Systems and methods for joining materials using expandable tool

Abstract

The invention relates to a system and method for joining materials using an expandable tool. A method for joining materials includes the steps of: (1) enclosing at least a portion of a first material and a second material within an interior volume of a confinement container; (2) expanding an expandable medium disposed within the internal volume; (3) applying a positive pressure to the confinement container and at least one of the first material and the second material in response to expanding the expandable medium; and (4) joining the first material and the second material together.

Description

Technical Field

[0001] This disclosure relates generally to material bonding, and more specifically to systems and methods for bonding materials using expandable tools. Background Technology

[0002] During manufacturing or assembly, various joining techniques are used to bond materials together. For many joining techniques, heat and / or pressure are applied to the materials to promote bonding. Typically, the equipment required for sufficient joining temperature and pressure is large, complex, and expensive. Furthermore, conventional joining techniques can lead to bottlenecks in manufacturing processes. Therefore, those skilled in the art continue to research and develop systems and methods for joining materials. Summary of the Invention

[0003] Systems for joining materials, methods for joining materials, and examples of joining workpieces are disclosed. The following is a non-exhaustive list of examples of the subject matter of this disclosure, which may or may not be claimed.

[0004] In the example, the disclosed system includes a constraint container and an expandable medium. The constraint container includes a base and a cover. The constraint container has an internal volume. The constraint container is configured to enclose at least a portion of a first material and a second material that are joined together. The expandable medium is configured to be disposed within the internal volume between at least one of the first material and the second material and at least a portion of the constraint container. The expandable medium is configured to expand such that it applies a positive pressure to at least one of the first material and the second material and to the constraint container.

[0005] In the example, the disclosed method includes the following steps: (1) enclosing at least a portion of a first material and a second material within an internal volume of a constraint container; (2) inflating an expandable medium disposed within the internal volume; (3) applying a positive pressure to at least one of the first material and the second material and the constraint container in response to the expansion of the expandable medium; and (4) joining the first material and the second material together.

[0006] In one example, the disclosed workpiece includes a first material and a second material to be joined together. At least a portion of the first and second materials is enclosed by a constraint container. An expandable medium is disposed within the internal volume of the constraint container between at least one of the first and second materials and at least a portion of the constraint container. The expandable medium is configured to expand to a predetermined volume when its properties undergo a predetermined change, such that the expandable medium applies a positive pressure to at least one of the first and second materials and the constraint container.

[0007] Other examples of systems, methods, and joined workpieces will become apparent from the following detailed description, accompanying drawings, and appended claims. Attached Figure Description

[0008] Figure 1A and Figure 1B This is a schematic block diagram of an example of a system for bonding materials;

[0009] Figure 2 This is a flowchart illustrating an example of a method for bonding materials;

[0010] Figure 3 This is a schematic cross-sectional view of an example constraint container applied to a sample workpiece;

[0011] Figure 4 yes Figure 3 The illustrated example is a schematic cross-sectional view of a system in which an expandable medium is disposed within the internal volume of a constrained container.

[0012] Figure 5 After the expandable medium expands Figure 4 A schematic cross-sectional view of an example system shown;

[0013] Figure 6 This is a schematic cross-sectional view of an example of a constraint container applied to another example workpiece;

[0014] Figure 7 yes Figure 6 The illustrated example is a schematic cross-sectional view of a system in which an expandable medium is disposed within the internal volume of a constrained container.

[0015] Figure 8 After the expandable medium expands Figure 7 A schematic cross-sectional view of an example system shown;

[0016] Figure 9 This is a schematic cross-sectional view of another example of a constraint container applied to the example workpiece;

[0017] Figure 10 yes Figure 9 The schematic cross-sectional view of an example system shown indicates that an expandable medium is disposed within the internal volume of a constrained container.

[0018] Figure 11 After the expandable medium expands Figure 10 A schematic cross-sectional view of an example of the system shown;

[0019] Figure 12 This is a schematic diagram of an example of a workpiece assembly that includes the workpiece to be joined and an expandable material.

[0020] Figure 13 This is a schematic diagram of an example of a workpiece assembly that includes the workpiece to be joined and an expandable material.

[0021] Figure 14 This is a schematic diagram of an example of a workpiece assembly that includes the workpiece to be joined and an expandable material.

[0022] Figure 15 This is a schematic diagram of an example of a workpiece assembly that includes the workpiece to be joined and an expandable material.

[0023] Figure 16 This is a flowchart illustrating examples of aircraft manufacturing and maintenance methods; and

[0024] Figure 17 This is a schematic block diagram of an example aircraft. Detailed Implementation

[0025] General Reference Figures 1A to 15 As an example, this disclosure relates to system 100, workpiece 200 (e.g., for forming a joint structure), and method 1000 for joining. In various examples, system 100 and method 1000 provide joining to achieve high-quality joint structures without requiring processing in autoclaves or other large, capital-intensive equipment. The joining process implemented by system 100 and / or according to method 1000 facilitates cheaper, faster, and smaller footprint joining.

[0026] Examples of system 100 and method 1000 utilize expandable materials and associated tools, enabling the fabrication and / or repair of welded components of the autoclave outside the autoclave. Examples of system 100 and method 1000 advantageously facilitate the application of omnidirectional and at least approximately uniform pressure on the surfaces of the components to be joined. Examples of system 100 and method 1000 also advantageously enable the use of expandable materials for structural joining and volume reduction, with or without adhesives.

[0027] Examples of system 100 and method 1000 utilize expandable materials for composite structural bonding and volume reduction, such as secondary bonding, with or without adhesives (e.g., for composite bonding under pressure (e.g., co-bonding)), wherein at least one component of the bonded structure is pre-cured. Additionally, examples of system 100 and method 1000 can bond non-composite materials (e.g., metals, metal alloys, ceramics, polymers, hybrids, metal matrix composites (MMCs), ceramic matrix composites (CMCs), polymer matrix composites (PMCs), etc.) using epoxy adhesives or any polymer adhesive (e.g., thermosetting or thermoplastic). Examples of system 100 and method 1000 utilize progressive and controlled compaction with a detector to monitor real-time pressure. In various examples, the detector may be a sensor or strain gauge that monitors the deformation of a pin. In various examples, the detector is the pin itself. In any of these examples, an alarm mode is activated when the pin fails (e.g., breaks).

[0028] Now for reference Figure 1A , Figure 1B and Figures 3 to 15 The following is an example of system 100 according to this disclosure. Examples of system 100 include multiple elements, features, and components. All elements, features, and / or components described or shown in one example are not required in that example. Some or all of the elements, features, and / or components described or shown in one example may be combined in various ways with other examples without needing to include other elements, features, and / or components described in those other examples, even if one or more such combinations are not explicitly described or shown by example herein.

[0029] Figures 3 to 15 At least a portion 210 of the workpiece 200 is shown. Figure 3 , Figure 6 and Figure 9 Various examples of system 100. Generally, part 210 of workpiece 200 refers to any part or all of workpiece 200 to be joined or being joined by system 100 and / or method 1000.

[0030] like Figure 1A , Figure 1B and Figures 3 to 15 As shown, in one or more examples, workpiece 200 includes a first material 204 and a second material 206. In one or more examples, workpiece 200 may also include any other number of materials 202, including substrates, material layers, components, accessories, etc., to be joined together.

[0031] Figures 3 to 15Various examples are shown of workpieces 200 and materials 202 that will be joined together using system 100 and / or according to method 1000. Workpiece 200 may include any suitable number of materials 202 or material layers. In various examples, workpiece 200 includes one or more composite materials, metallic materials, ceramic materials, polymer materials, thermoplastic materials, thermosetting materials, fiber-reinforced materials, and / or any other suitable materials depending on the desired properties of the joined structure.

[0032] Workpiece 200 can have any suitable one of a variety of different cross-sectional geometries. For example... Figures 3 to 11 As shown, in one or more examples, workpiece 200 is a composite reinforcement (e.g., a cap stringer), and material 202 comprises multiple composite layers (e.g., an uncured composite material) and an optional adhesive layer (e.g., ...). Figures 6 to 8 The multiple composite layers are bonded together using an expandable medium 120 to apply pressure to the workpiece 200. For example... Figure 14 and Figure 15 As shown, in one or more examples, workpiece 200 is a composite reinforcement (e.g., a blade stringer), and material 202 comprises multiple composite layers (e.g., uncured composite and / or cured composite) and optional adhesive layers, which are bonded together using an expandable medium 120.

[0033] In one or more examples, workpiece 200 includes multiple layers of material 202 (e.g., material layer 260) that are joined together using an expandable medium 120 to apply pressure to workpiece 200. Figures 12 to 15 As shown, in one or more examples, workpieces 200 are joined together and include a first material layer 261 (e.g., a first material sheet or packing), a second material layer 262 (e.g., a second material sheet or packing), a third material layer 263 (e.g., a bonding layer, such as an uncured prepreg composite layer or adhesive film), and a fourth material layer 264 (e.g., Figure 12 and Figure 13 optional core or Figure 15 A sandwich structure or multilayer panel structure consisting of a substrate and a fifth material layer 265 (e.g., a bonding layer, such as an uncured prepreg composite layer or adhesive film) in some combination (e.g., two or more).

[0034] In one or more examples, the expandable medium 120 may be positioned or positioned relative to the workpiece 200 such that a normal force 124 (e.g., an omnidirectional force) is applied to one side of the workpiece 200. Figure 12As shown, in one or more examples, a first quantity or first layer 182 of the expandable medium 120 is positioned on or above the stack of material layers 260, such that the expansion of the expandable medium 120 applies a positive pressure 124 to the workpiece 200 to compress the material layers 260 during bonding. Figure 13 As shown, in one or more examples, a first amount or first layer 182 of expandable medium 120 is positioned above or on the stack of material layers 260, and a second amount or second layer 184 of expandable medium 120 is positioned below or under the stack of material layers 260, such that the expansion of expandable medium 120 applies a positive pressure 124 to workpiece 200 to compress material layers 260 during bonding.

[0035] like Figure 1A , Figure 1B and Figures 3 to 11 As shown, in one or more examples, system 100 includes a constraint container 110 and an expandable medium 120. The constraint container 110 contains or encloses at least a portion of workpiece 200. The constraint container 110 also contains the expandable medium 120. The expandable medium 120 is configured to expand and, upon expansion, apply an omnidirectional force or pressure to at least the portion of workpiece 200 enclosed by the constraint container 110.

