Curing tool assemblies, methods, and systems for manufacturing composite material

Abstract

To provide a curing tool assembly, method and system for manufacturing a composite material.SOLUTION: There is provided a curing tool assembly for manufacturing a composite material, comprising a curing tool and a cover plate. The curing tool comprises a tool surface defining a resin channel. The cover plate overlays the resin channel. The cover plate defines openings in fluidic communication with the resin channel. The openings are arranged to provide different flow rate through different portions of the cover plate along the channel axis. There is also provided a method for manufacturing a composite material with the curing tool assembly. There is also provided a system for manufacturing a composite material, comprising the curing tool, the cover plate, a fluid impervious layer, and a differential pressure generator.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001]

[0001] The present disclosure relates generally to liquid resin distribution in a curing tool during composite manufacturing, and more particularly to the use of resin channels and channel cover plates to enhance resin distribution, reduce mark-off, and mitigate trap-off. Various types of cover plates with various types of openings to allow resin to flow from the channels to the dry fabric layup. To facilitate resin distribution, various widths of cover plates that exceed the width of the channels are devised. Additionally, various systems and techniques for controlling resin distribution for composite manufacturing are devised. [Background technology]

[0002] Current resin distribution methods for injection during composite manufacturing use flow media and grooves. Such methods require multiple inlets for large parts because the small cross-sectional area of ​​the grooves causes a pressure drop as the length of the resin flow increases. The pressure drop can increase the time it takes to fill the part. To compensate for the pressure drop, multiple inlets are used along with the flow media and grooves, which complicates the piping. In addition, strategic placement of the resin distribution media (e.g., flow media) or grooves is difficult due to the need for close proximity to the resin inlets. Large parts require a resin distribution method that covers a large surface area of ​​the part to reduce fill time. This is difficult to achieve with grooves due to the limited width for part mark-off. The use of expendable flow media is a concern for large parts because manually laying it up can lead to operator error, surface finish issues, molding difficulties, and increased overall production time and cost.

[0003]

[0003] Accordingly, those skilled in the art continue to undertake research and development efforts to improve the technology of resin infusion during composite manufacturing. Summary of the Invention

[0004]

[0004] Disclosed are example cure tool assemblies, methods and systems for composite manufacturing. The following are non-exhaustive examples of subject matter in accordance with the present disclosure, which may or may not be claimed.

[0005] In one embodiment, a curing tool assembly for composite manufacturing is disclosed that includes a curing tool and a cover plate. The curing tool includes a tool surface that defines a resin channel having a channel axis. The cover plate overlies at least a portion of the resin channel along the channel axis. The cover plate defines a plurality of openings in fluid communication with the resin channel. The plurality of openings are positioned to provide different flow rates through different portions of the cover plate along the channel axis.

[0006] In one embodiment, a method for composite manufacturing is disclosed that includes: (1) placing a dry fabric layup having a pad-up area on a tool surface of a curing tool. The tool surface defines a plurality of interconnected resin channels having a channel width and a channel axis. The plurality of interconnected resin channels define a strategic path for distributing resin to the dry fabric layup. The dry fabric layup having a pad-up region is disposed over a plurality of cover plates overlying the plurality of interconnected resin channels. Each cover plate has a plate width extending beyond the channel width. Each cover plate includes a plurality of openings, at least a portion of which extend beyond the channel width. The plurality of openings in each cover plate further define a strategic path for distributing resin to the dry fabric layup. The plate widths of the plurality of cover plates are strategically wider in the pad-up regions than in other regions. In this example, the disclosed method also includes (2) placing a fluid impermeable layer over the dry fabric layup facing the tool surface; (3) sealing the fluid impermeable layer over the dry fabric layup to the tool surface to form a sealed volume between the fluid impermeable layer and the tool surface; (4) supplying liquid resin from a resin source to the sealed volume; (5) supplying a pressure differential to the sealed volume to cause the liquid resin to flow from the resin source into the sealed volume; (6) in response to the pressure differential, directing the liquid resin in the sealed volume to the plurality of interconnected resin channels; and (7) further in response to the pressure differential, directing the liquid resin from the plurality of interconnected resin channels through a plurality of openings in the plurality of cover plates to the dry fabric layup having a pad-up region. Includes.

[0007] In another embodiment, a method for manufacturing a composite material is disclosed that includes: (1) placing a dry fabric layup on a tool surface of a curing tool, the tool surface defining a resin channel having a channel axis, the dry fabric layup being disposed over a cover plate overlying the resin channel; (2) placing a fluid-impermeable layer over the dry fabric layup facing the tool surface; and (3) sealing the fluid-impermeable layer to the tool surface over the dry fabric layup to form a sealed volume between the fluid-impermeable layer and the tool surface. (4) supplying liquid resin from a resin source to the sealed volume; (5) providing a pressure differential to the sealed volume to cause liquid resin to flow from the resin source into the sealed volume; (6) directing the liquid resin in the sealed volume to a resin channel in response to the pressure differential; and (7) further directing the liquid resin from the resin channel to a dry fabric lay-up through a plurality of openings in a cover plate and to a dry fabric lay-up, the plurality of openings in the cover plate being positioned to provide different flow rates through different portions of the cover plate to corresponding portions of the dry fabric lay-up. Includes.

[0008] In one embodiment, a system for composite manufacturing includes a curing tool, a cover plate, a fluid impermeable layer, and a differential pressure generator. The curing tool includes a tool surface defining a resin channel having a channel axis. The resin channel is configured to receive liquid resin from a resin source. The cover plate overlies at least a portion of the resin channel along the channel axis. The cover plate defines a plurality of openings in fluid communication with the resin channel. The plurality of openings are arranged to provide different flow rates through different portions of the cover plate along the channel axis. The cover plate and tool surface are configured to receive a dry fabric layup. The fluid impermeable layer faces the tool surface and is configured to overlie the dry fabric layup after the dry fabric layup is disposed on the tool surface and the cover plate. The fluid impermeable layer is configured to be sealed to the tool surface over the dry fabric layup to form a sealed volume between the fluid impermeable layer and the tool surface. The differential pressure generator is configured to establish a pressure differential within the sealed volume to cause liquid resin to flow from the resin supply into the sealed volume, to direct the liquid resin into resin channels within the sealed volume, and to direct the liquid resin from the resin channels to the dry fabric lay-up through a plurality of openings in the cover plate arranged to provide different flow rates through different portions of the cover plate to corresponding portions of the dry fabric lay-up.

