such as an opposing second surface of the mandrel tool 112) to support the mandrel tool 112.

[0201] In one or more examples, the mandrel tool 112 includes a complex cross-sectional shape 208. A first open cross-sectional shape 168 of the first container wall 134 is complementary to a first portion of the complex cross-sectional shape 208 of the mandrel tool 112. A second open cross-sectional shape 170 of the second container wall 144 is complementary to a second portion of the complex cross-sectional shape 208 of the mandrel tool 112. Alternatively, a first planar cross-sectional shape 172 of the second container wall 144 is complementary to a second portion of the complex cross-sectional shape 208 of the mandrel tool 112 to support the mandrel tool 112.

[0202] Other configurations are also possible, such as other cross-sectional shapes for the first processing tool 104, the second processing tool 106, and the mandrel tool 112.

[0203] refer to Figure 25 As an example, this disclosure also relates to a method 1000 for processing composite structure 102. Generally, refer to... Figures 1 to 24 In one or more examples, the disclosed device 100 is used to implement the method 1000.

[0204] The processing performed according to the disclosed method 1000 includes any suitable manufacturing process in which heat, pressure, or a combination of heat and pressure are used to process the composite structure 102. In one example, method 1000 is depicted as a compaction process, in which the composite layup is compacted to remove trapped air. In another example, method 1000 is depicted as a debulking process, in which a thick laminate is compacted under moderate heat and pressure and / or vacuum to remove most of the air, ensuring it is in place on a tool and preventing wrinkles. In yet another example, method 1000 is depicted as a curing process, in which the properties of the thermosetting resin are altered by a chemical reaction under heat and pressure and / or vacuum.

[0205] In one or more examples, method 1000 includes the step of laying a composite structure (box 1002). In one or more examples, the step of laying a composite structure (box 1002) includes the step of laying a composite structure 102 on a mandrel tool 112. The mandrel tool 112 is configured to support the composite structure 102 during processing and to provide shape to at least a portion of the composite structure 102.

[0206] In one or more examples, the step of laying the composite structure (block 1002) further includes applying a compression bag 162 to the composite structure 102 and sealing the compression bag 162 hermetically to the mandrel tool 112 to seal the composite structure 102 within the compression bag 162. It is understood that the compression bag 162 is not required in every example embodiment of the disclosed method 1000.

[0207] In one or more examples, method 1000 includes the step of positioning mandrel tool 112 (block 1004). In one or more examples, the step of positioning mandrel tool (block 1004) includes positioning mandrel tool 112 relative to tool assembly 164, such as positioning it between first processing tool 104 and second processing tool 106. In one or more examples, the step of positioning mandrel tool 112 relative to tool assembly 164 is performed using a processing trolley 184 that supports mandrel tool 112.

[0208] In one or more examples, the step of positioning the mandrel tool (box 1004) includes the following steps: with the tool assembly 164 in the open position 108, positioning (e.g., moving) the mandrel tool 112 within the tool assembly 164, such as positioning it between the first processing tool 104 and the second processing tool 106.

[0209] In one or more examples, the mandrel tool 112 includes a closed cross-sectional shape 182. A first processing tool 104 includes a first open cross-sectional shape 168 complementary to a first portion of the closed cross-sectional shape 182 of the mandrel tool 112. A second processing tool 106 includes a second open cross-sectional shape 170 complementary to a second portion of the closed cross-sectional shape 182 of the mandrel tool 112. The first processing tool 104 and the second processing tool 106, when hermetically sealed together and hermetically sealed with the mandrel tool 112, surround the composite structure 102 to form a container 114 in the closed position 110.

[0210] In one or more examples, the step of positioning the mandrel tool 112 (box 1004) includes the following steps: positioning the mandrel tool 112 supporting the composite structure 102 on the second processing tool 106 with the tool assembly 164 in the open position 108.

[0211] In one or more examples, mandrel tool 112 includes a second planar cross-sectional shape 188. Second processing tool 106 includes a first planar cross-sectional shape 172 configured to support the second planar cross-sectional shape 188 of mandrel tool 112. First processing tool 104 includes a first open cross-sectional shape 168 complementary to the shape of composite structure 102, such as the inner mold line 190 or outer mold line 192 of composite structure 102.

[0212] In one or more examples, method 1000 includes the step of closing tool assembly 164 (block 1006). In one or more examples, the step of closing tool assembly 164 (block 1006) includes positioning a first processing tool 104 and a second processing tool 106 of tool assembly 164 from an open position 108 (where the first processing tool 104 and the second processing tool 106 are separated) to a closed position 110. Typically, the step of closing tool assembly 164 (e.g., by positioning the first processing tool 104 and the second processing tool 106 in the closed position 110) (block 1006) positions tool assembly 164 (e.g., the first processing tool 104 and the second processing tool 106) in contact with a mandrel tool 112 supporting composite structure 102 to form a container 114 surrounding composite structure 102.

[0213] In one or more examples, the step of positioning tool component 164 from open position 108 to closed position 110 includes moving at least one of the first processing tool 104 and the second processing tool 106 relative to each other. In one example, at least one of the first processing tool 104 and the second processing tool 106 moves linearly (e.g., generally horizontally or generally vertically) relative to the other between open position 108 and closed position 110. In another example, the first processing tool 104 pivotally moves relative to the second processing tool 106 between open position 108 and closed position 110.

[0214] In one or more examples, method 1000 includes the step of sealing tool assembly 164 with mandrel tool 112 (block 1008). In one or more examples, the step of sealing tool assembly 164 with mandrel tool 112 (block 1008) includes the step of hermetically sealing tool assembly 164 and mandrel tool 112 together. Typically, the step of closing tool assembly 164 (e.g., by positioning first processing tool 104 and second processing tool 106 in closed position 110) (block 1006) seals tool assembly 164 (e.g., sealing first processing tool 104 and second processing tool 106 to each other), and seals tool assembly 164 (e.g., first processing tool 104 and second processing tool 106) with mandrel tool 112 supporting composite structure 102, and thereby seals container 114 surrounding composite structure 102 (e.g., forming sealed container 114).