[0036] like Figure 1A , Figure 1B As shown, in one or more examples, system 100 and method 1000 facilitate co-curing to bond workpieces 200 together. In these examples, the material 202 of workpiece 200 (e.g., first material 204 and second material 206) includes an uncured composite material 212. In one or more examples, the uncured composite material 212 is a thermosetting composite material. In one or more examples, the uncured composite material 212 is a thermoplastic composite material.

[0037] In one or more examples, co-curing is achieved without an adhesive. As an example, workpiece 200 includes a first wet prepreg cross-layer (e.g., first material 204) and a second wet prepreg cross-layer (e.g., second material 206).

[0038] In one or more examples, co-curing is achieved within an adhesive such as an adhesive film (e.g., adhesive 216). As an example, workpiece 200 includes a first wet prepreg cross-layer (e.g., first material 204), a second wet prepreg cross-layer (e.g., second material 206), and an adhesive (e.g., adhesive 216) located or disposed between the first wet prepreg cross-layer and the second wet prepreg cross-layer.

[0039] like Figure 1A , Figure 1BAs shown, in one or more co-curing examples, the uncured composite material 212 (e.g., a thermosetting composite material) has a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is up to the curing temperature 220 of the thermosetting composite material. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 reaches or at least equals the curing pressure 222.

[0040] like Figure 1A , Figure 1B As shown, in one or more co-curing examples, the uncured composite material 212 (e.g., a thermoplastic composite) has a consolidation temperature 224 and a consolidation pressure 226. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is higher than the consolidation temperature 224 of the thermoplastic composite. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is higher than the curing pressure 222.

[0041] like Figure 1A , Figure 1B As shown, in one or more examples, system 100 and method 1000 facilitate co-bonding to join workpieces 200 together. In these examples, at least one material 202 of workpiece 200 (e.g., a first material 204) comprises a cured composite material 214. At least another material 202 of workpiece 200 (e.g., a second material 206) comprises an uncured composite material 212. In one or more examples, the uncured composite material 212 is a thermosetting composite material. In one or more examples, the uncured composite material 212 is a thermoplastic composite material.

[0042] In one or more examples, co-bonding is achieved using an adhesive (e.g., adhesive 216) (such as an adhesive film). As an example, workpiece 200 includes a pre-cured laminate (e.g., a first material 204), a wet prepreg cross-layer (e.g., a second material 206), and an adhesive (e.g., adhesive 216) located or disposed between the pre-cured laminate and the wet prepreg cross-layer.

[0043] like Figure 1A , Figure 1B As shown, in one or more co-bonding examples, the uncured composite material 212 (e.g., a thermosetting composite material) has a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is higher than the curing temperature 220. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is higher than the curing pressure 222.

[0044] like Figure 1A , Figure 1B As shown, in one or more co-bonding examples, the uncured composite material 212 (e.g., a thermoplastic composite) has a consolidation temperature 224 and a consolidation pressure 226. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is higher than the consolidation temperature 224. At the activation temperature 122, the expandable medium 120 is configured to expand such that the normal pressure 124 is higher than the consolidation pressure 226.

[0045] like Figure 1A , Figure 1B As shown, in one or more examples, system 100 and method 1000 facilitate secondary joining to bond workpieces 200 together. In these examples, the material 202 of workpiece 200 (e.g., first material 204 and second material 206) includes any suitable material or combination of materials, such as, but not limited to, metallic materials, metallic alloys, ceramic materials, polymeric materials, hybrid materials, metal matrix composites, ceramic matrix composites, polymer matrix composites, etc.

[0046] In one or more examples, a secondary bonding is achieved using an adhesive such as an adhesive film (e.g., adhesive 216). As an example, workpiece 200 includes a first pre-cured composite or material layer (e.g., first material 204), a second pre-cured composite or material layer (e.g., second material 206), and an adhesive (e.g., adhesive 216) located or disposed between the first pre-cured composite or material layer and the second pre-cured composite or material layer.

[0047] like Figures 6 to 8 As shown, in one or more examples, adhesive 216 is located between the first material 204 and the second material 206. In these examples, the system 100 utilizing adhesive 216 is capable of secondary bonding, co-bonding, or co-curing with the adhesives of the first material 204 and the second material 206.

[0048] like Figure 1A , Figure 1BAs shown, in one or more of co-curing, co-bonding, and / or secondary bonding, the adhesive 216 has at least one of a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is higher than the curing temperature 220. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is higher than the curing pressure 222. In one or more examples, the curing temperature 220 and / or curing pressure 222 of the uncured composite material 212 and the adhesive 216 are at least substantially the same. In one or more examples, the curing temperature 220 and / or curing pressure 222 of the uncured composite material 212 and the adhesive 216 are different.

[0049] In the example where the first material 204 and the second material 206 are bonded together using adhesive 216, the material 202 of the workpiece 200 (e.g., the first material 204, the second material 206, etc.) can include any suitable material or combination of materials, including but not limited to cured composite materials (e.g., thermosetting or thermoplastic composite materials), metallic materials, metal alloys, ceramic materials, polymeric materials, etc. In one or more examples, the material 202 of the workpiece 200 is the same material. In one or more examples, at least one material 202 of the workpiece 200 is a different material.

[0050] In one or more examples, the constraint container 110 includes a base 112. In one or more examples, the constraint container 110 includes a cover 114. In one or more examples, the cover 114 is coupled to the base 112. In one or more examples, the cover 114 is configured to be coupled to the base 112. In one or more examples, the cover 114 is movable relative to the base 112. The container 110 has an internal volume 116 formed by the base 112 and the cover 114.

[0051] In one or more examples, the constraint container 110 is configured to enclose at least a portion (e.g., portion 210) of a first material 204 and a second material 206 of the workpiece 200, the first material 204 and the second material 206 being joined together. In one or more examples, the constraint container 110 is configured (e.g., in size and shape) to accommodate and / or enclose the entire workpiece 200. In one or more examples, the constraint container 110 is configured to accommodate and / or enclose a portion of material 202 of the joined workpiece 200.

[0052] In one or more examples, the expandable medium 120 is configured to be disposed, positioned, or otherwise loaded within the internal volume 116 of the restraint container 110. In one or more examples, the expandable medium 120 is disposed, positioned, or loaded between at least one of the first material 204 and the second material 206 and at least a portion of the restraint container 110 (e.g., the cap 114 and / or the base 112). The expandable medium 120 is configured to expand such that it applies a positive pressure 124 to the restraint container 110 and at least one of the first material 204 and the second material 206.

[0053] In one or more examples, system 100 is an adjustable tool system including a constraint container 110 and an expandable medium 120. The constraint container 110 is positioned relative to workpiece 200 such that at least a portion 210 of workpiece 200 and expandable medium 120 are positioned within the constraint container 110 or otherwise constrained.

[0054] In one or more examples, system 100 is configured to facilitate the application of positive pressure 124 on portion 210 of workpiece 200 contained in container 110 during processing of joined workpiece 200 by expansion of expandable medium 120. Thus, constrained container 110 and expandable medium 120 are configured to apply positive pressure 124 to workpiece 200 during processes that join two or more materials together to form or manufacture a joined structure.

[0055] In one or more examples, one or more of materials 202 are composite materials (e.g., composite parts, components, objects, etc.) comprising one or more composite layers (also referred to as layers). In one or more examples, one or more of materials 202 are metallic materials (e.g., metallic parts, components, objects, etc.). In one or more examples, one or more of materials 202 are ceramic materials (e.g., ceramic parts, components, objects, etc.). In one or more examples, one or more of materials 202 are polymeric materials (e.g., polymeric parts, components, objects, etc.).

[0056] In any of these examples, material 202 is bonded together using system 100 and / or according to method 1000. In one or more examples, material 202 is bonded together by co-curing (e.g., by applying heat and / or pressure). In one or more examples, material 202 is bonded together by co-bonding (e.g., by applying heat and / or pressure). In one or more examples, material 202 is bonded together by secondary bonding (e.g., by applying heat and / or pressure).

[0057] like Figures 3 to 11As shown, in one or more examples, the workpiece 200 is supported on or by the base 112. In one or more examples, the cover 114 is positioned relative to the base 112 and / or the workpiece 200 such that at least a portion 210 of the workpiece 200 and the expandable medium 120 are positioned within or otherwise constrained by the cover 114 or between the cover 114 and the base 112. In one or more examples, the cover 114 includes (e.g., forms or defines) an internal volume 116 and is configured to enclose a portion 210 of the workpiece 200. The cover 114 allows the expandable medium 120 and the workpiece 200 to be loaded within the internal volume 116 of the constrained container 110.

[0058] In one or more examples, the cover 114 has or forms a cross-sectional profile corresponding to the cross-sectional shape of the workpiece 200. Providing the cover 114 with a cross-sectional profile that corresponds to (e.g., at least approximately matches or complements) the cross-sectional shape of the workpiece 200 facilitates a reduction in the internal volume 116 of the constrained container 110, and thus a reduction in the amount of expandable medium 120 required.

[0059] In one or more examples, the base 112 is rigid. In one or more examples, the cover 114 is rigid. In one or more examples, at least one of the base 112 and the cover 114 is rigid. In one or more examples, both the base 112 and the cover 114 are rigid.

[0060] In one or more examples, the cover 114 substantially resists expansion, at least when the expandable medium 120 applies pressure to the inner surface of the cover 114. In this way, the pressure applied to the outer surface of the workpiece 200 (e.g., at least one of the first material 204 and the second material 206) works in conjunction with the cover 114 to generate a compressive force on the workpiece 200.

[0061] In one or more examples, at least a portion of the cover 114 (such as the wall 144 of the cover 114) is rigid (e.g., hard or non-flexible) and non-inflatable. In these examples, at least a portion of the cover 114 (such as the wall 144) may be made of any suitable material (including, but not limited to, metallic materials, composite materials, cement materials, ceramic materials, polymer materials, etc.). In these examples, the wall 144 confines the expandable medium 120 and responds to the positive pressure 124 generated by the expandable medium 120 upon expansion. In these examples, the wall 144 is capable of withstanding the pressure generated within the confinement container 110 when the expandable medium 120 expands.