[0009] Other embodiments of the disclosed cure tool assembly, method and system for composite manufacturing will become apparent from the following detailed description, the accompanying drawings and the claims. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a top view of one embodiment of a curing tool assembly for composite manufacturing. [Diagram 2]

[0011] 2 is a cross-sectional view of an embodiment of the hardening tool assembly of FIG. 1 along line AA. [Diagram 3]

[0012] FIG. 2 is a cross-sectional view of an embodiment of the hardening tool assembly of FIG. 1 . [Figure 4]

[0013] FIG. 2 is a cross-sectional view of an alternative embodiment of the hardening tool assembly of FIG. 1 taken along line AA. [Diagram 5]

[0014] FIG. 2 is a cross-sectional view taken along line AA of another alternative embodiment of the hardening tool assembly of FIG. 1. [Figure 6]

[0015] FIG. 13 is a top view of another embodiment of a curing tool assembly for composite manufacturing. [Figure 7]

[0016] FIG. 1 is a flow diagram of one embodiment of a method for composite manufacturing. [Figure 8A]

[0017] FIG. 8 is a flow diagram of another embodiment of a method for composite manufacturing, combined with FIG. [Figure 8B] FIG. 8 is a flow diagram of another embodiment of a method for composite manufacturing, combined with FIG. [Figure 9]

[0018] FIG. 8 is a flow diagram of yet another embodiment of a method for composite manufacturing, in combination with FIG. 7; [Figure 10]

[0019] FIG. 8 is a flow diagram of yet another embodiment of a method for composite manufacturing, in combination with FIG. [Figure 11]

[0020] FIG. 8 is a flow diagram of yet another embodiment of a method for composite manufacturing, in combination with FIG. [Figure 12]

[0021] FIG. 8 is a flow diagram of another embodiment of a method for composite manufacturing, combined with FIG. [Figure 13]

[0022] FIG. 8 is a flow diagram of yet another embodiment of a method for composite manufacturing, in combination with FIG. [Figure 14]

[0023] FIG. 1 is a functional diagram of one embodiment of a system for composite manufacturing. [Figure 15]

[0024] FIG. 2 is a functional diagram of another embodiment of a system for composite manufacturing. [Figure 16]

[0025] FIG. 2 is a functional diagram of yet another embodiment of a system for composite manufacturing. [Figure 17]

[0026] FIG. 2 is a functional block diagram of yet another embodiment of a system for composite manufacturing. [Figure 18]

[0027] FIG. 13 is a top perspective view of another embodiment of a curing tool assembly for composite manufacturing. [Figure 19]

[0028] FIG. 1 is a flow diagram of another embodiment of a method for composite manufacturing. [Figure 20]

[0029] FIG. 2 is a top perspective view of an embodiment of a cover plate for the cure tool assembly of FIG. [Figure 21]

[0030] FIG. 2 is a top perspective view of another embodiment of a cover plate for the curing tool assembly of FIG. [Figure 22]

[0031] FIG. 2 is a top perspective view of yet another embodiment of a cover plate for the curing tool assembly of FIG. [Figure 23]

[0032] FIG. 2 is a top perspective view of yet another embodiment of a cover plate for the curing tool assembly of FIG. [Figure 24]

[0033] FIG. 2 is a top perspective view of yet another embodiment of a cover plate for the curing tool assembly of FIG. [Diagram 25]

[0034] FIG. 2 is a top perspective view of another embodiment of a cover plate for the curing tool assembly of FIG. [Figure 26A]

[0035] FIG. 13 is a top perspective view of a composite part illustrating the stages of resin infusion into a dry fabric lay-up by modeling a composite manufacturing process. [Figure 26B] FIG. 13 is a top perspective view of a composite part illustrating the stages of resin infusion into a dry fabric lay-up by modeling a composite manufacturing process. [Figure 26C]FIG. 13 is a top perspective view of a composite part illustrating the stages of resin infusion into a dry fabric lay-up by modeling a composite manufacturing process. [Figure 26D] FIG. 13 is a top perspective view of a composite part illustrating the stages of resin infusion into a dry fabric lay-up by modeling a composite manufacturing process. [Figure 27]

[0036] FIG. 13 is a flow diagram of another embodiment of a method for composite manufacturing. [Figure 28]

[0037] FIG. 1 is a block diagram of an aircraft manufacturing and service methodology implementing one or more of the embodiment of the method for composite manufacturing disclosed herein. [Figure 29]

[0038] FIG. 1 is a schematic diagram of an aircraft incorporating one or more parts manufactured using one or more of the embodiments of the curing tool assemblies, methods, and systems for composite manufacturing disclosed herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011]

[0039] Various embodiments of the curing tool assemblies, methods and systems for composite manufacturing disclosed herein provide control of resin flow by using different slot widths in the cover plate over the channels to control the movement of resin from the channels in the mandrel to the preform. The channels increase the rate of resin movement to the preform. The cover plate reduces mark-off. The slot width affects the injection rate and mitigates trap-off. For example, the width of the cover plate, and therefore the reach of the slots, can be significantly larger than the groove width to increase the contact area of ​​the resin with the part. The cover plate is reusable, which may eliminate and / or reduce the need for consumable media during resin injection depending on the part and other considerations.

[0012]

[0040] By way of example, and referring generally to Figures 1-6 and 20-25, the present disclosure is directed to a set tool assembly 100 for composite manufacturing. Figures 1 and 6 disclose several embodiments of the set tool assembly 100. Figures 2, 4 and 5 show several types of embodiments of the set tool assembly 100 in cross-sectional views across the channel axis 106. Figure 3 shows the set tool assembly 100 in cross-sectional view along the channel axis 106. Figures 20-25 disclose several embodiments of cover plates 108 for the set tool assembly 100 having various types of openings 110 in the cover plate 108. 1, 2, and 12, in one or more embodiments, a curing tool assembly 100 for composite manufacturing includes a curing tool 102 and a cover plate 108. The curing tool 102 includes a tool surface 104 that defines a resin channel 202 having a channel axis 106. The cover plate 108 overlaps at least a portion of the resin channel 202 along the channel axis 106. The cover plate 108 defines a plurality of openings 110 in fluid communication with the resin channel 202. The plurality of openings 110 are positioned to provide different flow rates through different portions of the cover plate 108 along the channel axis 106. In another embodiment of the curing tool assembly 100, the cover plate 108 is parallel to the channel axis 106 and is customized based on a given resin flow requirement of a dry fabric layup 1404 associated with forming a composite part.

[0013]

[0041] In another embodiment of the cured tool assembly 100, each opening 110 of the plurality of openings 110 defines a cross-sectional open area. The cumulative cross-sectional open area varies at different portions of the cover plate 108 along the channel axis 106 to provide a differential flow rate along the cover plate 108. In a further embodiment, the cumulative cross-sectional open area of ​​a given portion relative to the maximum cumulative cross-sectional open area of ​​the given portion is about 100% or less, about 90% or less, about 80% or less, about 70% or less, about 60% or less, about 50% or less, about 40% or less, about 30% or less, about 20% or less, about 10% or less, or any other suitable percentage. In yet another embodiment, the differential cross-sectional open area of ​​different portions of the cover plate 108 is based on a differential cumulative cross-sectional open area of ​​openings 110 of the plurality of openings 110 along the channel axis 106. In yet another embodiment, the differential of openings 110 is based on a differential predetermined resin flow requirement at a corresponding location of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, the cumulative cross-sectional open area of ​​different portions of the cover plate 108 is defined by the cumulative cross-sectional open area of ​​the groups of openings 110 in the corresponding portions. The cumulative cross-sectional open area of ​​the groups of openings 110 is defined by the dimensions of the particular openings in the corresponding groups. In yet another embodiment, the different cumulative cross-sectional open areas of different portions of the cover plate 108 are due to a difference in the dimensions of the particular openings in at least some of the adjacent groups, a difference in the quantity of the particular openings in at least some of the adjacent groups, or a difference in any other suitable cross-sectional parameters in any suitable combination. In yet another embodiment of the cured tool assembly 100, at least one dimension of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106. In a further embodiment, the difference in the at least one dimension of the plurality of openings 110 is based on a difference in a predetermined resin flow requirement in a corresponding location of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, at least one dimension of the plurality of openings 110 varies by width, length, angle, diameter, depth, or any other suitable dimension in any suitable combination.