[0215] In one or more examples, the step of sealing the tool assembly 164 and the mandrel tool 112 together (block 1008) includes sealing the first processing tool 104 to the mandrel tool 112 supporting the composite structure 102. The step of sealing the tool assembly 164 and the mandrel tool 112 together (block 1008) also includes sealing the second processing tool 106 to the first processing tool 104 and the mandrel tool 112.

[0216] In one or more examples, the step of sealing the tool assembly 164 and the mandrel tool 112 together (box 1008) includes the step of sealing the first processing tool 104 to the second processing tool 106 and the mandrel tool 112.

[0217] In one or more examples, the step of sealing the tool assembly 164 and the mandrel tool 112 together (box 1008) includes the step of sealing the first processing tool 104 to the mandrel tool 112.

[0218] In one or more examples, method 1000 includes the step of forming container 114 (box 1010). In one or more examples, the step of forming container 114 (box 1010) is achieved by the steps of closing the tool assembly (box 1006); and sealing the tool assembly 164 and the mandrel tool 112 together (box 1008). Container 114 surrounds composite structure 102.

[0219] In one or more examples, the step of forming container 114 (block 1010) includes forming container 114 surrounding composite structure 102 using a first processing tool 104, a second processing tool 106 and a mandrel tool 112.

[0220] In one or more examples, the step of forming container 114 (box 1010) includes forming container 114 surrounding composite structure 102 using a first processing tool 104 and a mandrel tool 112.

[0221] In one or more examples, method 1000 includes the step of processing composite structure 102 (box 1012). In one or more examples, the step of processing composite structure 102 (box 1012) includes applying heat. In one or more examples, the step of processing composite structure 102 (box 1012) includes applying pressure. In one or more examples, the step of processing composite structure 102 (box 1012) includes applying both heat and pressure. In one or more examples, the step of processing composite structure 102 (box 1012) includes applying at least one of pressure and heat to composite structure 102, for example, to perform a compaction, tamping, or curing operation.

[0222] In one or more examples, the step of applying pressure includes using positive pressure. In one or more examples, the step of applying pressure to the composite structure 102 includes pressurizing a gas 118 located within the container 114. In these examples, the pressurized gas 118 (positive pressure) pushes against the outer surface 212 of the composite structure 102 to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0223] In one or more examples, the step of applying pressure includes using negative pressure. In one or more examples, the step of applying pressure to the composite structure 102 includes applying a vacuum (negative pressure) between the compression bag 162 surrounding or around the composite structure 102 and the mandrel tool 112. In these examples, negative pressure evacuates the gas between the compression bag 162 and the outer surface 212 of the composite structure 102 to create a pressure differential. Typically, evacuating the gas below the compression bag 162 (e.g., vacuum bagging) promotes the formation of a higher pressure outside the compression bag 162 to push against the compression bag 162, thereby causing compression of the composite structure 102. In these examples, a vacuum system 138 is used to apply a vacuum between the compression bag 162 and the mandrel tool 112. Additionally, evacuating the gas below the compression bag 162 removes air, water vapor, and / or other volatiles that may escape from the composite structure 102 during processing.

[0224] In one or more examples, the step of applying pressure to the composite structure 102 includes applying positive pressure between the first container wall 134 of the first processing tool 104 and the first conformal membrane 136 coupled to the first container wall 134. For example, applying positive pressure includes increasing the atmospheric pressure within the container 114, thereby increasing the compressive force acting on the composite structure 102 during processing. In these examples, pressurized gas 118 in the container 114 pushes the first conformal membrane 136 against a portion of the outer surface 212 of the composite structure 102 to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112. In these examples, a pressurization system 140 is used to pressurize the gas 118 between the first container wall 134 and the first conformal membrane 136 and to apply pressure to the first conformal membrane 136.

[0225] In one or more examples, the step of applying pressure to the composite structure 102 includes applying a vacuum (negative pressure) between the mandrel tool 112 and the first conformal membrane 136. In these examples, the negative pressure evacuates the gas between the first conformal membrane 136 and the outer surface 210 of the mandrel tool 112 to create a pressure differential. Typically, evacuating the gas between the first conformal membrane 136 and the outer surface 210 of the mandrel tool 112 facilitates the formation of a higher pressure outside the first conformal membrane 136 to push against it, thereby causing compression of the composite structure 102. In these examples, a vacuum system 138 is used to apply a vacuum between the first conformal membrane 136 and the mandrel tool 112. Additionally, evacuating the gas between the first conformal membrane 136 and the mandrel tool 112 removes air, water vapor, and / or other volatiles that may escape from the composite structure 102 during processing. In these examples, the first conformal membrane 136 may replace the compression bag 162 or serve a similar purpose to the compression bag 162.

[0226] In one or more examples, the step of processing the composite structure 102 (box 1012) includes shaping a portion of the composite structure 102 using a first conformal film 136 and / or a compression bag 162.

[0227] In one or more examples, positive pressure is applied via pressurized gas 118 in container 114 to push the first conformal membrane 136 and / or compressed bag 162 against a portion of the outer surface 212 of composite structure 102, which in turn shapes the outer surface 212 of composite structure 102.

[0228] In one or more examples, the pressure difference between the container atmospheric pressure and the vacuum below the first conformal membrane 136 and mandrel tool 112 or the vacuum below the compression bag 162 results in a compressive force being applied to the composite structure 102 during processing.

[0229] In one or more examples, the portion of composite structure 102 formed by the first conformal film 136 or compression bag 162 is at least a portion of the outer mold line 192 of composite structure 102. In these examples, mandrel tool 112 forms the inner mold line 190 of composite structure 102.

[0230] In one or more examples, the portion of composite structure 102 formed by the first conformal film 136 or compression bag 162 is at least a portion of the inner mold line 190 of composite structure 102. In these examples, mandrel tool 112 shapes the outer mold line 192 of composite structure 102.