[0062] In one or more examples, at least a portion of the base 112 is flexible. In one or more examples, at least a portion of the cover 114 is flexible. In one or more examples, at least a portion of the base 112 is flexible and non-inflatable. In one or more examples, at least a portion of at least one of the base 112 and the cover 114 is flexible and non-inflatable or inflatable. In one or more examples, at least a portion of both the base 112 and the cover 114 is flexible and non-inflatable or inflatable. At least a portion of at least one of the base 112 and the cap 114 is made flexible and non-expandable such that the cap 114 and / or the base 112 can form (e.g., more closely match) and / or facilitate conforming to the shape of at least a portion of the workpiece 200 and / or the expandable medium 120 before the expandable medium 120 expands, resulting in a smaller internal volume 116 of the constrained container 110 and thus a reduction in the amount of expandable medium 120 required. In these examples, at least a portion of the cap 114 and / or the base 112 can be made of any suitable flexible and non-expandable material, including but not limited to metal mesh (e.g., chainmail), ceramic mesh, polymer mesh, etc.

[0063] In one or more examples, at least a first portion of the cover 114 is flexible and non-inflatable, and at least a second portion of the cover 114 is rigid and non-inflatable. In other examples, at least a first portion of the cover 114 is non-inflatable (e.g., flexible and / or rigid), and at least a second portion of the cover 114 is inflatable.

[0064] In one or more examples, the cover 114 may be movable relative to the workpiece 200, such that the portion 210 of the workpiece 200 to be joined can be selected, isolated, and / or targeted. Movable cover 114 facilitates partial joining of separated areas or portions of the workpiece 200. In one or more examples, cover 114 may be completely removed from the base 112. Movable cover 114 facilitates loading or positioning the expandable medium 120 and the workpiece 200 within the internal volume 116 of the constraint container 110.

[0065] In one or more examples, the size and / or dimensions of the cover 114 are adapted to cover at least the portion 210 of the workpiece 200 to be engaged. In these examples, the dimensions of the cover 114 (e.g., length and / or width) are smaller than at least one of the dimensions of the workpiece 200 (e.g., length and / or width).

[0066] In one or more examples, the cover 114 includes a wall 144. In one or more examples, the wall 144 forms or defines at least a portion of the internal volume 116 of the constraint container 110. In one or more examples, the wall 144 has or forms a cross-sectional profile of the cover 114 corresponding to the cross-sectional shape of the workpiece 200. In these examples, an expandable medium 120 is configured to be disposed within the internal volume of the cover 114 formed by the wall 144. In one or more examples, the expandable medium 120 is disposed between the wall 144 and the joined portion 210 of the workpiece 200.

[0067] In one or more examples, workpiece 200 (e.g., portion 210) is positioned on base 112 during the joining process. To apply appropriate compressive forces (e.g., normal pressure 124) to workpiece 200 while it is within constraint container 110, at least the joined portion 210 of workpiece 200 may need to be well supported. In one or more examples, base 112 provides a substantially incompressible surface to support one side of workpiece 200.

[0068] In one or more examples, the base 112 substantially resists compression, at least when pressure is applied to the support surface of the base 112 that contacts and supports the workpiece 200. In this way, the pressure applied to the surface of the workpiece 200 works in conjunction with the base 112 to generate compressive forces on the workpiece 200 during engagement.

[0069] In one or more examples, the internal volume 116 of the constraint container 110 is selectively (e.g., controllably) variable. In one or more examples, at least one of the walls 144 of the cover 114 is movable to modify (e.g., reduce) the internal volume 116 of the constraint container 110. This selective modification or change of the internal volume 116 facilitates a reduction in the internal volume 116 and a corresponding reduction in the amount of expandable medium 120 required to fill the internal volume 116 during expansion. The selective modification or change of the internal volume 116 also makes it possible to selectively or reactively control and modify the internal pressure 118 of the constraint container 110 (e.g., within the internal volume 116 and acting on the workpiece 200).

[0070] In one or more examples, the cover 114 includes any suitable elements or features that facilitate the application and / or removal of the expandable medium 120 from the internal volume 116. In one or more examples, the cover 114 includes a removable or openable panel (e.g., a door) that, once positioned relative to the workpiece 200, enables access to the internal volume 116 and the application of the expandable medium 120.

[0071] like Figure 1A , Figure 1Band Figures 9 to 11 As shown, in one or more examples, system 100 includes a pressure detector 130. The pressure detector 130 is configured to detect the internal pressure 118 of the internal volume 116 within the constraint container 110. In one or more examples, the pressure detector 130 facilitates monitoring of the internal pressure 118 of the internal volume 116 within the constraint container 110. In one or more examples, the pressure detector 130 also functions as a fail-safe device to limit the internal pressure 118 within the constraint container 110.

[0072] like Figure 1A , Figure 1B and Figures 9 to 11 As shown, in one or more examples, the pressure detector 130 includes or takes the form of a sensor 132 and is configured to detect or otherwise determine the internal pressure 118 in the constrained container 110, and therefore the normal pressure 124 or omnidirectional force applied to the workpiece 200 by the expandable medium 120 during and after the expansion of the expandable medium 120. In these examples, the sensor 132 may include any suitable type or number of sensors, such as, but not limited to, pressure sensors, load sensors, strain gauges, other sensor devices, and combinations thereof.

[0073] like Figure 1A , Figure 1B As shown, in one or more examples, system 100 includes controller 150. In one or more examples, controller 150 receives input signals or data from sensor 132, enabling it to monitor the internal pressure 118 within the constraint container 110, and subsequently increase or decrease the internal pressure 118 as needed to achieve and / or maintain a desired amount of positive pressure 124 applied to workpiece 200 by the expansion of expandable medium 120.

[0074] In one or more examples, controller 150 includes or takes the form of a closed-loop controller, or otherwise utilizes closed-loop control of the internal pressure 118 within the constraint container 110 and / or applied to the workpiece 200 during engagement operations. In one or more examples, controller 150 uses real-time pressure measurements from sensor 132 to control or regulate the internal pressure 118 within the constraint container 110 and / or applied to the workpiece 200.

[0075] In one or more examples, the internal pressure 118 is controlled by increasing or decreasing the internal volume 116 of the constraint container 110, such as by selectively changing the position of one or more of the walls 144 of the constraint container 110. In one or more examples, the internal pressure 118 is controlled by selectively expanding or contracting the expandable medium 120 within the internal volume 116. In one or more examples, the internal pressure 118 is controlled by selectively expanding or contracting the expandable element 176, which is also located within the internal volume 116.

[0076] In one or more examples, the expansion and / or contraction of the expandable medium 120 is selectively controlled. For example, the expandable medium 120 is configured to expand and contract selectively or controllably as a method for controlling the pressure applied to the workpiece 200 within the constraint container 110 and / or during engagement. In various examples, the expansion and / or contraction of the expandable medium 120 can be controlled in any of a variety of ways, such as applying heat or cooling the expandable medium 120.

[0077] In one or more examples, the pressure detector 130 includes or takes the form of a fail-safe mechanism configured to prevent over-pressurization and / or regulation of pressure within the internal volume 116 of the restraint container 110. As an example, the pressure detector 130 includes at least one instance of a pin 134 (e.g., a shear pin) for engaging the cover 114 to the base 112 or engaging multiple sections or portions of the cover 114 together. In one or more examples, the pin 134 is configured to fail at a predetermined pressure greater than the pressure required or desired for the engagement process, thereby releasing the cover 114 and relieving pressure within the restraint container 110.

[0078] In one or more examples, pressure detector 130 includes a combination of pin 134 and sensor 132. In these examples, sensor 132 may be a strain gauge coupled to pin 134 and configured to detect deformation of pin 134 and / or strain or load applied to pin 134 in response to internal pressure 118 within the restraint container 110. In these examples, pressure detector 130 provides real-time pressure detection and fault protection. In one or more examples, if the detected pressure value (e.g., magnitude) exceeds an alarm or threshold pressure, system 100 is configured to initiate automatic shutdown and other safety measures, such as forced air cooling, releasing internal pressure, and opening restraint container 110. In one or more examples, pin 134 is a sacrificial pin with a known failure strength corresponding to the maximum permissible internal pressure of the alarm. In these examples, if pin 134 breaks, system 100 will enter an alarm mode. In other examples, system 100 includes multi-layered safety controls.

[0079] like Figure 1A , Figure 1B and Figures 3 to 5 As shown, in one or more examples, system 100 includes heater 140. Heater 140 is in thermal communication with expandable medium 120. Heater 140 is configured to heat expandable medium 120 to activation temperature 122, at which activation temperature 122 expands within internal volume 116 to apply positive pressure 124 to workpiece 200.

[0080] In one or more examples, heater 140 is an internal heater and is configured to be disposed within the internal volume 116 of the constraint container 110 together with the expandable medium 120. In one or more examples, heater 140 is an external heater and is configured to be disposed outside the constraint container 110. In one or more examples, heater 140 is integrated into the constraint container 110 and / or the expandable medium 120, for example, using a smart sensor heating element.

[0081] The heater 140 can take any suitable form or include any suitable heating device. In various examples where the expandable medium 120 is thermally activated to expand, the confinement container 110 (such as at least the lid 114) can be externally heated. Alternatively or additionally, the system 100 may include one or more heating elements configured to heat the expandable medium 120 to a predetermined temperature at which the expandable medium 120 will expand.

[0082] In one or more examples, at least a portion of the constraint container 110 (such as at least a portion of the lid 114) is heat-reflective. As an example, at least one of the walls 144 of the lid 114 is heat-reflective. In one or more examples, at least a portion of the inner surface of the lid 114 and / or the base 112 comprises or is coated with a heat-reflective material. Heat reflectivity facilitates improved heating of the expandable medium 120 to activate the expansion of the expandable medium 120 during the bonding process.

[0083] like Figure 1A , Figure 1BAs shown, in one or more examples, system 100 includes a retainer 146. The retainer 146 is configured to hold the constraint container 110 in a closed configuration. As an example, the retainer 146 is configured to hold the cover 114 against the base 112 or otherwise secure the base 112 and cover 114 together during engagement processing after the workpiece 200 and the expandable medium 120 have been loaded into the internal volume 116 of the constraint container 110. The retainer 146 includes any suitable mechanism capable of securing the cover 114 relative to the base 112. In one or more examples, the retainer 146 includes at least one clamp configured to fasten or secure the cover 114 in place relative to the base 112. The clamp can include any suitable type of clamping and fastening device, such as, but not limited to, mechanical clamps, magnetic clamps, pneumatic clamps, spring clamps, latches, pins, fasteners, counterweights, etc. The retainer 146 can include any number of clamps.