[0014]

[0042] In yet another embodiment, the at least one dimension is a width of the plurality of openings 110, the width ranging from about 0.50 inches to about 2.25 inches, about 0.75 inches to about 2.00 inches, about 1.00 inches to about 1.75 inches, about 1.25 inches to about 1.5 inches, or any other suitable width range in any suitable combination. In a further embodiment, the width of the plurality of openings 110 is based on predetermined resin flow requirements of the dry fabric layup 1404 associated with molding the composite part to improve resin infusion rate and mitigate trap-off.

[0015]

[0043] In yet another embodiment, the at least one dimension is a length of the plurality of openings 110, the length ranging from about 0.50 inches to about 2.25 inches, from about 0.75 inches to about 2.00 inches, from about 1.00 inches to about 1.75 inches, from about 1.25 inches to about 1.5 inches, or any other suitable length in any suitable combination. In yet another embodiment, the at least one dimension is an angle of the plurality of openings 110, the angle ranging from about 5 degrees to about 175 degrees, from about 25 degrees to about 155 degrees, from about 45 degrees to about 135 degrees, from about 65 degrees to about 115 degrees, from about 85 degrees to about 95 degrees, or any other suitable angle range in any suitable combination. In yet another embodiment, the at least one dimension is a diameter of the plurality of openings 110, the diameter ranging from about 0.050 inches to about 0.750 inches, from about 0.100 inches to about 0.700 inches, from about 0.150 inches to about 0.650 inches, from about 0.200 inches to about 0.600 inches, from about 0.250 inches to about 0.550 inches, from about 0.300 inches to about 0.500 inches, from about 0.350 inches to about 0.450 inches, or any other suitable diameter range in any suitable combination. In yet another embodiment, the at least one dimension is a depth of the plurality of openings 110, the depth ranging from about 0.040 inches to about 0.100 inches, from about 0.050 inches to about 0.090 inches, from about 0.060 inches to about 0.080 inches, or any other suitable depth range in any suitable combination.

[0016]

[0044] In yet another embodiment of the curing tool assembly 100, the locations of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In a further embodiment, the difference in the locations of the plurality of openings 110 is based on the difference in the predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, the locations of the plurality of openings 110 are based on the different amounts of openings in different portions of the cover plate 108 along the channel axis 106. In a further embodiment, the amount of openings in a given portion relative to the maximum amount of openings in the given portion is about 100% or less, about 90% or less, about 80% or less, about 70% or less, about 60% or less, about 50% or less, about 40% or less, about 30% or less, about 20% or less, about 10% or less, or any other suitable percentage in any suitable combination. In yet another embodiment, the locations of the plurality of openings 110 are based on an array of rows across the channel axis 106 and columns along the channel axis 106, with the different locations being formed by varying the amount of openings from row to row for at least some of the plurality of rows.

[0017]

[0045] In yet another embodiment of the curing tool assembly 100, the shapes of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In a further embodiment, the difference in the shapes of the plurality of openings 110 is based on the difference in the predetermined resin flow requirements at the corresponding locations of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, the shapes of the plurality of openings 110 include a rectangular shape (see, e.g., FIG. 25), a square shape, a circular shape (see, e.g., FIGS. 22 and 23), an elliptical shape, a triangular shape, a hexagonal shape, an octagonal shape, a pentagonal shape, an elongated shape (see, e.g., FIG. 20), a parallelogram shape (see, e.g., FIG. 21), a trapezoid shape, a curved slit shape (see, e.g., FIG. 24), or any other suitable shape in any suitable combination. In yet another embodiment, at least a portion of the plurality of openings 110 include a curved slit opening (see, e.g., FIG. 24) defined by at least one curve radius, at least one width, and at least one length. In further embodiments, the radius of curvature of at least one of the curved slit openings ranges from about 0.050 inches to about 0.750 inches, from about 0.100 inches to about 0.700 inches, from about 0.150 inches to about 0.650 inches, from about 0.200 inches to about 0.600 inches, from about 0.250 inches to about 0.550 inches, from about 0.300 inches to about 0.500 inches, from about 0.350 inches to about 0.450 inches, or any other suitable range of curvature radii in any suitable combination. In yet further embodiments, the width of at least one of the curved slit openings ranges from about 0.50 inches to about 2.25 inches, from about 0.75 inches to about 2.00 inches, from about 1.00 inches to about 1.75 inches, from about 1.25 inches to about 1.5 inches, or any other suitable range of widths in any suitable combination. In yet another embodiment, the length of at least one of the curved slit openings ranges from about 0.50 inches to approximately the length of the resin channel 202, from about 1 inch to about 120 inches, from about 2 inches to about 96 inches, from about 4 inches to about 72 inches, from about 6 inches to about 48 inches, from about 8 inches to about 24 inches, or any other suitable length range in any suitable combination.

[0018]

[0046] In another embodiment of the curing tool assembly 100, the pitch of the sidewalls 208 of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106. In a further embodiment, the difference in the pitch of the sidewalls 208 of the plurality of openings 110 is based on the difference in the predetermined resin flow requirements at the corresponding locations of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, the pitch of the sidewalls 208 of the plurality of openings 110 varies by the angle of the sidewalls 208, the slope of the sidewalls 208, the depth of the sidewalls 208, or any other suitable sidewall parameters in any suitable combination. For example, the pitch of the sidewalls 208 can position the end of the sidewall 208 facing the resin channel 202 farther away than the opposite end of the sidewall 208. Conversely, the pitch of the sidewalls 208 can position the end of the sidewall 208 facing the resin channel 202 closer together than the opposite end of the sidewall 208. In yet another embodiment, the pitch of the sidewalls 208 of the plurality of openings 110 ranges from about 45 degrees to about 90 degrees, from about 50 degrees to about 85 degrees, from about 55 degrees to about 80 degrees, from about 60 degrees to about 75 degrees, from about 65 degrees to about 70 degrees, or any other angle range in any suitable combination. The reference point (zero degrees) for the angle range is the channel axis.