[0231] In one or more examples, the step of processing composite structure 102 (block 1012) includes shaping and / or smoothing a portion of composite structure 102 using a first pad 142 coupled to a first conformal membrane 136. In these examples, the first pad 142 is pressed against a portion of the outer surface 212 of composite structure 102 to shape and / or smooth the outer surface 212 of composite structure 102 due to the application of pressure (e.g., positive pressure) and / or vacuum (e.g., negative pressure) on the first conformal membrane 136. For example, the first pad 142 is pushed into composite structure 102 by a pressure difference on either side of the first conformal membrane 136 to shape and / or smooth the outer surface 212 of composite structure 102.

[0232] In one or more examples, the portion of composite structure 102 formed by the first pad 142 is at least a portion of the outer mold line 192 of composite structure 102. In these examples, the mandrel tool 112 forms the inner mold line 190 of composite structure 102.

[0233] In one or more examples, the portion of composite structure 102 formed by the first pad 142 is at least a portion of the inner mold line 190 of composite structure 102. In these examples, mandrel tool 112 forms the outer mold line 192 of composite structure 102.

[0234] In one or more examples, the step of applying pressure to the composite structure 102 includes applying positive pressure between the second container wall 144 of the second processing tool 106 and the second conformal membrane 146 coupled to the second container wall 144. For example, applying positive pressure includes increasing the atmospheric pressure within the container 114, thereby increasing the compressive force on the composite structure 102 during processing. In these examples, pressurized gas 118 in the container 114 pushes the second conformal membrane 146 against a portion of the outer surface 212 of the composite structure 102 to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112. In these examples, a pressurization system 140 is used to pressurize the gas 118 located between the second container wall 144 and the second conformal membrane 146, and to apply pressure to the first conformal membrane 136.

[0235] In one or more examples, the step of applying pressure to the composite structure 102 includes applying a vacuum (negative pressure) between the mandrel tool 112 and the second conformal membrane 146. In these examples, the negative pressure evacuates the gas between the second conformal membrane 146 and the outer surface 210 of the mandrel tool 112 to create a pressure differential. Typically, evacuating the gas between the second conformal membrane 146 and the outer surface 210 of the mandrel tool 112 facilitates the creation of a higher pressure outside the second conformal membrane 146 to push against it, thereby causing compression of the composite structure 102. In these examples, a vacuum system 138 is used to apply a vacuum between the second conformal membrane 146 and the mandrel tool 112. Additionally, evacuating the gas between the second conformal membrane 146 and the mandrel tool 112 removes air, water vapor, and / or other volatiles that may escape from the composite structure 102 during processing. In these examples, the second conformal membrane 146 may replace the compression bag 162 or serve a similar purpose to the compression bag 162.

[0236] In one or more examples, the step of processing the composite structure 102 (box 1012) includes shaping a portion of the composite structure 102 using a second conformal film 146 and / or a compression bag 162.

[0237] In one or more examples, positive pressure is applied via pressurized gas 118 in container 114 to push the second conformal membrane 146 and / or the compressed bag 162 against a portion of the outer surface 212 of the composite structure 102, which in turn shapes the outer surface 212 of the composite structure 102.

[0238] In one or more examples, the pressure difference between the container atmospheric pressure and the vacuum below the second conformal membrane 146 and mandrel tool 112 or the vacuum below the compression bag 162 results in a compressive force being applied to the composite structure 102 during processing.

[0239] In one or more examples, the portion of composite structure 102 formed by the second conformal membrane 146 is at least a portion of the outer mold line 192 of composite structure 102. In these examples, mandrel tool 112 forms the inner mold line 190 of composite structure 102.

[0240] In one or more examples, the portion of composite structure 102 formed by the second conformal membrane 146 is at least a portion of the inner mold line 190 of composite structure 102. In these examples, mandrel tool 112 forms the outer mold line 192 of composite structure 102.

[0241] In one or more examples, the step of processing composite structure 102 (block 1012) includes shaping and / or smoothing a portion of composite structure 102 using a second pad 148 coupled to a second conformal membrane 146. In these examples, the second pad 148 is pressed against a portion of the outer surface 212 of composite structure 102 to shape and / or smooth the outer surface 212 of composite structure 102 due to the application of pressure (e.g., positive pressure) and / or vacuum (e.g., negative pressure) on the second conformal membrane 146. For example, the second pad 148 is pushed into composite structure 102 by a pressure difference on either side of the second conformal membrane 146 to shape and / or smooth the outer surface 212 of composite structure 102.

[0242] In one or more examples, the portion of composite structure 102 formed by the second pad 148 is at least a portion of the outer mold line 192 of composite structure 102. In these examples, mandrel tool 112 forms the inner mold line 190 of composite structure 102.

[0243] In one or more examples, the portion of composite structure 102 formed by the second pad 148 is at least a portion of the inner mold line 190 of composite structure 102. In these examples, mandrel tool 112 forms the outer mold line 192 of composite structure 102.

[0244] In one or more examples, the step of processing the composite structure 102 (block 1012) includes heating at least one of the tool assembly 164, the gas 118 located in the container 114, and the mandrel tool 112 to heat the composite structure 102.

[0245] In one or more examples, the step of applying at least one of pressure and heat to the composite structure 102 includes the step of passing gas 108 between the first processing tool 104 and the second processing tool 106 in the closed position 110. In these examples, gas 118 is at least one of a heated gas and a pressurized gas. In these examples, gas 118 is pressurized using a pressurization system 140. In these examples, gas 118 is heated using a heating system 116.

[0246] In one or more examples, the step of processing composite structure 102 (block 1012) includes a combination of two or more of the following steps: (1) applying pressure between the first container wall 134 and the first conformal membrane 136; (2) applying pressure between the second container wall 144 and the second conformal membrane 146; (3) applying a vacuum between mandrel tool 112 and the first conformal membrane 136; (4) applying a vacuum between mandrel tool 112 and the second conformal membrane 146; (5) applying a vacuum between compression bag 162 and mandrel tool 112; (6) heating tool assembly 164 (e.g., first processing tool 104, second processing tool 106, first conformal membrane 136, second conformal membrane 146, first pad 142 and / or second pad 148); (7) heating gas 118 located in container 114; and (8) heating mandrel tool 112.