[0084] In one or more examples, retainer 146 and pressure detector 130 are integrated into a single component. As an example, pin 134 may be used to secure container 110 in a closed position (e.g., to hold base 112 and cap 114 together). Optionally, sensor 132 may be used to detect internal pressure 118.

[0085] like Figure 1A , Figure 1B As shown, in one or more examples, the system includes at least one example of an intermediate layer 164. In these examples, the intermediate layer 164 is located within the internal volume 116 of the constraint container 110 together with the expandable medium 120 and the workpiece 200. In one or more examples, the intermediate layer 164 is positioned between the constraint container 110 and the expandable medium 120. In one or more examples, the intermediate layer 164 is located between the expandable medium 120 and the workpiece 200. In one or more examples, the intermediate layer 164 is located within the expandable medium 120.

[0086] In one or more examples, the intermediate layer 164 comprises a bladder or takes the form of a bladder. In one or more examples, the bladder is filled with a fluid (e.g., gas or liquid) and configured to apply a uniform positive pressure to the workpiece 200, such that the positive pressure 124 is applied more evenly. The bladder may be selected to be heat-resistant and easily removed after the workpiece 200 has been joined.

[0087] like Figure 1A , Figure 1BAs shown, in one or more examples, the expandable medium 120 is configured to expand to an expansion volume 128 when a predetermined change occurs in the property 126 of the expandable medium 120, such that the expandable medium 120 applies or exerts a positive pressure 124 on the workpiece 200 and the constraint container 110. Typically, the expansion volume 128 is known or can be calculated based on the material composition, property 126, and / or activation temperature 122 of the expandable medium 120.

[0088] In one or more examples, the expansion volume 128 of the expandable medium 120 in its expanded state is greater than the internal volume 116 of the constraint container 110. For the purposes of this disclosure, the internal volume 116 refers to the actual usable, fillable internal volume of the internal cavity of the constraint container 110. In various examples, the expansion volume 128 is substantially the same as or slightly larger than the internal volume 116, such that when the expandable medium 120 expands, the expandable medium 120 exerts a positive pressure 124 on the workpiece 200, unless the internal volume 116 can be changed (e.g., by moving wall 144, controlling expandable element 176, etc.). In one or more examples, the amount (e.g., volume) of the unexpanded expandable medium 120 to be loaded into the internal volume 116 of the constraint container 110 is determined by testing or modeling to predict the pressure during and after expansion within the constraint volume.

[0089] The expandable medium 120 may comprise any one or more of a variety of suitable types of materials or material compositions configured to expand upon activation or in response to a change in at least one example of property 126. Figure 1A , Figure 1B As shown, in one or more examples, the expandable medium 120 includes expandable granules 162. In one or more examples, the expandable granules 162 are thermally activated at an activation temperature 122. In these examples, the expandable granules 162 are configured to expand when the temperature of the expandable granules 162 rises to the activation temperature 122.

[0090] In one or more examples, any suitable quantity of expandable granules 162 may be placed within the internal volume 116 of the constraint container 110, provided that when expanded, they can apply sufficient positive pressure 124 to the workpiece 200 for engagement. The quantity of expandable granules 162 depends on the size of the internal volume 116. That is, a smaller quantity of expandable granules 162 may be required where the constraint container 110 fits more tightly around the contour of the workpiece 200.

[0091] In various examples, each of the expandable pellets 162 may have any suitable size. In one or more examples, the length of the expandable pellets 162 is less than about 1 cm. The size of the expandable pellets 162 may be substantially uniform, or may include pellets of different sizes.

[0092] In one or more examples, the activation temperature 122 of the expandable granules 162 is at least less than or greater than the curing temperature 220 of the workpiece 200. In one or more examples, the activation temperature 122 of the expandable granules 162 is at least less than or greater than the curing temperature 220 of the uncured composite material 212 and / or the adhesive 216. In one or more examples, the activation temperature 122 of the expandable granules 162 is at least less than or greater than the consolidation temperature 224 of the uncured composite material 212.

[0093] like Figure 1A , Figure 1B As shown, in one or more examples, the expandable medium 120 (such as expandable granules 162) includes or takes the form of foamable granules 166. In one or more examples, the foamable granules 166 are configured to foam when heated to at least a predetermined foaming temperature (e.g., activation temperature 122). In one or more examples, the foamable granules 166 include foamable materials, such as thermoplastic materials treated with a foaming agent; inflatable balls; hollow microspheres; metals; any other suitable components configured to expand upon heating, or any combination thereof.

[0094] like Figure 1A , Figure 1B As shown, in one or more examples, the expandable medium 120 includes an encapsulation element 168. In one or more examples, the expandable medium 120 is disposed within the encapsulation element 168. In one or more examples, expandable granules 162 are disposed within the encapsulation element 168. In one or more examples, the encapsulation element 168 encloses the expandable medium 120 (e.g., expandable granules 162) to better facilitate the handling of the expandable medium 120 and its removal after bonding is completed.

[0095] Encapsulation element 168 can take any suitable form, such as a sealing film, a sealing material layer, a bag, a pouch, etc. In one or more examples, encapsulation element 168 is non-inflatable. In one or more examples, encapsulation element 168 is inflatable. In one or more examples, encapsulation element 168 is made of braided nylon or polyester fabric (e.g., fire hose material).

[0096] In one or more examples, the expandable medium 120 is in an unexpanded state prior to the bonding process (e.g., Figure 4 , Figure 7 and Figure 10 In its unexpanded state, the expandable medium 120 may be referred to as unexpanded or unexpanded element. During the bonding process, the expandable medium 120 is expanded to an expanded state (e.g., Figure 5 , Figure 8 and Figure 11 In the expanded state, the expandable medium 120 may be referred to as an expander or an expandable element.

[0097] In one or more examples, in the expanded state, the expandable medium 120 applies pressure to the inner surface of the constraint container 110 (e.g., the inner surface of the cap 114 and / or the base 112) and the surface of the portion 210 of the workpiece 200 (e.g., unbonded material or components of the workpiece). In one or more examples, the expanded expandable medium 120 applies a positive pressure 124 (generated by the expansion of the expandable medium 120) to the workpiece 200 during some or all of the bonding processes to promote compression. In one or more examples, after the workpiece 200 has been bonded, the expandable medium 120 may be removed from the constraint container 110 before, simultaneously with, or after the workpiece 200 is removed from its current bonded state from the constraint container 110.

[0098] For the purposes of this disclosure, the terms "expandable," "expandable," "positively expandable," and similar terms refer to the ability to be expanded or the potential or capability to increase in size and / or volume. An expandable substance or separating element may be able to increase in size or volume symmetrically or asymmetrically. In the case where an expandable substance is capable of symmetrical expansion, the substance undergoes substantially equal expansion along each axis. In the case where an expandable substance exhibits asymmetrical expansion, the substance may undergo greater relative expansion along a first axis, or a first axis and a second axis, than along different axes. In various examples, the expandable medium 120 is configured to expand when a predetermined change occurs in the expandable medium 120. The predetermined change is generally a change in the physical or chemical properties of the expandable medium 120, or a combination thereof, and / or a change in any other suitable property associated with the expansion of the expandable medium 120. Unless otherwise stated, the expansion of the expandable medium 120 refers to an increase in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. As an example, the expandable medium 120 can be configured to expand when its temperature rises from a lower temperature (such as ambient temperature) to a predetermined higher temperature (e.g., activation temperature 122). Therefore, in cases where the joining of workpieces 200 involves raising the temperature of workpieces 200, the expandable medium 120 expands within the internal volume 116 during the joining process. During the joining process, the expandable medium 120 (e.g., during or after expansion) abuts against the interior of the constraint container 110 and abuts against or applies pressure to the workpiece 200.

[0099] In one or more examples, the expandable medium 120 is selected such that, when expanded within the internal volume 116 of the constrained container 110, the expandable medium 120 applies sufficient pressure to effectively compact the material 202 of the workpiece 200 for proper bonding. For some materials 202, an applied pressure of less than one atmosphere may be sufficient for bonding, while for others, an applied pressure of one atmosphere or greater may bond more effectively. In one or more examples, the expandable medium 120 is selected to apply sufficient pressure such that pressures typically previously required by an autoclave (e.g., 15 atmospheres) can be applied.

[0100] In one or more examples, the bonding process is simplified and facilitated by adding an expandable medium 120 as a plurality of expandable granules 162 (also referred to as expandable beads). In these examples, the expandable granules 162 are configured to undergo volume expansion when heated to at least a predetermined temperature (e.g., activation temperature 122).

[0101] In one or more examples, the expandable medium 120 includes one or more different types, kinds, or compositions of expandable materials (e.g., expandable granules 162 of different types or compositions). In these examples, each of the different types of expandable materials is configured to expand (e.g., expand to a predetermined volume) when heated to a predetermined temperature. In one or more examples, the composition of the different types of expandable medium 120 (e.g., expandable granules 162 of different types) can be designed to achieve a desired relationship between the expansion volume of each type and the temperature change of each type over time.

[0102] In one or more examples, the degree of expansion of a given type or composition of the expandable medium 120 (e.g., expandable granules 162) can be measured and recorded, as can the force generated by the expansion. Therefore, the formulation of the composition can be varied to obtain the desired degree of expansion and expansion force. In this way, the amount of expandable medium 120 used (e.g., the quantity of expandable granules 162) and / or the composition of the expandable medium 120 (e.g., expandable granules 162) can be selected such that expansion within a known enclosed volume (e.g., internal volume 116) will exert the desired pressure on the workpiece 200 in one or more stages of the joining process.

[0103] like Figure 1A , Figure 1BAs shown, in one or more examples, system 100 includes additional elements configured to alter or mitigate the pressure exerted by expandable medium 120, such as, but not limited to, one or more examples of volume-invariant element 172 (e.g., substantially incompressible element) and / or one or more examples of contractile element 174 (e.g., fluid-filled bladder), which may increase in volume before or during engagement and / or decrease in volume after engagement.