[0019]

[0047] In yet another embodiment of the cure tool assembly 100, the spacing between adjacent openings of the plurality of openings 110 is greater than about 0.0375 inches or any other suitable spacing.

[0020]

[0048] In yet another embodiment of the curing tool assembly 100, the resin channels 202 have a channel depth 204 ranging from about 0.15 inches to about 0.60 inches, about 0.20 inches to about 0.50 inches, about 0.25 inches to about 0.45 inches, about 0.30 inches to about 0.40 inches, or any other suitable channel depth range. In yet another embodiment of the curing tool assembly 100, the resin channels 202 have a channel width 206 ranging from about 0.20 inches to about 0.80 inches, about 0.30 inches to about 0.70 inches, about 0.40 inches to about 0.60 inches, or any other suitable channel width range in any suitable combination. In another embodiment of the curing tool assembly 100, the location of the resin channels 202 relative to the curing tool 102 is based on a predetermined resin flow requirement of a dry fabric layup 1404 associated with forming a composite part.

[0021]

[0049] In another embodiment of the curing tool assembly 100, the resin channel 202 has a channel width 206 and the cover plate 108 has a plate width that is greater than the channel width 206. In this embodiment, at least a portion of the plurality of openings 110 in the cover plate 108 extend beyond the channel width 206. In further embodiments, the plate width is up to 400 percent of the channel width 206, up to 350 percent of the channel width 206, up to 300 percent of the channel width 206, up to 250 percent of the channel width 206, up to 200 percent of the channel width 206, up to 150 percent of the channel width 206, or any other suitable percentage of the channel width 206 in any suitable combination.

[0022]

[0050] In yet another embodiment of the curing tool assembly 100, the curing tool 102 includes shoulders 402 (see FIG. 4 ) along both sides 210 of the resin channel 202 of the tool surface 104 for aligning the cover plate 108 with the resin channel 202. In a further embodiment, the cover plate 108 overlaps at least a portion of the shoulders 402 such that the plate surface 404 of the cover plate 108 is substantially flush with the tool surface 104. In a further embodiment, the resin channel 202 has a channel width 206, and the cover plate 108 includes a support member 406 that elevates the plate surface 404 above the shoulders 402. In this embodiment, at least a portion of the plurality of openings 110 of the cover plate 108 extend beyond the channel width 206 above the shoulders 402. In yet another embodiment, the cover plate 108 provides a fluid path from the resin channel 202 through the portions of the plurality of openings 110 that extend beyond the channel width 206. The fluid path is along the shoulder 402 and through the corresponding opening 110 .

[0023]

[0051] In yet another embodiment of the curing tool assembly 100, the curing tool 102 includes chamfers 502 (see FIG. 5 ) along the sides 210 of the resin channel 202 of the tool surface 104 for aligning the cover plate 108 with the resin channel 202. In a further embodiment, the cover plate 108 overlaps at least a portion of the chamfer 502 such that the plate surface 404 of the cover plate 108 is substantially flush with the tool surface 104. In a further embodiment, the resin channel 202 has a channel width 206 and at least a portion of the plurality of openings 110 extend beyond the channel width 206 above the chamfer 502. In this embodiment, the cover plate 108 provides a fluid path from the resin channel 202 through the portions of the plurality of openings 110 that extend beyond the channel width 206. The fluid path is along the chamfer 502 and through the corresponding opening 110.

[0024]

[0052] In yet another embodiment, the curing tool assembly 100 also includes a second cover plate 602 configured to overlap a second portion of the resin channel 202 along the channel axis 106. The second cover plate 602 defines a plurality of openings 604 in fluid communication with the resin channel 202. The second plurality of openings 604 are arranged to provide different flow rates through different portions of the second cover plate 602 along the channel axis 106. In a further embodiment, the cover plate 108 and the second cover plate 602 overlap different portions of the resin channel 202 along the channel axis 106. In another further embodiment, the difference in flow rates through different portions of the second cover plate 602 is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0025]

[0053] In another example, the curing tool assembly 100 also includes a second cover plate 602 configured to overlap at least a portion of the resin channel 202 along the channel axis 106, the second cover plate 602 defining a second plurality of openings 604 in fluid communication with the resin channel 202. The second plurality of openings 604 are positioned to provide different flow rates through different portions of the second cover plate 602 along the channel axis 106. In a further example, the cover plate 108 and the second cover plate 602 are interchangeable in relation to the curing tool 102 and the resin channel 202. In another further example, the difference in flow rates through different portions of the second cover plate 602 is based on a difference in predetermined resin flow requirements at corresponding locations of a second dry fabric layup 1404 associated with molding a second composite part.

[0026]

[0054] Referring generally to, by way of example, Figures 1-5, 14, 18, 19, and 26A-D, the present disclosure is directed to a method 1900 for composite manufacturing. Figures 1 and 18 disclose several embodiments of a curing tool assembly 100, 1800. Figures 2, 4, and 5 show several types of embodiments of a curing tool assembly 100 in cross-sectional views across the channel axis 106. Figure 3 shows a curing tool assembly 100 in cross-sectional view along the channel axis 106. Figure 14 discloses one embodiment of a system 1400 for composite manufacturing. Figure 19 discloses a method 1900 for composite manufacturing. Figures 26A-D are top perspective views showing stages of a model of a composite part where resin is infused into a dry fabric layup 1404 during a composite manufacturing process. Figure 26A shows a first stage during modeling showing the dry fabric layup 1404 prior to resin infusion. Figure 26B shows a second stage during modeling showing resin infused into a first portion of the dry fabric layup 1404. Figure 26C shows a third stage during modeling showing resin infused into a larger portion of the dry fabric layup 1404. Figure 26D shows a fourth stage during modeling showing resin completely infused into the dry fabric layup 1404.

[0027]

[0055] 1, 2, 14, 18, and 19, in one or more embodiments, a method 1900 for composite manufacturing includes placing 1902 a dry fabric layup 1404 having a pad-up region 1405 on a tool surface 104 of a curing tool 102. The tool surface 104 defines a plurality of interconnected resin channels 202 having a channel width 206 and a channel axis 106. The interconnected resin channels 202 define strategic paths for distributing resin to the dry fabric layup 1404. The dry fabric layup 1404 having the pad-up region 1405 is disposed on a plurality of cover plates 108 overlapping the interconnected resin channels 202. Each cover plate 108 has a plate width that extends beyond the channel width 206. Each cover plate 108 includes a plurality of openings 110, at least a portion of which extend beyond the channel width 206. The plurality of openings 110 in each cover plate 108 further define strategic paths for distributing resin to the dry fabric layup 1404. The plate width of the plurality of cover plates 108 is strategically wider in the pad-up region 1405 than in other regions. At 1904, a fluid impermeable layer 1406 facing the tool surface 104 is placed over the dry fabric layup 1404. At 1906, the fluid impermeable layer 1406 is sealed to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the fluid impermeable layer 1406 and the tool surface 104. At 1908, liquid resin from a resin source 1402 is provided to the sealed volume. At 1910, a differential pressure is provided to the sealed volume to cause liquid resin to flow from the resin source 1402 into the sealed volume. At 1912, the liquid resin in the sealed volume is directed to the plurality of interconnected resin channels 202 in response to the differential pressure. At 1914, in response to the pressure differential, the liquid resin is further directed from the interconnected resin channels 202 through the multiple openings 110 in the multiple cover plates 108 to the dry fabric layup 1404 having a pad-up area 1405.