[0247] In one or more examples, the step of processing the composite structure 102 (block 1012) includes the step of forming the inner mold line 190 of the composite structure 102 using a mandrel tool 112 and the step of forming at least a portion of the outer mold line 192 of the composite structure 102 using a tool assembly 164.

[0248] In one or more examples, the step of processing the composite structure 102 (block 1012) includes the step of forming the outer mold line 192 of the composite structure 102 using a mandrel tool 112 and the step of forming at least a portion of the inner mold line 190 of the composite structure 102 using a tool assembly 164.

[0249] In one or more examples, the mandrel tool 112 includes a closed cross-sectional shape 182. In one or more examples, the step of processing the composite structure 102 (block 1012) includes pressurizing the internal volume 160 formed by the mandrel tool 112. Pressurizing the internal volume 160 of the mandrel tool 112 enables the mandrel tool 112 to structurally respond to the positive pressure applied to the composite structure 102 and the mandrel tool 112 during processing. In these examples, a pair of end caps 158 are used to close the internal volume 160 of the mandrel tool 112, and a pressurization system 140 is used to pressurize the internal volume 160 of the mandrel tool 112.

[0250] In one or more examples, the mandrel tool 112 includes a third open cross-sectional shape 186. In one or more examples, the step of processing the composite structure 102 (block 1012) includes pressurizing an internal volume 160 at least partially formed by the mandrel tool 112. Pressurizing the internal volume 160 of the mandrel tool 112 enables the mandrel tool 112 to structurally respond to the positive pressure applied to the composite structure 102 and the mandrel tool 112 during processing. In these examples, a pair of end caps 158 are used to close the internal volume 160 of the mandrel tool 112, and a pressurization system 140 is used to pressurize the internal volume 160 of the mandrel tool 112.

[0251] In one or more examples, the step of processing the composite structure 102 (block 1012) includes the step of clamping the composite structure 102 in response to applying clamping pressure to the composite structure 102.

[0252] In one or more examples, the step of processing the composite structure 102 (block 1012) includes the step of compacting the composite structure 102 in response to applying at least one of compaction pressure and compaction heat to the composite structure 102.

[0253] In one or more examples, the step of processing the composite structure 102 (block 1012) includes the step of curing the composite structure 102 in response to applying at least one of curing pressure and curing heat to the composite structure 102.

[0254] Therefore, the disclosed apparatus 100 and method 1000 provide a minimally sized container 114 (e.g., a processing chamber) by combining a mandrel tool 112 with a tool assembly 164, which complements the mandrel tool 112 to form a container 114 surrounding or enclosing the composite structure 102. The minimal volume of the container 114 results in a significant reduction in heating and ventilation compared to conventional autoclaves. For example, the smaller volume leads to faster pressurization and faster heating and cooling during each processing cycle.

[0255] Now for reference Figure 26 and Figure 27 Examples of device 100 and method 1000 can be found in, for example... Figure 26 The flowchart shows the aircraft manufacturing and maintenance methods 1100 and such Figure 27 Used in the background of the schematically illustrated aircraft 1200.

[0256] refer to Figure 27In one or more examples, the aircraft 1200 includes a fuselage 1202 and multiple advanced systems 1204. Examples of advanced systems 1204 include one or more of a propulsion system 1208, an electrical system 1210, a hydraulic system 1212, and an environmental system 1214. In other examples, the aircraft 1200 may include any number of other types of systems, such as communication systems, guidance systems, etc.

[0257] The composite structure 102 manufactured using equipment 100 or according to method 1000 can be any of the structure, component, sub-component, part, component, or any other part of the aircraft 1200, such as one or more of the advanced systems 1204, a part of the fuselage 1202, or the interior 1206. For example, the composite structure 102 can be any of the aircraft spars, wing sections, fuselage sections, internal panels, external skin panels, etc.

[0258] refer to Figure 26 During pre-production, method 1100 includes the specification and design of aircraft 1200 (box 1102) and material procurement (box 1104). During the production of aircraft 1200, the manufacturing of aircraft 1200 components and sub-assemblies (box 1106) and system integration (box 1108) occur. Subsequently, aircraft 1200 undergoes certification and delivery (box 1110) for entry into service (box 1112). Routine maintenance and servicing (box 1114) includes modification, refactoring, refurbishment, etc., of one or more systems of aircraft 1200.

[0259] Figure 26 Each process of method 1100 shown may be performed or executed 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 spacecraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0260] Examples of the device 100 and method 1000 shown and described herein may be found in Figure 26The disclosed apparatus 100 and method 1000 are employed during any one or more stages of the manufacturing and maintenance method 1100 shown in the flowchart. In the example, embodiments of the disclosed apparatus 100 and method 1000 may form part of component and sub-component manufacturing (box 1106) and / or system integration (box 1108). For example, the assembly of an aircraft 1200, fuselage 1202, and / or its components using embodiments of the disclosed apparatus 100 and method 1000 may correspond to component and sub-component manufacturing (box 1106) and may be prepared in a manner similar to that of components or sub-components prepared when the aircraft 1200 is put into service (box 1112). Furthermore, embodiments of the disclosed apparatus 100 and method 1000 may be utilized during system integration (box 1108) and certification and delivery (box 1110). Similarly, embodiments of the disclosed apparatus 100 and method 1000 may be used, for example, but not limited to, while the aircraft 1200 is in service (box 1112) and during maintenance and upkeep (box 1114).

[0261] Therefore, refer to Figures 1 to 27 It also disclosed a portion of the aircraft 1200 manufactured using equipment 100. Figure 11 The method is described. A portion of an aircraft 1200 manufactured according to method 1000 is also disclosed.