[0104] like Figure 1A , Figure 1B As shown, in one or more examples, system 100 includes at least one example of an expandable element 176. In one or more examples, the expandable element 176 is located within the internal volume 116 of the constraint container 110 along with the expandable medium 120 and the workpiece 200. In one or more examples, the expandable element 176 is a volume-modifying component of system 100 configured to selectively expand and / or contract to selectively reduce or increase the internal volume 116 of the constraint container 110, which can be filled by the expandable medium 120 during expansion. In one or more examples, the expandable element 176 comprises or takes the form of a closed capsule or sphere having some type of expandable material (e.g., expandable medium 120). In one or more examples, a chemical (e.g., baking soda powder) may be loaded inside the sphere. After heating the chemical and generating gas, the sphere will expand and reduce the fillable volume (internal volume 116) of the constraint container 110 and / or apply additional positive pressure in the constraint space. In other examples, the expandable element 176 is an example of one of different types of expandable media 120.

[0105] like Figure 1A , Figure 1B and Figure 15 As shown, in one or more examples, system 100 includes at least one example of a reinforcing member 178. In one or more examples, the reinforcing member 178 is located within the internal volume 116 of the constraint container 110 along with the expandable medium 120 and the workpiece 200. In one or more examples, the reinforcing member 178 is another type or example of the expandable medium 120 or a different type of expandable material. In one or more examples, the reinforcing member 178 can be selectively expanded to increase or enhance the pressure applied to the workpiece 200 at one or more locations. As an example, the reinforcing member 178 may be positioned near a predetermined location or region of the workpiece 200 (e.g., in or near), such as a cavity or contour between different portions of the workpiece 200), such that enhanced pressure is applied to the radius of the contour during engagement.

[0106] Now for reference Figure 2 The following are examples of method 1000 according to this disclosure. In one or more examples, system 100 ( Figure 1A , Figure 1B To implement method 1000, examples of method 1000 include multiple elements, steps, operations, or processes. All elements, steps, operations, or processes described or shown in one example are not required in that example. Some or all of the elements, steps, operations, or processes described or shown in one example may be combined with other examples in various ways without needing to include other elements, steps, operations, or processes described in those other examples, even if one or more such combinations are not explicitly described or shown by example herein.

[0107] In one or more examples, method 1000 includes the step of enclosing 1002 at least a portion 210 of workpiece 200 (such as at least a portion of first material 204 and second material 206) within the internal volume 116 of constraint container 110. In one or more examples, the materials 202 of separated portions of workpiece 200 are joined. In these examples, the base 112 and cover 114 of constraint container 110 are positioned to enclose the portion 210 of workpiece 200 to be joined. In one or more examples, the materials 202 of the entire workpiece 200 are joined. In these examples, the entire workpiece 200 is positioned (e.g., loaded) within the internal volume 116 of constraint container 110.

[0108] In one or more examples, method 1000 includes enclosing 1004 the expandable medium 120 within the internal volume 116 of the constraint container 110. In one or more examples, the workpiece 200 and the expandable medium 120 may be enclosed together within the constraint container 110. In one or more examples, a predetermined amount of the expandable medium 120 in an unexpanded state is loaded or otherwise applied within the constraint container 110 surrounding the workpiece 200 (e.g., surrounding at least a portion of the workpiece 200). Figures 9 to 12 As shown, in one or more examples, the expandable medium 120 is typically positioned on one side of the workpiece 200 such that the workpiece 200 is compressed or compacted between the expandable medium 120 and another underlying or supporting structure (e.g., base 112) during engagement. Figures 12 to 15 As shown, in one or more examples, the expandable medium 120 is typically positioned on more than one side (e.g., two opposite sides) of the workpiece 200 such that the workpiece 200 is compressed or compacted between a first volume of the expandable medium 120 and an opposite second volume of the expandable medium 120 during engagement.

[0109] In one or more examples, method 1000 includes raising the temperature 1006. In one or more examples, the temperature of the expandable medium 120 is raised to an activation temperature 122. In one or more examples, the temperature of the workpiece 200 is raised to a suitable processing temperature to promote bonding of the material 202.

[0110] In one or more examples, method 1000 includes the step of expanding 1008 an expandable medium 120 disposed within an internal volume 116. In one or more examples, the expandable medium 120 expands in response to a change in property 126 of the expandable medium 120. In one or more examples, the expandable medium 120 expands in response to raising the temperature of the expandable medium 120 to an activation temperature 122.

[0111] In one or more examples, method 1000 includes the step of applying a positive pressure 124 to the constraint container 110 and the workpiece 200 (such as at least one of a first material 204 and a second material 206). The positive pressure 124 is applied to the workpiece 200 in response to the expansion of the expandable medium 120. During expansion, the expandable medium 120 fills the internal volume 116 and applies the positive pressure 124 to the workpiece 200.

[0112] In one or more examples, the expansion of the expandable medium 120 applies an omnidirectional force to at least one surface or portion of the workpiece 200. For example... Figures 3 to 12 As shown, in one or more examples, the expansion of the expandable medium 120 applies a bonding force (e.g., normal pressure 124) to one side of the workpiece 200, causing the workpiece 200 to be compressed or compacted between the expandable medium 120 and the base 112. Figures 13 to 15 As shown, in one or more examples, the expansion of the expandable medium 120 applies a bonding force (e.g., positive pressure 124) on more than one side (e.g., two opposite sides) of the workpiece 200, such that the workpiece 200 is compressed or compacted between a first volume of the expandable medium 120 and an opposite second volume of the expandable medium 120 during bonding.

[0113] In one or more examples, method 1000 includes the step of bonding materials 202 (such as at least a first material 204 and a second material 206) together 1012. In one or more examples, according to method 1000, bonding 1012 includes co-curing materials 202 (e.g., the first material 204 and the second material 206) together 1014. In one or more examples, according to method 1000, bonding 1012 includes co-bonding materials 202 (e.g., the first material 204 and the second material 206) together 1016. In one or more examples, according to method 1000, bonding 1012 includes secondary bonding of materials 202 (e.g., the first material 204 and the second material 206) together 1018.

[0114] In one or more examples, according to method 1000, the first material 204 and the second material 206 comprise an uncured composite material 212. The uncured composite material 212 has one of a curing temperature 220 (e.g., a thermosetting composite material) or a settling temperature 224 (e.g., a thermoplastic composite material). In these examples, bonding can be achieved by co-curing with or without an adhesive.

[0115] In one or more examples, according to method 1000, the first material 204 comprises a cured composite material 214. The second material 206 comprises an uncured composite material 212. The uncured composite material 212 has one of a curing temperature 220 (e.g., a thermosetting composite material) or a settling temperature 224 (e.g., a thermoplastic composite material). In these examples, bonding can be achieved by co-bonding.

[0116] In one or more examples, according to method 1000, the first material 204 and the second material 206 comprise any of a variety of material compositions other than the uncured composite material 212 and the adhesive 216. In these examples, bonding can be achieved through secondary bonding.

[0117] In one or more examples, the curing temperature 220 of the uncured composite material 212 (e.g., a thermosetting composite material) is equal to or higher than the activation temperature 122. In one or more examples, the uncured composite material 212 has a curing pressure 222 equal to or less than the positive pressure 124 (e.g., the pressure required for full curing and / or bonding of the uncured composite material).

[0118] In one or more examples, the consolidation temperature 224 of the uncured composite material 212 (e.g., a thermoplastic composite material) is equal to or higher than the activation temperature 122. In one or more examples, the uncured composite material 212 has a consolidation pressure 226 equal to or less than the normal pressure 124 (e.g., the pressure required for full consolidation and bonding of the uncured composite material).

[0119] In one or more examples, according to method 1000, adhesive 216 is located between materials 202 (e.g., first material 204 and second material 206). Adhesive 216 has a curing temperature 220. The curing temperature 220 of adhesive 216 is equal to or higher than the activation temperature 122. In one or more examples, adhesive 216 has a curing pressure 222 equal to or less than the positive pressure 124 (e.g., the pressure required for full bonding of the adhesive materials).

[0120] In one or more examples, method 1000 includes detecting internal pressure 118 within internal volume 116 of 1020. In these examples, pressure detector 130 is used to detect internal pressure 118. In one or more examples, internal pressure 118 is monitored by sensor 132 (e.g., in real time). In one or more examples, pressure failure protection is provided by pin 134.

[0121] Refer again Figure 1A , Figure 1B The following is an example of workpiece 200 according to this disclosure. In one or more examples, system 100 and / or method 1000 are used. Figure 2 The workpieces 200 are joined to form a joined structure. Examples of workpieces 200 include multiple elements, steps, operations, or processes. All elements, steps, operations, or processes described or shown in one example are not required in that example. Some or all of the elements, steps, operations, or processes described or shown in one example may be combined in various ways with other examples without needing to include other elements, steps, operations, or processes described in those other examples, even if one or more such combinations are not explicitly described or shown by example herein.

[0122] In one or more examples, workpiece 200 is a joining workpiece or forms a joining structure. Workpiece 200 includes a plurality of materials 202 to be joined together, such as at least a first material 204 and a second material 206. At least a portion of the first material 204 and the second material 206 is enclosed by a constraint container 110. An expandable medium 120 is disposed within an internal volume 116 of the constraint container 110 between at least one of the first material 204 and the second material 206 and the constraint container 110. The expandable medium 120 is configured to expand to a predetermined volume when a predetermined change occurs in a property 126 of the expandable medium 120, such that the expandable medium 120 applies a positive pressure 124 to the constraint container 110 and at least one of the first material 204 and the second material 206.

[0123] In one or more examples of workpiece 200, the first material 204 and the second material 206 comprise an uncured composite material 212 (e.g., a thermosetting composite material) having a curing temperature 220 and a curing pressure 222. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to the activation temperature 122 (which is up to the curing temperature 220), and to apply a positive pressure 124 up to or greater than the curing pressure 222.

[0124] In one or more examples of workpiece 200, the first material 204 and the second material 206 comprise an uncured composite material 212 (e.g., a thermoplastic composite material) having a consolidation temperature 224 and a consolidation pressure 226. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 up to the consolidation temperature 224, and to apply a positive pressure 124 up to or greater than the consolidation pressure 226.