[0028]

[0056] Referring again to FIGS. 26A-D, the composite manufacturing process has been modeled and the drawings show successive stages of resin infusion into the dry fabric layup 1404. FIG. 26A shows the dry fabric layup 1404 before resin infusion. FIG. 26B shows resin infused into a first portion of the dry fabric layup 1404. FIG. 26C shows resin infused into a larger portion of the dry fabric layup 1404. FIG. 26D shows resin fully infused into the dry fabric layup 1404. The composite manufacturing model shows how resin is infused into the dry fabric layup 1404. The resin channels 202 and the openings 110 in the cover plate 108 allow a wave front of resin to travel along the edges of the dry fabric layup 1404 and gradually fill the remaining portions. For example, FIG. 26D shows the dry fabric layup 1404 impregnated with resin. This composite manufacturing process can be used to infuse very long composite parts because it moves the resin quickly before the resin viscosity begins to drop below the desired infusion level. In various embodiments, the resin can travel long distances without significant pressure loss. Additional resin channels 202 can be added to the pad-up area 1403.

[0029]

[0057] Referring generally to, by way of example, Figures 1, 2-5, 14, and 27, the present disclosure is directed to a method 2700 for composite manufacturing. Figure 1 discloses one embodiment of a set tool assembly 100. Figures 2, 4, and 5 show several types of embodiments of the set tool assembly 100 in cross-sectional views across the channel axis 106. Figure 3 shows the set tool assembly 100 in cross-sectional view along the channel axis 106. Figure 14 discloses one embodiment of a system 1400 for composite manufacturing. Figure 27 discloses a method 2700 for composite manufacturing.

[0030]

[0058] 1, 2, 14, and 27, in one or more embodiments, a method 2700 for composite manufacturing includes flowing 2702 a wave front of resin through the resin channels 202. At 2704, the wave front of resin is caused to flow from the resin channels 202 onto the cover plate 108. At 2706, the wave front of resin is caused to flow through the openings 110 in the cover plate 108. At 2708, the wave front of resin is caused to flow through the openings 110 in the cover plate 108 into the dry fabric layup 1404 until impregnation is reached. In another embodiment of the method 1700, the cover plate 108 includes a slotted cover and the openings 110 include slots. In yet another embodiment of the method 1700, the dry fabric layup 1402 includes a dry preform.

[0031]

[0059] With general reference to, by way of example, Figures 1-7, 8A-B, 9-11, and 14-16, the present disclosure is directed to methods 700, 800, 900, 1000, 1100, 1200, 1300 for composite manufacturing. Figure 1 discloses one embodiment of a set tool assembly 100. Figures 2, 4, and 5 show several types of embodiments of the set tool assembly 100 in cross-sectional views across the channel axis 106. Figure 3 shows the set tool assembly 100 in cross-sectional view along the channel axis 106. Figure 7 discloses a method 700 for composite manufacturing. Figures 8A-B disclose a method 800 for composite manufacturing. Figure 9 discloses a method 900 for composite manufacturing. Figure 10 discloses a method 1000 for composite manufacturing. Figure 11 discloses a method 1100 for composite manufacturing. Figure 12 discloses a method 1200 for composite manufacturing. Figure 13 discloses a method 1300 for composite manufacturing. Figures 14-16 disclose several embodiments of systems 1400, 1500, 1600 for composite manufacturing.

[0032]

[0060] 1, 2, 7, and 14, in one or more embodiments, a method 700 for composite manufacturing includes placing 702 a dry fabric layup 1404 on a tool surface 104 of a curing tool 102. The tool surface 104 defines a resin channel 202 having a channel axis 106. The dry fabric layup 1404 is placed on a cover plate 108 overlapping the resin channel 202. At 704, a fluid impermeable layer 1406 facing the tool surface 104 is placed on the dry fabric layup 1404. At 706, the fluid impermeable layer 1406 is sealed to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the fluid impermeable layer 1406 and the tool surface 104. At 708, liquid resin from a resin source 1402 is provided to the sealed volume. At 710, a pressure differential is provided to the sealed volume to cause liquid resin to flow from the resin source 1402 into the sealed volume. At 712, the liquid resin in the sealed volume is directed to the resin channel 202 in response to the pressure differential. At 714, the liquid resin is further directed from the resin channel 202 to the dry fabric layup 1404 through a plurality of openings 110 in the cover plate 108 in further response to the pressure differential. The plurality of openings 110 in the cover plate 108 are arranged to provide different flow rates through different portions of the cover plate 108 to corresponding portions of the dry fabric layup 1404. In another embodiment of the method 700, the dry fabric layup 1404 includes a preformed dry fabric layup. In a further embodiment, the preformed dry fabric layup includes a plurality of tacked dry fabric plies. In yet another embodiment of the method 700, the dry fabric layup 1404 includes a stack of dry fabric plies. In a further embodiment, the plies of dry fabric are tacked into the stack.

[0033]

[0061] 1, 2, 7, 8A-B, 14, and 15, in one or more embodiments of a method 800 for composite manufacturing, the fluid impermeable layer 1406 includes a vacuum bag 1502 and the pressure differential is a vacuum. The method 800 includes the method 700 of FIG. 7, where the placing 704 includes placing 802 the vacuum bag 1502 over the dry fabric layup 1404. The sealing 706 of FIG. 7 includes sealing 804 the vacuum bag 1502 to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the vacuum bag 1502 and the tool surface 104. In another embodiment, the method 800 also includes placing 806 a release film 1410 over the dry fabric layup 1404 prior to placing 802 the vacuum bag 1502. In a further embodiment, the method 800 also includes placing 808 a breather cloth 1412 on the release film 1410 prior to placing 802 the vacuum bag 1502. In yet another embodiment, the method 800 also includes placing 810 a breather cloth 1412 on the dry fabric layup 1404 prior to placing 802 the vacuum bag 1502.

[0034]

[0062] In yet another example, the method 800 also includes placing 812 a release film 1410 on the tool surface 104 of the curing tool 102 prior to placing 702 the dry fabric layup 1404 on the tool surface 104. Resin flows through the release film 1410 and into the dry fabric layup 1404. In other examples, the release film 1410 may be referred to as a peel ply. In a further example, the method also includes placing 814 a breather cloth 1412 on the release film 1410 prior to placing 702 the dry fabric layup 1404. Resin flows through the release film 1410 and the breather cloth 1412 and into the dry fabric layup 1404. In other examples, the breather cloth 1410 may be referred to as a flow distribution medium. In yet another embodiment, the method 800 also includes placing 816 a breather cloth 1412 on the tool surface 104 of the curing tool 102 prior to placing 702 the dry fabric layup 1404 on the tool surface 104 .