[0262] While aerospace examples are shown, the examples and principles disclosed herein can be applied to other industries, such as the automotive, space, construction, and other design and manufacturing sectors. Therefore, in addition to aircraft, the examples and principles disclosed herein can be applied to composite and stand-alone structures of other vehicles (e.g., land vehicles, ships, spacecraft, etc.).

[0263] As used herein, a system, apparatus, device, structure, article, element, component, or hardware "constructed" to perform a specified function is indeed capable of performing the specified function without any changes, rather than having the potential to perform the specified function only after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "constructed" to perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, "constructed" means an existing characteristic of a system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as "constructed" to perform a particular function may additionally or alternatively be described as "suitable" and / or "operably" to perform that function.

[0264] Unless otherwise stated, the terms “first,” “second,” “third,” etc., are used herein as labels only and are not intended to impose any order, position, or hierarchy requirements on the items referred to by these terms. Furthermore, references to items such as “second” do not require or exclude the existence of items such as “first” or lower-numbered items and / or items such as “third” or higher-numbered items.

[0265] For the purposes of this disclosure, the term "connection" and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, arranged to communicate, or otherwise associated with each other (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, these elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. Therefore, connections other than those depicted in the figures may also exist.

[0266] As used herein, the terms “approximately” and “approximately” refer to or indicate a condition that is close to but not exactly the stated condition, which still performs the desired function or achieves the desired result. As an example, the terms “approximately” and “approximately” refer to a condition within an acceptable predetermined tolerance or precision. For instance, the terms “approximately” and “approximately” refer to a condition within 10% of the stated condition. However, the terms “approximately” and “approximately” do not preclude a condition that is exactly the stated condition.

[0267] The above-mentioned Figures 22 to 24 In this diagram, blocks may represent functional elements, features, or components thereof, and the lines connecting the blocks do not necessarily imply any specific structure. Therefore, the illustrated structure can be modified, added to, and / or omitted. Furthermore, those skilled in the art will understand that this is not limited to the structures mentioned above. Figures 1 to 24 , Figure 27 All elements described and illustrated herein are required to be included in every example, and not all elements described herein are necessarily depicted in every illustrative example. Unless otherwise expressly stated, all elements mentioned above are not included in this example. Figures 1 to 24 , Figure 27 The illustrations depicted are not intended to imply any structural limitations on the illustrative examples. On the contrary, while an illustrative structure is indicated, it should be understood that the structure can be modified where appropriate.

[0268] The above-mentioned Figure 25 and Figure 26 In this document, boxes may represent operations, steps, and / or parts thereof, and the lines connecting the boxes do not imply any particular order or dependency of the operations or their parts. It will be understood that not all dependencies among the various disclosed operations must be represented. Figure 25 and Figure 26 The accompanying disclosure describing the operations of the methods set forth herein should not be construed as requiring a predetermined order of operations. Rather, while an illustrative order is indicated, it should be understood that the order of these operations can be modified where appropriate. Therefore, the operations shown can be modified, added to, and / or omitted, and some operations can 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.

[0269] Furthermore, references to features, advantages, or similar language used throughout this specification do not imply that all features and advantages that can be implemented using the examples disclosed herein should be, or be, included in any single example. Rather, the language used to refer to features and advantages is to be understood as meaning that a particular feature, advantage, or characteristic described in conjunction with an example is included in at least one example. Therefore, the discussion of features, advantages, and similar language used throughout this disclosure may, but does not necessarily, refer to the same examples.

[0270] The features, advantages, and characteristics of one example described can be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein can be practiced without the presence of one or more specific features or advantages of a particular example. In other cases, additional features and advantages that may not be present in all examples can be identified in certain examples. Furthermore, although various examples of device 100 and method 1000 have been shown and described, modifications can be made by those skilled in the art upon reading this specification. This application includes such modifications and is limited only by the scope of the claims.

[0271] Furthermore, this disclosure includes the following provisions, which are not to be confused with the appended claims that define the scope of protection.

[0272] Group 1 Clause:

[0273] 1. An apparatus for processing composite structures, the apparatus comprising:

[0274] A first processing tool and a second processing tool, the first processing tool and the second processing tool being movable between an open position and a closed position, wherein in the open position the first processing tool and the second processing tool are separated from each other, and in the closed position the first processing tool and the second processing tool are configured to be sealed to each other; and wherein:

[0275] In the closed position, the first processing tool and the second processing tool are configured to seal to a mandrel tool located between the first processing tool and the second processing tool and supporting the composite structure; and

[0276] In the closed position, the first processing tool, the second processing tool, and the mandrel tool form a container, the container being configured to apply at least one of pressure and heat to the composite structure.

[0277] 2. The device according to Clause 1, wherein:

[0278] The first processing tool includes a first interface seal;

[0279] The first interface seal is configured to seal the first interface between the first processing tool and the second processing tool in the closed position; and

[0280] The first interface seal is configured to seal the second interface between the first processing tool and the mandrel tool in the closed position.

[0281] 3. The equipment according to Clause 2, wherein:

[0282] The second processing tool includes a second interface seal;

[0283] The second interface seal is configured to seal the first interface between the first processing tool and the second processing tool in the closed position; and

[0284] The second interface seal is configured to seal the third interface between the second processing tool and the mandrel tool in the closed position.

[0285] 4. The device according to Clause 3, wherein the first interface seal and the second interface seal have complementary geometries and are configured to engage with each other in the closed position.

[0286] 5. The equipment according to clause 2 or 3, wherein:

[0287] The first processing tool includes:

[0288] The first container wall forming the first part of the container; and

[0289] The first interface surface forms the periphery of the first container wall; and

[0290] The first interface seal extends along the entire surface of the first interface.

[0291] 6. The device according to Clause 5, wherein:

[0292] The second processing tool includes:

[0293] A second container forming the second part of the container; and

[0294] The second interface surface forms the periphery of the second container wall; and

[0295] The second interface seal extends along the entire surface of the second interface.

[0296] 7. The equipment according to Clause 6, wherein:

[0297] The first container wall includes a first non-planar member; and

[0298] The second container wall includes a second non-planar member.