[0125] In one or more examples of workpiece 200, the first material 204 comprises a cured composite material 214. In one or more examples, the second material 206 comprises an uncured composite material 212 (e.g., a thermosetting composite material) having a curing temperature 220 and a curing pressure 222. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 (which is up to the curing temperature 220), and to apply a positive pressure 124 up to or greater than the curing pressure 222. In one or more examples, the second material 206 comprises an uncured composite material 212 (e.g., a thermoplastic composite material) having a consolidation temperature 224 and a consolidation pressure 226. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 up to the consolidation temperature 224, and to apply a positive pressure 124 up to or greater than the consolidation pressure 226.

[0126] In one or more examples, workpiece 200 includes adhesive 216. Adhesive 216 is located between at least two of the materials 202 of workpiece 200, such as a first material 204 and a second material 206. Adhesive 216 has at least one of a curing temperature 220 and a curing pressure 222. Expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is higher than the curing temperature 220. At the activation temperature 122, expandable medium 120 is configured to expand such that a positive pressure 124 is higher than the curing pressure 222.

[0127] like Figure 1A , Figure 1B , Figure 4 , Figure 7 , Figure 10and Figures 12 to 15 As shown, in one or more examples, workpiece assembly 250 includes workpiece 200 and system 100. Workpiece 200 is disposed within constraint container 110. Constraint container 110 is configured to enclose portion 210 of workpiece 200. In one example, portion 210 of workpiece 200 is covered or otherwise enclosed by constraint container 110. Constraint container 110 is configured to facilitate the application of pressure on the surface of workpiece 200 by expansion of expandable medium 120. In one or more examples, workpiece 200 is disposed on base 112, or supported by reinforcements from a position opposite to the direction of cover 114 and positive pressure 124, as needed.

[0128] like Figure 4 , Figure 7 , Figure 10 and Figures 12 to 15 As shown, in one or more examples, expandable medium 120 is added to internal volume 116. An appropriate amount of expandable medium 120 is used such that during and / or after expansion, expandable medium 120 contacts both the inner surfaces of workpiece 200 and constraint container 110 to generate and apply positive pressure 124 on one or more surfaces of workpiece 200.

[0129] The expandable medium 120 can take any suitable form. In one or more examples, the expandable medium 120 is added to the confinement container 110, for example, as granules, beads, particles, powder, or foam. Alternatively or additionally, the expandable medium 120 is added to the confinement container 110 as a separate portion of solid or semi-solid material, such as a layer of expandable medium 120 that may cover portion 210 of workpiece 200. Layers of expandable medium 120 can be added by adding various examples of encapsulation elements 168 (e.g., large bags or pouches) filled with granules, beads, or other smaller portions of the expandable medium 120. Although Figures 3 to 15 The expandable medium 120 is depicted as a plurality of expandable granules 162, but this is a representative depiction and should not be considered as limiting the structure or configuration of the expandable medium 120.

[0130] In various examples, when in an unexpanded state, the expandable medium 120 is added to the internal volume 116 of the constrained container 110. For example... Figure 4 , Figure 5 , Figure 7 , Figure 8 , Figure 10 and Figure 11As shown, before and / or during the joining process, the expandable medium 120 is expanded (e.g., its volume increases) to at least partially fill the internal volume 116, such that the expandable medium 120 (in its expanded state) applies positive pressure directly or indirectly to at least some of the inner surfaces of the constraint container 110 and the surfaces (e.g., the outer surfaces) of the workpiece 200. Thus, when the expandable medium 120 expands, the pressure applied by the expandable medium 120 promotes the compression and consolidation of portions 210 of the workpiece 200 during joining.

[0131] In various examples, the expandable medium 120 is configured to expand (e.g., to a predetermined volume and / or pressure) when a predetermined change occurs in the property 126 of the expandable medium 120 (e.g., in an unexpanded state). In one or more examples, the expandable medium 120 is applied (e.g., inserted or added) within the internal volume 116 of the constrained container 110 in an unexpanded state. When the expandable medium 120 (in an unexpanded state) is within the internal volume 116, a predetermined change occurs in the property 126 of the expandable medium 120 in the unexpanded state. The expandable medium 120 expands in response to the resulting predetermined change. The property 126 of the expandable medium 120 may be a physical and / or chemical property.

[0132] In one or more examples, the expandable medium 120 is configured to expand in volume when it interacts with water. As an example, the expandable medium 120 is or includes a desiccant, the volume of which can increase when water is absorbed. For example, anhydrous calcium sulfate (hard gypsum) exhibits a volume increase of approximately 61 percent when it absorbs water to form gypsum. In these examples, water can be added directly to the expandable medium 120, for example, by adding liquid water or water vapor to the interior of the confinement container 110. Alternatively or additionally, water or water vapor can be generated within the confinement container 110 itself, for example, through a suitable chemical reaction.

[0133] In one or more examples, a predetermined change in property 126 of the expandable medium 120 includes a change in the temperature of the expandable medium 120 and / or the temperature of one or more portions of the expandable medium 120. Therefore, generating a predetermined change in property 126 of the expandable medium 120 may include raising the temperature of the unexpanded expandable element from a lower temperature (such as ambient temperature, e.g., room temperature) to a predetermined temperature at least greater than the initial temperature or ambient temperature (e.g., a predetermined temperature a few degrees higher than the ambient temperature suitable for generating predetermined expansion of the expandable element). The expandable element then undergoes thermal expansion due to the temperature increase.

[0134] In one or more examples, the expandable medium 120 is a thermally activated expandable element. In these examples, the thermally activated expandable element is configured to expand when the temperature of the expandable medium 120 rises to at least a predetermined temperature. Alternatively or additionally, the expandable medium 120 is expanded by heating it to at least a predetermined temperature to generate a predetermined pressure against the workpiece 200. Typically, the predetermined pressure is sufficient to fully cure the composite material.

[0135] In one or more examples, the predetermined change produced in property 126 of expandable medium 120 is a combination of two or more properties of expandable medium 120, such as a ratio or product of quantitative values ​​associated with the properties of expandable medium 120, such as two materials with different coefficients of thermal expansion.

[0136] In various examples, the process of joining workpieces 200 includes generating a predetermined change in property 126 of the expandable medium 120. In one or more examples, the expansion of the expandable medium 120 occurs automatically during the joining process. For example, property 126 may be the temperature of the expandable medium 120, and the heat applied to the workpiece assembly 250 during the joining process generates a predetermined change in the temperature of the expandable medium 120. That is, the heat applied to the workpiece assembly 250 during the joining process raises the temperature of the expandable medium 120 to at least a predetermined temperature associated with a desired volume and / or a desired volume increase. One or more properties of the expandable medium 120 may be designed such that a temperature change induced in the expandable medium 120 during the joining of workpieces 200 causes the expandable medium 120 to expand by a desired predetermined amount due to thermal expansion. Alternatively or additionally, expanding the expandable medium 120 may require additional steps beyond those required for curing the workpiece 200. As an example, expanding the expandable medium 120 may include applying an electric field, injecting a liquid, gas, and / or another suitable material and / or causing any other suitable changes in the expandable medium 120.

[0137] In various examples, the expandable medium 120 is thermally expandable and includes any material capable of expansion upon reaching a predetermined temperature. In a particular example, a family of plastic polymers capable of softening upon heating is referred to as thermoplastic materials. When heated above their glass transition temperature but below their melting point, solid thermoplastic materials soften, becoming viscous liquids. In this state, thermoplastics can be reformed, and more specifically, can expand.

[0138] Various types of thermoplastic materials are known, including acrylic polymers, acrylonitrile butadiene styrene (ABS) polymers, nylon polymers, polylactic acid (PLA) polymers, polybenzimidazole polymers, polycarbonate polymers, polyethersulfone (PES) polymers, polyetherimide (PEI) polymers, polyethylene (PE) polymers, polyphenylene ether (PPO) polymers, polyphenylene sulfide (PPS) polymers, polyvinyl chloride (PVC) polymers, polyvinylidene fluoride (PVDF) polymers, and polytetrafluoroethylene (PTFE) polymers. In particular, expandable media 120 comprising acrylonitrile butadiene styrene (ABS) polymers exhibit advantageous physical properties when used in conjunction with the embodiments described herein.

[0139] In one or more examples, the expandable medium 120 (e.g., expandable granules 162) may additionally include a foaming agent. The foaming agent is selected such that, when heated to at least a predetermined temperature, it forms a plurality of pores, pockets, or voids within the material of the expandable medium 120, thereby increasing the volume of the expandable medium 120. For example, a suitable foaming agent may be an inert gas that permeates into the expandable medium 120 under pressure. This foaming agent can be configured to expand at multiple locations within the expandable medium 120 as the temperature of the expandable medium 120 increases from ambient temperature or an initial temperature to a predetermined higher temperature, and the expanding gas forms pores, pockets, or voids within the granules. The foaming agent (if present) may be applied to the expandable medium 120 prior to heating.

[0140] In examples where the expandable medium 120 includes a blowing agent, the blowing agent can be any suitable substance capable of producing the desired degree of expansion. The blowing agent can include physical blowing agents, such as chlorofluorocarbons, hydrochlorofluorocarbons, hydrocarbons, or liquid CO2. Alternatively or additionally, the blowing agent can include chemical blowing agents selected to react with one or more components of the expandable medium 120, such as isocyanates and water for polyurethanes, azodicarbonamide for vinyl groups, hydrazine and other nitrogen-based materials for thermoplastic and elastomeric foams, and sodium bicarbonate for thermoplastic foams.

[0141] In examples where the expandable medium 120 includes a foaming agent, the foaming agent may include a foaming agent. In these examples, the foaming agent may be selected to form a gas, and the foaming agent may be a material that promotes foam formation, such as a surfactant. Suitable foaming agents may include sodium lauryl ether sulfate, sodium lauryl ether sulfate (SLES), sodium lauryl sulfate (also known as sodium dodecyl sulfate or SDS), and ammonium lauryl sulfate (ALS), etc.

[0142] In the processing of the joined workpiece 200, the expandable medium 120 (e.g., expandable granules 162) is manufactured in a state of never expanding. Figure 5 and Figure 7) Expand to an expanded state ( Figure 6 and Figure 8 In one or more examples, the expandable granules 162 are configured to expand in response to heat applied to the workpiece assembly 250 during bonding. The expandable granules 162 expand to fill the internal volume 116 of the cap 114, such that the expanded expandable granules 162 apply positive pressure to the workpiece 200 and the workpiece 200 is cured.