[0035]

[0063] 1, 7, 9, 14, and 16, in one or more embodiments of a method 900 for composite manufacturing, the fluid impermeable layer 1406 includes a second tool 1602 having a second surface 1604 facing the tool surface 104 of the curing tool 102, and the pressure differential is positive. The method 900 includes the method 700 of FIG. 7, where the placing 704 includes placing 902 the second tool 1602 over the dry fabric layup 1404. The sealing 706 of FIG. 7 includes sealing 904 the second surface 1604 to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the second surface 1604 and the tool surface 104. In another embodiment, the method 900 also includes placing 906 a release film 1410 over the dry fabric layup 1404 prior to placing 902 the second tool 1602.

[0036]

[0064] 1, 2, 7, 10, and 14, in one or more embodiments of a method 1000 for composite manufacturing, each opening 110 of the plurality of openings 110 defines a cross-sectional open area. The cumulative cross-sectional open area varies at different portions of the cover plate 108 along the channel axis 106 to provide a differential flow rate along the cover plate 108. The difference in the cumulative cross-sectional open area at different portions of the cover plate 108 is based on a difference in the cumulative cross-sectional open area of ​​the openings 110 of the plurality of openings 110 along the channel axis 106. The method 1100 includes the method 700 of FIG. 7, where further directing 714 of the liquid resin includes directing 1002 the liquid resin from the resin channel 202 through the different cumulative cross-sectional open areas of the openings 110 along the channel axis 106 to the dry fabric layup 1404. In another embodiment of the method 1000, the variations in the openings 110 are based on the variations in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0037]

[0065] 1 , 2 , 7 and 14 , in one or more additional embodiments of the method 700 for composite manufacturing, a dimension of at least one of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106. In a further embodiment, the difference in the dimension of at least one of the plurality of openings 110 is based on a difference in predetermined resin flow requirements at a corresponding location of the dry fabric layup 1404 associated with forming the composite part.

[0038]

[0066] In another embodiment of the method 700, the locations of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In a further embodiment, the differences in the locations of the plurality of openings 110 are based on differences in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0039]

[0067] In yet another embodiment of the method 700, the shapes of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In a further embodiment, the differences in the shapes of the plurality of openings 110 are based on differences in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part. In another further embodiment, at least a portion of the plurality of openings 110 include curved slit openings defined by at least one curve radius, at least one width, and at least one length.

[0040]

[0068] In yet another embodiment of the method 700, the pitch of the sidewalls 208 of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106. In a further embodiment, the difference in the pitch of the sidewalls 208 of the plurality of openings 110 is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0041]

[0069] In yet another embodiment of the method 700, the resin channel 202 has a channel width 206 and the cover plate 108 has a plate width greater than the channel width 206. At least a portion of the plurality of openings 110 extend beyond the channel width 206.

[0042]

[0070] 1, 2, 4, 7, 11, and 14, in one or more embodiments of a method 1100 for composite manufacturing, the resin channel 202 has a channel width 206 and the curing tool 102 includes shoulders 402 along both sides 210 of the resin channel 202 on the tool surface 104. The cover plate 108 provides a fluid path from the resin channel 202 through a portion of the plurality of openings 110 that extend beyond the channel width 206 of the resin channel 202. The fluid path is along the shoulders 402 and through the corresponding openings 110. The method 1100 includes the method 700 of FIG. 7, where further directing 714 the liquid resin includes directing 1102 the liquid resin from the resin channel 202 through the portion of the plurality of openings 110 that extend beyond the channel width 206, via a fluid path along the shoulders 402, and to the dry fabric layup 1404.

[0043]

[0071] 1, 2, 5, 7, 12, and 14, in one or more embodiments of a method 1200 for composite manufacturing, the resin channel 202 has a channel width 206 and the curing tool 102 includes chamfers 502 along both sides 210 of the resin channel 202 on the tool surface 104. The cover plate 108 provides a fluid path from the resin channel 202 through a portion of the plurality of openings 110 that extend beyond the channel width 206 of the resin channel 202. The fluid path is along the chamfers 502 and through the corresponding openings 110. The method 1200 includes the method 700 of FIG. 7, where further directing 714 the liquid resin includes directing 1202 the liquid resin from the resin channel 202 through the portion of the plurality of openings 110 that extend beyond the channel width 206, via a fluid path along the chamfers 502, to the dry fabric layup 1404.

[0044]

[0072] 1, 2, 6, 7, 13, and 14, in one or more embodiments of the method 1200 for composite manufacturing, the dry fabric layup 1404 is also disposed on the second cover plate 602 overlapping a second portion of the resin channel 202 along the channel axis 106. The method 1300 includes the method 700 of FIG. 7, where further directing 714 of the liquid resin further includes directing 1302, in response to the pressure differential, the liquid resin from the resin channel 202 through a second plurality of openings 604 in the second cover plate 602 to the dry fabric layup 1404. The second plurality of openings 604 are positioned to provide different flow rates through different portions of the second cover plate 602 along the channel axis 106. In another embodiment of the method 1200, the cover plate 108 and the second cover plate 602 overlap different portions of the resin channel 202 along the channel axis 106. In yet another embodiment of the method 1300, the difference in flow rate through different portions of the second cover plate 602 is based on the difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0045]

[0073] Referring generally to Figures 1-6 and 14-17, by way of example, the present disclosure is directed to a set tool assembly 100 for composite manufacturing. Figures 1 and 6 disclose several embodiments of the set tool assembly 100. Figures 2, 4 and 5 show several types of embodiments of the set tool assembly 100 in cross-sectional views across the channel axis 106. Figure 3 shows the set tool assembly 100 in cross-sectional view along the channel axis 106. Figures 14-17 disclose several embodiments of systems 1400, 1500, 1600, 1700 for composite manufacturing.

[0046]

[0074] 1, 2, and 14, in one or more embodiments, a system 1400 for composite manufacturing includes a curing tool 102, a cover plate 108, a fluid impermeable layer 1406, and a differential pressure generator 1408. The curing tool 102 includes a tool surface 104 defining a resin channel 202 having a channel axis 106. The resin channel 202 is configured to receive liquid resin from a resin source 1402. The cover plate 108 overlaps at least a portion of the resin channel 202 along the channel axis 106. The cover plate 108 defines a plurality of openings 110 in fluid communication with the resin channel 202. The plurality of openings 110 are positioned to provide different flow rates through different portions of the cover plate 108 along the channel axis 106. The cover plate 108 and the tool surface 104 are configured to receive a dry fabric layup 1404. The fluid impermeable layer 1406 faces the tool surface 1406 and is configured to overlie the dry fabric layup 1404 after the dry fabric layup 1404 is disposed on the tool surface 104 and the cover plate 108. The fluid impermeable layer 1406 is configured to be sealed to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the fluid impermeable layer 1406 and the tool surface 104. The differential pressure generator 1408 is configured to establish a differential pressure within the sealed volume to cause liquid resin to flow from the resin source 1402 into the sealed volume, to direct the liquid resin in the sealed volume into the resin channels 202, and to direct the liquid resin from the resin channels 202 through the multiple openings 110 in the cover plate 108 to the dry fabric layup 1404. The multiple openings 110 are arranged to provide different flow rates through different portions of the cover plate 108 to corresponding portions of the dry fabric layup 1404.