[0299] 8. The device according to Clause 6, wherein:

[0300] The first container wall includes a first non-planar member; and

[0301] The second container wall includes planar members.

[0302] 9. The apparatus according to Clause 1, wherein the first processing tool comprises:

[0303] The first container wall forming the first part of the container; and

[0304] A first conformal membrane is attached to the first container wall and configured to be pressed against the composite structure.

[0305] 10. The apparatus according to Clause 9, further comprising a vacuum system configured to apply a vacuum between the first conformal membrane and the mandrel tool.

[0306] 11. The device according to any one of clauses 9 or 10, the device further comprising a pressurization system configured to apply pressure between the first container wall and the first conformal membrane.

[0307] 12. The device according to any one of clauses 9 to 11, the device further comprising a first pad connected to the first conformal membrane and configured to shape the composite structure.

[0308] 13. The device according to any one of clauses 9 to 12, wherein the second processing tool comprises:

[0309] The second container wall forming the second part of the container; and

[0310] A second conformal membrane is attached to the second container wall and configured to be pressed against the composite structure.

[0311] 14. The apparatus according to Clause 13, further comprising a vacuum system configured to apply a vacuum between the first conformal membrane and the mandrel tool and between the second conformal membrane and the mandrel tool.

[0312] 15. The apparatus according to clause 13 or 14, further comprising a pressurization system configured to apply pressure between the first container wall and the first conformal membrane and between the second container wall and the second conformal membrane.

[0313] 16. The device according to any one of clauses 13 to 15, the device further comprising a second pad coupled to the second conformal membrane and configured to shape the composite structure.

[0314] 17. The equipment according to any one of clauses 13 to 16, wherein:

[0315] The first processing tool includes a first partition, which is connected to the first container wall and includes a first hole;

[0316] The second processing tool includes a second partition, which is connected to the second container wall and includes a second orifice; and

[0317] In the closed position, the first partition and the second partition are in contact with each other, such that the first hole and the second hole are aligned with each other to allow gas to pass between the first processing tool and the second processing tool.

[0318] 18. The apparatus according to any one of clauses 1 to 17, the apparatus further comprising a heating system configured to heat at least one of the first processing tool, the second processing tool, the mandrel tool, and the gas located within the container.

[0319] 19. The apparatus according to any one of clauses 1 to 18, the apparatus further comprising a pressurization system configured to pressurize a gas located within the container.

[0320] 20. The device according to clauses 1 to 19, wherein the device further comprises:

[0321] A heating system configured to heat at least one of the first processing tool, the second processing tool, the mandrel tool, and a gas located within the container; and

[0322] A pressurization system configured to pressurize gas located within the container.

[0323] 21. The device according to any one of clauses 1 to 20, the device further comprising a pair of end caps configured to seal the internal volume of the mandrel tool to pressurize the internal volume.

[0324] 22. The apparatus according to any one of clauses 1 to 21, the apparatus further comprising a compression bag configured to surround the composite structure, wherein a vacuum is applied between the compression bag and the mandrel tool.

[0325] 23. The device according to any one of clauses 1 to 22, wherein the first processing tool includes a first open cross-sectional shape.

[0326] 24. The device according to any one of clauses 1 to 23, wherein the second processing tool includes a second open cross-sectional shape.

[0327] 25. The device according to any one of clauses 1 to 24, wherein the second processing tool comprises a first planar cross-sectional shape.

[0328] 26. A method for manufacturing a part of an aircraft using the equipment of any of the preceding clauses.

[0329] 27. An apparatus for processing composite structures, the apparatus comprising:

[0330] A mandrel tool configured to support the composite structure during processing;

[0331] Tool assembly, the tool assembly being movable relative to the mandrel tool between an open position and a closed position; and

[0332] An interface seal is configured to seal the tool assembly and the mandrel tool together to form a container surrounding the composite structure in the closed position.

[0333] 28. The device according to Clause 27, further comprising at least one of the following:

[0334] A heating system configured to heat at least one of the tool assembly, the mandrel tool, and the gas located within the container; and

[0335] A pressurization system configured to pressurize gas located within the container.

[0336] 29. The device according to Clause 27, further comprising:

[0337] A compression bag, wherein the compression bag is sealed to the mandrel tool and surrounds the composite structure; and

[0338] At least one of the following:

[0339] A vacuum system, coupled to the mandrel tool and configured to apply a vacuum between the compression bag and the mandrel tool; and

[0340] A pressurization system, which is coupled to the tool assembly and configured to apply pressure to the compression bag.

[0341] 30. The device according to Clause 27, wherein:

[0342] The tool components include:

[0343] The first container wall forming the first part of the container; and

[0344] A first conformal membrane connected to the first container wall; and

[0345] At least one of the following:

[0346] A vacuum system, coupled to at least one of the mandrel tool and the tool assembly, and configured to apply a vacuum between the first conformal membrane and the mandrel tool; and

[0347] A pressurization system, which is coupled to the tool assembly and configured to apply pressure between the first container wall and the first conformal membrane.

[0348] 31. The device according to Clause 30, the device further comprising a first pad located between the first conformal membrane and the composite structure.

[0349] 32. The device according to clause 30 or 31, wherein:

[0350] The tool components include:

[0351] The second container wall forming the second part of the container; and

[0352] A second conformal membrane connected to the second container wall; and

[0353] At least one of the following:

[0354] The vacuum system is configured to apply a vacuum between the second conformal membrane and the mandrel tool; and

[0355] The pressurization system is configured to apply pressure between the second container wall and the second conformal membrane.

[0356] 33. The device according to Clause 32, the device further comprising a second pad located between the second conformal membrane and the composite structure.

[0357] 34. The device as described in clause 32 or 33, wherein:

[0358] The mandrel tool has a closed cross-sectional shape;

[0359] The first container wall includes a first open cross-sectional shape that is complementary to a first portion of the closed cross-sectional shape of the mandrel tool; and

[0360] The second container wall includes a second open cross-sectional shape that is complementary to the second portion of the closed cross-sectional shape of the mandrel tool.