[0143] In one or more examples, the expandable medium 120 (e.g., expandable granules 162) is configured (e.g., formulated) such that it is at least partially deformable after, during, and / or before expansion. This degree of deformability allows the expandable medium 120 to squeeze into small gaps that would otherwise be present, such as between granules, between granules and the inner surface of cap 114, and / or between granules and workpiece 200. Filling such gaps allows the expandable medium 120 to present a substantially smooth surface to workpiece 200.

[0144] In various examples, after portion 210 of workpiece 200 has cured, cap 114 can be unsealed, opened, or removed as needed, and expandable medium 120 can be removed. While expandable medium 120 is generally easily removed after workpiece 200 has cured, in some cases, expandable medium 120 may remain expanded and tightly packed after workpiece 200 has cured and cooled, which may tend to hinder removal. In such cases, expandable medium 120 may be additionally configured in one or more ways to facilitate separation from workpiece 200, base 112, and / or cap 114. As an example, expandable granules 162 may be configured such that their shape and / or size can be changed as needed, making them easier to extract. For example, expandable granules 162 may be configured to shrink upon cooling, such that after workpiece 200 has cured and cooled, expandable granules 162 shrink within internal volume 116, thereby facilitating their removal.

[0145] In one or more examples, the expandable medium 120 is modified to minimize sintering (self-adhesion) upon heating and expansion. Alternatively or additionally, the expandable medium 120 is configured to minimize potential adhesion to surfaces, for example by coating the expandable granules 162 with a suitable agent configured to prevent adhesion and / or promote separation.

[0146] In one or more examples, suitable agents for addition to the expandable medium 120 include lubricants. As an example, a lubricant may be added to the expandable granules 162 to reduce adhesion between the expandable granules 162 before and / or after volume expansion. A suitable lubricant is one that does not interfere with the curing and / or bonding of the workpiece 200 and prevents the expandable granules 162 from adhering substantially to each other, to the confinement container 110, or to components of the workpiece assembly 250. Suitable lubricants may include liquids, powders, or combinations thereof. When added as a powder, a suitable lubricant may include nanoparticles. Optionally or additionally, a suitable lubricant may include silicon-based materials, fluoropolymers, or other substantially inert substances. For example, a suitable lubricant may include polytetrafluoroethylene (PTFE) powder, PTFE nanoparticles, silicone, perfluoropolyether (PFPE), perfluoroalkyl ether (PFAE), perfluoropolyalkyl ether (PFPAE), etc. Such a lubricant may be applied to the expandable granules 162 before adding them to the confinement container 110. Alternatively or additionally, when the expandable granules 162 are disposed within the confinement container 110, a suitable lubricant may be applied to the expandable granules 162. Coating at least some of the expandable granules 162 with a suitable lubricant may include mixing the lubricant with a plurality of granules and / or pouring the lubricant onto a plurality of granules. Additionally or alternatively, at least a subset of the plurality of expandable granules 162 may be coated with a desired lubricant and then mixed with a plurality of uncoated granules.

[0147] In one or more examples, the crystallinity and / or semi-crystallinity along the outer surface of the expandable granules 162 can promote the prevention of sintering between the granules. In one or more examples, at least some of the expandable granules 162 are configured (e.g., through pretreatment) to have crystalline regions along the outer surface of the granules, such that adding the expandable medium 120 includes adding a plurality of expandable granules 162 with surface regions of increased crystallinity to reduce adhesion between granules before and / or after the volume expansion of the expandable granules 162. In one or more examples, the expandable granules 162 may be used with a high degree of crystallinity on the outer surface of the granules (e.g., a high percentage of the volume of the region near the outer surface of each granule is crystalline). Crystallinity can be induced in the expandable granules 162 by controlling one or more factors, including the material composition of the granules, the production temperature to which the granules are heated during production, the time the granule temperature is maintained at the production temperature during production, the electric and / or magnetic fields applied during production, the distribution of the foaming agent in the granules, the composition and / or concentration of the foaming agent, etc. The outer surface of the expandable granules 162 may be crystalline before, during and / or after foaming.

[0148] As shown and described herein, examples of System 100 and Method 1000 offer numerous advantages and benefits over conventional bonding techniques. Examples of System 100 and Method 1000 enable composite bonding under pressure, co-bonding where at least one side is pre-cured, and secondary bonding of non-composite materials (metals, ceramics, hybrids, MMC, CMC, etc.) using epoxy adhesives or any polymer adhesive (thermosetting or thermoplastic). Examples of System 100 and Method 1000 allow for progressive and controlled compaction, rather than catastrophic high pressure. This eliminates the need for high-pressure gas tanks and / or storage units. It also enables controlled failure modes or fault-protected designs. Examples of System 100 and Method 1000 enable convenient and portable or modular tooling applications, including heating elements and compaction equipment that can be integrated into the same tool. This eliminates the need for additional heating equipment. Examples of System 100 and Method 1000 facilitate a target thermal environment in which foam can be used as an insulation layer where it is necessary to isolate heat from certain areas of the workpiece 200. This allows for adaptive thermal management and / or unilateral heating configurations (e.g., from prepreg to precured). Examples of system 100 and method 1000 enable in-situ tooling of workpiece 200 (particularly for co-joining or secondary joining scenarios). Examples of system 100 and method 1000 enable the use of a wide range of expandable materials, not necessarily foamed materials, such as bladders or other soft materials with high coefficients of thermal expansion (CTE). Examples of system 100 and method 1000 allow pressure to be applied in all directions (compared to hot pressing, etc.). Examples of system 100 and method 1000 allow for control of heat transfer through various heating configurations. Examples of system 100 and method 1000 allow for stress annealing, which can utilize continuous pressure from the expandable medium 120 to alleviate localized stress concentrations. Examples of system 100 and method 1000 enable control of the pressure distribution for structural joining, for example, by using isolated pressure compartments within a constrained container (e.g., different design geometries and / or different expandable materials), the pressure can be uniform or localized. Examples of System 100 and Method 1000 can be made sustainable by using reusable expandable materials, saving equipment footprint, and reducing dependence on sources such as energy and waste disposal. Examples of System 100 and Method 1000 enable the extrusion of adhesives and / or air, thereby reducing porosity in the bond line. For thermoplastic composite applications, examples of System 100 and Method 1000 can achieve pressures higher than normal (>100 psi). Examples of System 100 and Method 1000 enable the application of continuous high pressure on extremely smooth surfaces (e.g., metals or composites). Examples of System 100 and Method 1000 achieve pre-compression strength prior to final bonding or final curing. Examples of System 100 and Method 1000 allow for hybrid bonding.Examples of system 100 and method 1000 enable the use of expandable materials that can be mixed in an adhesive, which serve as a bonding line controller, such as glass beads, to ensure uniform bonding and intentionally control differences between bonding surfaces.

[0149] Now for reference Figure 14 and Figure 15 The examples of system 100, method 1000, and workpiece 200 described herein may be related to or used in aerospace manufacturing and maintenance method 1100, such as... Figure 16 As shown in the flowchart, the aircraft 1200 and / or the manufacturing and maintenance method 1100 may utilize the joint structure (e.g., workpiece 200) manufactured using the system 100 and / or according to the method 1000.

[0150] refer to Figure 17 The illustration shows an example of an aircraft 1200. Aircraft 1200 can be any aerospace vehicle or platform. In one or more examples, aircraft 1200 includes a fuselage 1202 with an interior 1206. Aircraft 1200 includes multiple onboard systems 1204 (e.g., advanced systems). Examples of onboard systems 1204 of aircraft 1200 include a propulsion system 1208, a hydraulic system 1212, an electrical system 1210, and an environmental system 1214. In other examples, onboard systems 1204 also include one or more control systems coupled to the fuselage 1202 of aircraft 1200. In other examples, onboard systems 1204 also include one or more other systems, such as, but not limited to, communication systems, avionics systems, software distribution systems, network communication systems, passenger information / entertainment systems, guidance systems, radar systems, weapon systems, etc. The aircraft 1200 may have any number of parts including workpiece 200, which are manufactured, fabricated, joined and / or installed using system 100 and / or according to method 1000.

[0151] refer to Figure 16 During the pre-production phase of aircraft 1200, manufacturing and maintenance methods 1100 include the specification and design of aircraft 1200 1102 and material procurement 1104. During the production phase of aircraft 1200, the manufacturing of aircraft 1200 components and sub-assemblies 1106 and system integration 1108 occur. Thereafter, aircraft 1200 is certified and delivered 1110 for service 1112. Routine maintenance and servicing 1114 includes modification, reconfiguration, refurbishment, etc., of one or more systems of aircraft 1200.

[0152] Figure 14Each process of the manufacturing and maintenance method 1100 shown may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0153] Examples of the system 100, method 1000, and workpiece 200 shown and described herein can be found in... Figure 16 This is employed during any or more stages of the manufacturing and repair method 1100 shown in the flowchart. In the example, components of the aircraft 1200 including workpiece 200 may be manufactured, fabricated, joined, and / or installed using system 100 and / or according to method 1000 during part and sub-component manufacturing 1106 and / or system integration 1108. Furthermore, components of the aircraft 1200 including workpiece 200 may be manufactured, fabricated, joined, and / or installed using system 100 and / or according to method 1000 when the aircraft 1200 is put into service 1112. Additionally, components of the aircraft 1200 including workpiece 200 may be manufactured, fabricated, joined, and / or installed using system 100 and / or according to method 1000 during system integration 1108 and certification and delivery 1110. Similarly, components of aircraft 1200, including workpiece 200, may be manufactured, fabricated, joined, and / or installed using system 100 and / or according to method 1000 during the commissioning of aircraft 1200 1112 and during maintenance and service 1114.

[0154] The foregoing detailed description refers to the accompanying drawings, which illustrate specific examples described in this disclosure. 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 components. Throughout this disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be referred to collectively as an item and may be referred to by the same reference numerals. Furthermore, as used herein, a feature, element, component, or step preceding the word "a" or "an" should be understood to not exclude a plurality of features, elements, components, or steps unless such exclusion is expressly stated.

[0155] The foregoing provides illustrative, non-exhaustive examples that may, but do not necessarily, claim protection for the subject matter according to this disclosure. Reference to “example” herein means that one or more features, structures, elements, components, characteristics, and / or operational steps described in connection with the 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.