[0047]

[0075] 1, 2, 14, and 15, in one or more embodiments of a system 1500 for composite manufacturing, the pressure difference is a vacuum. The system 1500 includes the system 1400 of FIG. 14, where the fluid impermeable layer 1406 includes a vacuum bag 1502 configured to overlay the dry fabric layup 1404 and configured to be sealed to the tool surface 104 over the dry fabric layup 1404, forming a sealed volume between the vacuum bag 1502 and the tool surface 104. In another embodiment, the system 1500 also includes a release film 1410 configured to be placed over the dry fabric layup 1404 prior to placing the vacuum bag 1502 over the dry fabric layup 1404. In yet another embodiment, the system 1500 also includes a breather cloth 1412 configured to be placed over the dry fabric layup 1404 prior to placing the vacuum bag 1502 over the dry fabric layup 1404. In yet another embodiment of the system 1500, the differential pressure generator 1408 is configured to establish a vacuum within the sealed volume between the vacuum bag 1502 and the tool surface 104 to cause liquid resin to flow from the resin supply into the sealed volume, and includes a vacuum pump 1504 configured to direct the liquid resin in the sealed volume to the resin channels 202, and further direct the liquid resin from the resin channels 202 through the multiple openings 110 in the cover plate 108 to the dry fabric layup 1404, and configured to direct resin waste from the sealed volume to a resin collector 1506.

[0048]

[0076] Referring again to FIGS. 1, 2, and 14-17, in one or more embodiments of a system 1600 for composite manufacturing, the pressure differential is positive. The system 1600 includes the system 1400 of FIG. 14, where the fluid impermeable layer 1406 includes a second tool 1602 having a second surface 1604 facing the tool surface 104 of the curing tool 102. The second tool 1602 configured to overlie the dry fabric layup 1404 and the second surface 1604 is configured to be sealed to the tool surface 104 over the dry fabric layup 1404 to form a sealed volume between the second surface 1604 and the tool surface 104. In another embodiment, the system 1600 also includes a release film 1410 configured to be placed over the dry fabric layup 1404 prior to placing the second tool 1602 over the dry fabric layup 1404. In yet another embodiment of the system 1600, the differential pressure generator 1408 is configured to establish a positive pressure inside the sealed volume between the second surface 1604 and the tool surface 104 to cause liquid resin to flow from the resin source into the sealed volume, and includes a resin pump 1702 configured to direct the liquid resin in the sealed volume to the resin channels 202, and further direct the liquid resin from the resin channels 202 through the multiple openings 110 in the cover plate 108 to the dry fabric layup 1404, and configured to direct resin waste from the sealed volume to a resin collector 1506.

[0049]

[0077] Referring again to FIGS. 1, 2, 4-6, and 14, in one or more embodiments of the system 1400 for composite manufacturing, each opening 110 in the plurality of openings 110 defines a cross-sectional open area. The cumulative cross-sectional open area varies at different portions of the cover plate 108 along the channel axis 106, providing a differential flow rate along the cover plate 108. In another embodiment of the system 1400, at least one dimension of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106. In yet another embodiment of the system 1400, the positions of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In yet another embodiment of the system 1400, the shapes of the plurality of openings 110 in the cover plate 108 vary along the channel axis 106. In yet another embodiment of the system 1400, the pitch of the sidewalls 208 of the plurality of openings 110 in the cover plate 108 varies along the channel axis 106.

[0050]

[0078] In another embodiment of the system 1400, the resin channel 202 has a channel width 206, the cover plate 108 has a plate width greater than the channel width 206, and at least a portion of the plurality of openings 110 extend beyond the channel width 206. In yet another embodiment of the system 1400, the resin channel 202 has a channel width 206. In this embodiment, the curing tool 102 includes shoulders 402 along both sides 210 of the resin channel 202 on the tool surface 104. The cover plate 108 provides a fluid path from the resin channel 202 through a portion of the plurality of openings 110 that extend beyond the channel width 206 of the resin channel 202. The fluid path is along the shoulders 402 and through the corresponding openings 110. The differential pressure generator 1408 is configured to direct the liquid resin from the resin channel 202, through the portion of the plurality of openings 110 that extend beyond the channel width 206, through the fluid path along the shoulders 402, and to the dry fabric layup 1404.

[0051]

[0079] In yet another embodiment of the system 1400, the resin channel 202 has a channel width 206. In this embodiment, the curing tool 102 includes chamfers 502 along both sides 210 of the resin channel 202 on the tool surface 104. The cover plate 108 provides a fluid path from the resin channel 202 through a portion of the plurality of openings 110 that extend beyond the channel width 206 of the resin channel 202. The fluid path is along the chamfers 502 and through the corresponding openings 110. The differential pressure generator 1408 is configured to direct the liquid resin from the resin channel 202, through the portion of the plurality of openings 110 that extend beyond the channel width 206, through the fluid path along the chamfers 502, and to the dry fabric layup 1404.

[0052]

[0080] In yet another embodiment, the system 1400 also includes a second cover plate 602 configured to overlap a second portion of the resin channel 202 along the channel axis 106. The second cover plate 602 defines a plurality of openings 604 in fluid communication with the resin channel 202. The second plurality of openings 604 are arranged to provide different flow rates through different portions of the second cover plate 602 along the channel axis 106. In a further embodiment, the cover plate 108 and the second cover plate 602 overlap different portions of the resin channel 202 along the channel axis 106. In another further embodiment, the difference in flow rates through different portions of the second cover plate 602 is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup 1404 associated with forming the composite part.

[0053]

[0081] In another example, the system 1400 also includes a second cover plate 602 configured to cover at least a portion of the resin channel 202 along the channel axis 106. The second cover plate 602 defines a plurality of openings 604 in fluid communication with the resin channel 202. The second plurality of openings 604 are arranged to provide different flow rates through different portions of the second cover plate 602 along the channel axis 106. In a further example, the cover plate 108 and the second cover plate 602 are interchangeable in relation to the curing tool 102 and the resin channel 202. In another further example, the difference in flow rates through different portions of the second cover plate 602 is based on a difference in predetermined resin flow requirements at corresponding locations of a second dry fabric layup 1404 associated with molding a second composite part.