[0361] 35. The device as described in clause 32 or 33, wherein:

[0362] The mandrel tool includes a third open cross-sectional shape;

[0363] The first container wall includes a first open cross-sectional shape that is complementary to the third open cross-sectional shape of the mandrel tool; and

[0364] The second container wall includes a first planar cross-sectional shape.

[0365] 36. The device as described in clause 32 or 33, wherein:

[0366] The mandrel tool includes a second planar cross-sectional shape;

[0367] The first container wall includes a first open cross-sectional shape; and

[0368] The second container wall includes a first planar cross-sectional shape that is complementary to a portion of the second planar cross-sectional shape of the mandrel tool.

[0369] 37. The equipment according to any one of clauses 27 to 36, wherein:

[0370] The tool component includes a first processing tool and a second processing tool; and

[0371] In the closed position, the first processing tool and the second processing tool are in fluid communication with each other.

[0372] 38. The device according to any one of clauses 27 to 37, wherein, in the closed position, a portion of the mandrel tool is located outside the container.

[0373] 39. The apparatus according to any one of clauses 27 to 38, the apparatus further comprising a processing trolley configured to support the mandrel tool during processing, wherein, in the closed position, the processing trolley is located outside the container.

[0374] 40. A method for manufacturing a part of an aircraft using the equipment of any one of the preceding clauses 27 to 39.

[0375] 41. An apparatus for processing composite structures, the apparatus comprising:

[0376] A tool assembly configured to form a sealed container with a mandrel tool and configured to apply at least one of pressure and heat to the composite structure supported by the mandrel tool.

[0377] 42. The device according to Clause 41, the device further comprising the mandrel tool.

[0378] 43. The device according to clause 41 or 42, wherein:

[0379] The mandrel tool is configured to shape the inner mold line of the composite structure; and

[0380] The tooling assembly is configured to shape the outer mold line of the composite structure.

[0381] 44. The equipment pursuant to any one of clauses 41 to 43,

[0382] The mandrel tool is configured to shape the outer mold line of the composite structure; and

[0383] The tooling assembly is configured to shape the inner mold line of the composite structure.

[0384] Group 2 Clause:

[0385] 1. A method for processing composite structures, the method comprising:

[0386] Positioning the first processing tool and the second processing tool of the tool assembly from an open position to a closed position, wherein in the open position the first processing tool and the second processing tool are separated, and in the closed position the first processing tool and the second processing tool are sealed to each other and to the mandrel tool supporting the composite structure to form a container surrounding the composite structure; and

[0387] Process the composite structure.

[0388] 2. The method according to Clause 1, further comprising: positioning the mandrel tool between the first processing tool and the second processing tool of the tool assembly when the tool assembly is in the open position.

[0389] 3. The method according to clause 1 or 2, wherein processing the composite structure includes pressurizing the gas located within the container.

[0390] 4. The method according to any one of the preceding clauses, wherein processing the composite structure includes applying a vacuum between the compression bag surrounding the composite structure and the mandrel tool.

[0391] 5. The method according to any one of the foregoing clauses, wherein processing the composite structure includes at least one of the following:

[0392] Pressure is applied between the first container wall of the tool assembly and the first conformal membrane coupled to the first container wall; and

[0393] A vacuum is applied between the mandrel tool and the first conformal membrane.

[0394] 6. The method according to Clause 5, wherein processing the composite structure further includes smoothing a portion of the composite structure using a first pad coupled to the first conformal membrane.

[0395] 7. The method according to any one of the foregoing clauses, wherein processing the composite structure includes at least one of the following:

[0396] Pressure is applied between the second container wall of the tool assembly and the second conformal membrane coupled to the second container wall; and

[0397] A vacuum is applied between the mandrel tool and the second conformal membrane.

[0398] 8. The method according to Clause 7, wherein processing the composite structure further includes smoothing a portion of the composite structure using a second pad coupled to the second conformal membrane.

[0399] 9. The method according to any one of the preceding clauses, wherein processing the composite structure includes heating at least one of the tool assembly, the mandrel tool, and the gas located within the container to heat the composite structure.

[0400] 10. The method according to any one of the preceding clauses, wherein processing the composite structure comprises:

[0401] At least one of the heated gas and the pressurized gas; and

[0402] The gas is transferred between the first processing tool and the second processing tool in the closed position.

[0403] 11. The method according to any one of the preceding clauses, further comprising:

[0404] The mandrel tool is used to shape the inner mold line of the composite structure; and

[0405] The tool assembly is used to form the outer mold line of the composite structure.

[0406] 12. The method according to any one of the preceding clauses, further comprising:

[0407] The mandrel tool is used to shape the outer mold line of the composite structure; and

[0408] The tool assembly is used to form the inner mold line of the composite structure.

[0409] 13. The method according to any of the foregoing clauses, wherein:

[0410] The mandrel tool includes a closed cross-sectional shape; and

[0411] The method also includes pressurizing the internal volume formed by the mandrel tool.

[0412] 14. The method according to any of the foregoing clauses, wherein:

[0413] The mandrel tool includes a third open cross-sectional shape; and

[0414] The method also includes pressurizing an internal volume formed at least in part by the mandrel tool.

[0415] 15. The method according to any one of the preceding clauses, wherein processing the composite structure includes compacting the composite structure in response to applying at least one of pressure and heat to the composite structure.

[0416] 16. The method according to any one of the preceding clauses, processing the composite structure includes curing the composite structure in response to applying at least one of pressure and heat to the composite structure.

[0417] 17. A portion of a flight manufactured according to the method of any one of the preceding clauses.

[0418] 18. A method for processing composite structures, optionally according to any one of the preceding clauses, the method comprising:

[0419] Seal the first processing tool to the mandrel tool supporting the composite structure;

[0420] Seal the second processing tool to the first processing tool and the mandrel tool; and

[0421] A container surrounding the composite structure is formed using the first processing tool, the second processing tool, and the mandrel tool.