[0156] As used herein, a system, apparatus, device, structure, article, element, component, or hardware "configured to" perform a specified function is indeed capable of performing the specified function without any changes, and not merely has the potential to perform the specified function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for performing the specified function. As used herein, "configured to" indicates existing characteristics of the system, apparatus, structure, article, element, component, or hardware that enable 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, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "suitable" and / or "operable to" perform that function.

[0157] Unless otherwise stated, the terms “first,” “second,” “third,” etc., are used merely as labels in this document and are not intended to impose any order, position, or hierarchy on the items referred to by these terms. Furthermore, references to an item such as “second” do not require or exclude the existence of an item such as “first” or a lower-numbered item and / or an item such as “third” or a higher-numbered item.

[0158] As used herein, when used with a list of items, the phrase “at least one of” means that different combinations of one or more of the listed items may be used, and it may be necessary to use only one of each item in the list. For example, “at least one of item A, item B, and item C” may include, but is not limited to, item A or items A and B. This example may also include items A, B, and C, or items B and C. In other examples, “at least one” may be, for example, but not limited to, two of items A, one of items B, and ten of items C; four items B and seven items C; and other suitable combinations. As used herein, the terms “and / or” and the “ / ” symbol include any and all combinations of one or more associated listed items.

[0159] For the purposes of this disclosure, the terms "connected," "connecting," and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, communicated, or otherwise associated with each other (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, the 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. It should be understood that not all associations between the various disclosed elements are necessarily represented. Therefore, connectors other than those depicted in the figures may also exist.

[0160] As used herein, the term "approximately" means or indicates a condition that is close to but not exactly close to the stated condition, which still performs the desired function or achieves the desired result. As an example, the term "approximately" means a condition within an acceptable predetermined tolerance or accuracy, such as a condition within 10% of the stated condition. However, the term "approximately" does not exclude a condition that is exactly the stated condition. As used herein, the term "substantially" means a condition that substantially performs the desired function or achieves the desired result.

[0161] The above-mentioned Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 It may represent its functional elements, features, or components, and does not necessarily imply any specific structure. Therefore, the illustrated structure may be modified, added to, and / or omitted. Furthermore, those skilled in the art will understand that it is not limited to the structures mentioned above. Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 All elements, features, and / or components described and illustrated herein need to be included in every example, and not all elements, features, and / or components described herein need to be depicted in every exemplary example. Therefore, Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 Some of the elements, features, and / or components described and shown herein can be combined in various ways without needing to be included. Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 Other features described and illustrated in the accompanying drawings and / or disclosures, even if one or more such combinations are not expressly shown herein. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise expressly stated, the features mentioned above are not limited to those in the examples presented herein. Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 The schematic diagrams depicted are not intended to imply structural limitations regarding the exemplary examples. Rather, while an exemplary structure is shown, it should be understood that this structure can be modified as appropriate. Therefore, modifications, additions, and / or omissions can be made to the illustrated structure. Furthermore, elements, features, and / or components used for similar or at least substantially similar purposes may be omitted. Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 Each of these elements, features, and / or components is labeled with the same number, and these elements, features, and / or parts may not be referenced herein. Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 Each of these will be discussed in detail. Similarly, in Figure 1A , Figure 1B , Figures 3 to 15 and Figure 17 Each element, feature, and / or component may not be labeled, but for consistency, the associated reference numerals may be used herein.

[0162] The above-mentioned Figure 2 and Figure 16 In this document, boxes may represent operations, steps, and / or parts thereof, and the lines connecting the various boxes do not imply any particular order or dependency between the operations or their parts. It should be understood that this does not necessarily represent all dependencies between the various operations disclosed. Figure 2 and Figure 16 The accompanying disclosures 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 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.

[0163] This application involves the following provisions:

[0164] 1. A system for bonding materials, the system comprising:

[0165] A constraint container, comprising a base and a lid, and having an internal volume, wherein the constraint container is configured to enclose at least a portion of a first material and a second material being joined; and

[0166] An expandable medium is configured to be disposed within the internal volume between at least one of the first material and the second material and at least a portion of the constraint container, and to expand such that the expandable medium applies a positive pressure to at least one of the first material and the second material and the constraint container.

[0167] 2. The system according to Clause 1, wherein at least one of the base and the cover is rigid.

[0168] 3. The system according to Clause 1, wherein at least a portion of at least one of the base and the cover is flexible.

[0169] 4. The system according to Clause 1, wherein:

[0170] The first material and the second material comprise uncured composite materials having a curing temperature; and

[0171] The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

[0172] 5. The system according to Clause 1, wherein:

[0173] The first material includes a cured composite material;

[0174] The second material comprises an uncured composite material having a curing temperature; and

[0175] The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

[0176] 6. The system according to Clause 1, wherein:

[0177] The adhesive is located between the first material and the second material;

[0178] The adhesive has at least one of a curing temperature and a curing pressure;

[0179] The expandable medium is configured to expand when its temperature rises to an activation temperature up to the curing temperature; and

[0180] The positive pressure is as high as the curing pressure.

[0181] 7. The system according to Clause 1, further comprising: a pressure detector configured to detect internal pressure within the internal volume.

[0182] 8. The system according to Clause 1, further comprising: a heater, the heater being in thermal communication with the expandable medium.

[0183] 9. A method for bonding materials, the method comprising:

[0184] At least a portion of the first material and the second material are enclosed within the internal volume of the constraint container;

[0185] To cause the expandable medium disposed within the internal volume to expand;

[0186] In response to expanding the expandable medium, a positive pressure is applied to at least one of the first material and the second material and the confinement container; and

[0187] The first material and the second material are joined together.

[0188] 10. The method according to Clause 9, wherein bonding comprises: co-curing the first material and the second material.

[0189] 11. The method according to Clause 10, further comprising: raising the temperature of the expandable medium to an activation temperature,

[0190] The first material and the second material include an uncured composite material, wherein the curing temperature of the uncured composite material is equal to or greater than the activation temperature.

[0191] 12. The method according to Clause 9, wherein the joining comprises: co-joining the first material and the second material.

[0192] 13. The method according to Clause 12, further comprising: raising the temperature of the expandable medium to an activation temperature,

[0193] in:

[0194] The first material includes a cured composite material; and

[0195] The second material includes an uncured composite material, wherein the curing temperature of the uncured composite material is equal to or greater than the activation temperature.

[0196] 14. The method according to Clause 9, wherein the joining comprises: a secondary joining of the first material and the second material.

[0197] 15. The method according to Clause 14, further comprising: raising the temperature of the expandable medium to an activation temperature,

[0198] in:

[0199] The adhesive is located between the first material and the second material; and

[0200] The adhesive has at least one of a curing temperature equal to or greater than the activation temperature and a curing pressure equal to or greater than the positive pressure.

[0201] 16. The method according to Clause 9, the method further comprising: detecting the internal pressure within the internal volume.

[0202] 17. A workpiece, the workpiece comprising:

[0203] A first material and a second material, which will be bonded together.

[0204] in:

[0205] At least a portion of the first material and the second material are confined within the container;

[0206] An expandable medium is disposed within the internal volume of the constraint container between at least one of the first material and the second material and the constraint container; and

[0207] The expandable medium is configured to expand to a predetermined volume when the properties of the expandable medium undergo a predetermined change, such that the expandable medium applies positive pressure to at least one of the first material and the second material, as well as the constraint container.

[0208] 18. The workpiece as described in Clause 17, wherein:

[0209] The first material and the second material comprise uncured composite materials having a curing temperature; and

[0210] The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

[0211] 19. The workpiece as described in Clause 17, wherein:

[0212] The first material includes a cured composite material;

[0213] The second material comprises an uncured composite material having a curing temperature; and

[0214] The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

[0215] 20. The workpiece according to Clause 17, further comprising: an adhesive, the adhesive being disposed between the first material and the second material,

[0216] in:

[0217] The adhesive has at least one of a curing temperature and a curing pressure;

[0218] The expandable medium is configured to expand when its temperature rises to an activation temperature up to the curing temperature; and

[0219] The positive pressure is as high as the curing pressure.

[0220] 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 are not present in any single example. Rather, references to features and advantages are to be understood as indicating that a particular feature, advantage, or characteristic described in connection 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.

[0221] The features, advantages, and characteristics described in one example 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 in a particular example. In other cases, additional features and advantages that may not be present in all examples can be recognized in some examples. Furthermore, although various examples of system 100, method 1000, and workpiece 200 have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A system for bonding materials, the system comprising: A constraint container, comprising a base and a lid, and having an internal volume, wherein the constraint container is configured to enclose at least a portion of a first material and a second material being joined; and An expandable medium is configured to be disposed within the internal volume between at least one of the first material and the second material and at least a portion of the constraint container, and to expand such that the expandable medium applies a positive pressure to at least one of the first material and the second material and the constraint container.

2. The system according to claim 1, wherein, At least one of the base and the cover is rigid.

3. The system according to claim 1, wherein, At least a portion of at least one of the base and the cover is flexible.

4. The system according to claim 1, wherein: The first material and the second material comprise uncured composite materials having a curing temperature; and The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

5. The system according to claim 1, wherein: The first material includes a cured composite material; The second material comprises an uncured composite material having a curing temperature; and The expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature up to the curing temperature.

6. The system according to claim 1, wherein: The adhesive is located between the first material and the second material; The adhesive has at least one of a curing temperature and a curing pressure; The expandable medium is configured to expand when its temperature rises to an activation temperature up to the curing temperature; and The positive pressure is as high as the curing pressure.

7. The system according to claim 1, further comprising: A pressure detector configured to detect the internal pressure within the internal volume.

8. The system according to claim 1, further comprising: A heater, which is in thermal communication with the expandable medium.

9. A method for bonding materials, the method comprising: At least a portion of the first material and the second material are enclosed within the internal volume of the constraint container; The expandable medium disposed within the internal volume expands; In response to expanding the expandable medium, a positive pressure is applied to at least one of the first material and the second material, as well as the confined container; as well as The first material and the second material are joined together.

10. A workpiece, the workpiece comprising: A first material and a second material, which will be bonded together. in: At least a portion of the first material and the second material are confined within the container; An expandable medium is disposed within the internal volume of the constraint container between at least one of the first material and the second material and at least a portion of the constraint container; and The expandable medium is configured to expand to a predetermined volume when the properties of the expandable medium undergo a predetermined change, such that the expandable medium applies positive pressure to at least one of the first material and the second material, as well as the constraint container.

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