[0422] 19. The method according to Clause 18, further comprising:

[0423] At least one of pressure and heat is applied to the composite structure.

[0424] 20. The method according to clause 18 or 19, wherein the method further comprises at least one of the following:

[0425] Pressure is applied between the first container wall of the first processing tool and the first conformal membrane attached to the first container wall, and between the second container wall of the second processing tool and the second conformal membrane attached to the second container wall; and

[0426] A vacuum is applied between the mandrel tool and the first conformal membrane, and between the mandrel tool and the second conformal membrane.

[0427] 21. The method according to Clause 20, the method further comprising smoothing the composite structure using a first pad coupled to the first conformal membrane and a second pad coupled to the second conformal membrane.

[0428] 22. A part of an aircraft manufactured according to any one of clauses 18 to 21.

[0429] 23. A method for processing a composite structure, optionally according to any one of clauses 1 to 21, said method comprising:

[0430] Position the mandrel tool that supports the composite structure on the second processing tool;

[0431] Seal the first processing tool to the second processing tool and the mandrel tool; and

[0432] A container surrounding the composite structure is formed using the first processing tool, the second processing tool, and the mandrel tool.

[0433] 24. The method according to Clause 23, further comprising:

[0434] At least one of pressure and heat is applied to the composite structure.

[0435] 25. The method according to clause 23 or 24, wherein the method further comprises at least one of the following:

[0436] Pressure is applied between the first container wall of the first processing tool and the first conformal membrane coupled to the first container wall; and

[0437] A vacuum is applied between the mandrel tool and the first conformal membrane.

[0438] 26. The method according to Clause 25, the method further comprising smoothing the composite structure using a first pad coupled to the first conformal membrane.

[0439] 27. A part of an aircraft manufactured according to any one of clauses 23 to 26.

Claims

1. An apparatus (100) for processing a composite structure (102), the apparatus (100) comprising: A first processing tool (104) and a second processing tool (106), the first processing tool (104) and the second processing tool (106) being movable between an open position (108) and a closed position (110), wherein in the open position the first processing tool (104) and the second processing tool (106) are separated from each other, and in the closed position the first processing tool (104) and the second processing tool (106) are configured to seal to each other; and wherein: In the closed position (110), the first processing tool (104) and the second processing tool (106) are configured to be sealed to a mandrel tool (112) located between the first processing tool (104) and the second processing tool (106) and supporting the composite structure (102); and In the closed position (110), the first processing tool (104), the second processing tool (106), and the mandrel tool (112) form a container (114), which is configured to apply at least one of pressure and heat to the composite structure (102). The first processing tool (104) includes: A first container wall (134) forms a first portion of the container (114); and A first conformal membrane (136) is attached to the first container wall (134) and configured to be pressed against the composite structure (102). The second processing tool (106) includes: A second container wall (144) forms a second part of the container (114); and A second conformal membrane (146) is attached to the second container wall (144) and configured to be pressed against the composite structure (102). The mandrel tool (112) has a closed cross-sectional shape.

2. The device (100) according to claim 1, the device (100) further comprising a vacuum system (138) configured to apply a vacuum between the first conformal membrane (136) and the mandrel tool (112).

3. The device (100) according to claim 1 or 2, the device (100) further comprising a pressurization system (140) configured to apply pressure between the first container wall (134) and the first conformal membrane (136).

4. The device (100) according to any one of claims 1 to 3, the device (100) further comprising a first pad (142) connected to the first conformal membrane (136) and configured to shape the composite structure (102).

5. The device (100) according to any one of claims 1 to 4, the device (100) further comprising a vacuum system (138) configured to apply a vacuum between the first conformal membrane (136) and the mandrel tool (112) and between the second conformal membrane (146) and the mandrel tool (112).

6. The device (100) according to any one of claims 1 to 5, the device (100) further comprising a pressurization system (140) configured to apply pressure between the first container wall (134) and the first conformal membrane (136) and between the second container wall (144) and the second conformal membrane (146).

7. The device (100) according to any one of claims 1 to 6, the device (100) further comprising a second pad (148) connected to the second conformal membrane (146) and configured to shape the composite structure (102).

8. The device (100) according to any one of claims 1 to 7, wherein, The first processing tool (104) includes a first partition (150) connected to the first container wall (134) and including a first hole (152); The second processing tool (106) includes a second partition (154) coupled to the second container wall (144) and including a second hole (156); and In the closed position (110), the first partition (150) and the second partition (154) are in contact with each other, such that the first hole (152) and the second hole (156) are aligned with each other to allow gas (118) to pass between the first processing tool (104) and the second processing tool (106).

9. The device (100) according to any one of claims 1 to 8, the device (100) further comprising a heating system (116) configured to heat at least one of the first processing tool (104), the second processing tool (106), the mandrel tool (112), and the gas (118) located within the container (114).

10. The device (100) according to any one of claims 1 to 9, the device (100) further comprising a pressurization system (140) configured to pressurize a gas (118) located within the container (114).

11. The device (100) according to any one of claims 1 to 10, wherein the device (100) further comprises: A heating system (116) configured to heat at least one of the first processing tool (104), the second processing tool (106), the mandrel tool (112), and a gas (118) located within the container (114); and A pressurization system (140) is configured to pressurize the gas (118) located within the container (114).

12. The device according to any one of claims 1 to 11, the device further comprising a pair of end caps (158) configured to seal the internal volume (160) of the mandrel tool (112) to pressurize the internal volume (160).

13. The apparatus according to any one of claims 1 to 12, further comprising a compression bag (162) configured to surround the composite structure (102), wherein, A vacuum is applied between the compression bag (162) and the mandrel tool (112).

14. The device according to any one of claims 1 to 13, wherein, The first processing tool (104) includes a first open cross-sectional shape (168).

15. The device according to any one of claims 1 to 14, wherein, The second processing tool (106) includes a second open cross-sectional shape (170) and / or a first planar cross-sectional shape (172).

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