[0054]

[0082] Embodiments of the curing tool assembly 100, 1800, methods 700, 800, 900, 1000, 1100, 1200, 1300, 1900, 2700, and systems 1400, 1500, 1600, 1700 for composite manufacturing may be related to or used in the context of aircraft manufacturing. Although an aircraft example is described, the embodiments and principles disclosed herein may also be applied to other products in the aerospace industry, as well as other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Thus, in addition to aircraft, the embodiments and principles disclosed herein may be applied to the use of composite products in the manufacture of various types of vehicles and the construction of various types of buildings.

[0055]

[0083] The foregoing detailed description refers to the accompanying drawings, which show specific embodiments described by the present disclosure. Other embodiments having different structures and steps do not depart from the scope of the present disclosure. Similar reference numbers may represent the same features, elements, or components in different drawings. 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 items and may be referred to using similar reference numbers. Furthermore, as used herein, a feature, element, component, or step following the word "a" or "an" should be understood not to exclude a plurality of features, elements, components, or steps, unless expressly stated to exclude such.

[0056]

[0084] Illustrative and non-exhaustive examples of the subject matter according to the present disclosure that may, but are not necessarily, claimed are provided above. Reference herein to an "example" means that one or more features, structures, elements, components, properties, and / or operational steps described in connection with such example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, "one example," "another example," "one or more examples," and similar phrases used throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Furthermore, the subject matter characterizing any one example may, but does not necessarily, be combined with the subject matter characterizing any other example.

[0057]

[0085] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is in fact capable of performing that particular function without any modification, rather than merely having the capability to perform that particular function. In other words, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, "configured to" refers to a characteristic of an existing system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a particular function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" to perform and / or "operable" to perform that function.

[0058]

[0086] Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels and are not intended to impose any order, position, or hierarchy requirements on the items to which they refer. Moreover, a reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower numbered item and / or, for example, a "third" or higher numbered item.

[0059]

[0087] As used herein, the phrase "at least one of" used in conjunction with enumerated items means that different combinations of one or more of the enumerated items may be used and only one of each enumerated item may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, "item A" or "item A and item B". This example may also include "item A, item B, and item C" or "item B and item C". In other examples, "at least one of" may be, for example, but is not limited to, "2 items A, 1 item B, and 10 items C", "4 items B, and 7 items C", and other suitable combinations. As used herein, the term "and / or" and the symbol " / " include any and all combinations of one or more of the associated enumerated items.

[0060]

[0088] As used herein, the terms "coupled," "coupled," and similar terms refer to two or more elements that are coupled, connected, secured, attached, connected, placed in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various embodiments, the elements may be directly or indirectly associated. For example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, e.g., through another element C. It should be understood that not all associations between the various disclosed elements are necessarily shown. Correspondingly, other couplings may exist than those shown in the figures.

[0061]

[0089] The term "approximately" as used herein refers to or describes a condition that is close to, but not exactly, the described condition that still performs the desired function or achieves the desired result. As an example, the term "about" refers to a condition that is within an acceptable range of a given tolerance or precision, for example, within 10% of the described condition. However, the term "about" does not exclude a condition that is exactly as described. The term "substantially" as used herein refers to a condition that is essentially the described condition that performs the desired function or achieves the desired result.

[0062]

[0090] The above-mentioned Figures 1-6, 14-18, and 20-25 may represent functional elements, features, or components thereof, and do not necessarily refer to a specific structure. Thus, modifications, additions, and / or omissions may be made to the illustrated structures. In addition, a person skilled in the art will appreciate that not all of the elements, features, and / or components described and illustrated in the above-mentioned Figures 1-6, 14-18, and 20-25 need to be included in every embodiment, and not all of the elements, features, and / or components described herein are necessarily shown in each embodiment. Thus, some of the elements, features, and / or components described and illustrated in Figures 1-6, 14-18, and 20-25 can be combined in various ways without necessarily including other features described and illustrated in Figures 1-6, 14-18, and 20-25, other drawings, and / or the accompanying disclosure, even if one or more such combinations are not explicitly shown herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. Unless expressly stated otherwise, the schematic diagrams of the examples shown in the above-mentioned Figures 1-6, 14-18, and 20-25 do not imply structural limitations on the examples. Rather, it should be understood that although one exemplary structure is shown, the structure may be modified as necessary. Thus, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, elements, features, and / or components that serve similar or at least substantially similar purposes are numbered similarly in each of Figures 1-6, 14-18, and 20-25, and such elements, features, and / or components may not be described in detail herein with reference to each of Figures 1-6, 14-18, and 20-25. Similarly, not all elements, features and / or components are numbered in each of Figures 1-6, 14-18 and 20-25, but reference numerals associated therewith may be used herein for consistency.

[0063]

[0091] In the above-mentioned FIG. 7, FIG. 8A-B, FIG. 9-13, and FIG. 19, the blocks may represent processes, steps, and / or portions thereof, and the lines connecting various blocks do not imply a particular order or dependency of the processes or portions thereof. It should be understood that not all dependencies between the various disclosed processes are necessarily depicted. FIG. 7, FIG. 8A-B, FIG. 9-13, and FIG. 19, which describe the steps of the disclosed method shown herein, and the accompanying disclosure, should not be construed as necessarily dictating the sequence in which the steps are performed. Rather, it should be understood that even if one exemplary order is shown, the sequence of the steps may be changed as necessary. Thus, modifications, additions, and / or omissions may be made to the illustrated steps, and some steps may be performed in a different order or simultaneously. In addition, one skilled in the art will appreciate that it is not necessary to perform all the steps described.

[0064]

[0092] Furthermore, throughout this specification, references to features, advantages, or similar language used herein do not indicate that all features and advantages that may be realized by the embodiments disclosed herein should or will be present in any single embodiment. Rather, references to features and advantages should be understood to mean that the particular feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, descriptions of features, advantages, and similar language used throughout this disclosure may, but do not necessarily, refer to the same embodiment.

[0065]

[0093] Examples of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method 2800 shown in FIG. 28 and aircraft 2900 shown in FIG. 29. In one or more embodiments, the disclosed method and system for relating test data of a part under test to a coordinate system of a final product may be used in aircraft manufacturing. During pre-production, method 2800 may include specification and design of aircraft 2900 (block 2802) and procurement of materials (block 2804). During production, manufacturing of components and subassemblies of aircraft 2900 (block 2806) and system integration (block 2808) may occur. Thereafter, aircraft 2900 may undergo certification and delivery (block 2810) and be placed into service (block 2812). During its operational life, aircraft 2900 may be scheduled for routine maintenance and upkeep (block 2814). Periodic maintenance and upkeep may include modification, reconfiguration, modification, etc. of one or more systems of aircraft 2900.

[0066]

[0094] Each of the processes of method 2800 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For 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; an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0067]

[0095] 29 , an aircraft 2900 produced by the maintenance method 2800 may include an airframe 2902 having a number of high level systems 2904 and an interior 2906. Examples of high level systems 2904 include one or more of a propulsion system 2908, an electrical system 2910, a hydraulic system 2912, and an environmental system 2914. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Thus, in addition to the aircraft 2900, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, etc.

[0068]

[0096] The disclosed systems and methods for relating test data of a part under test to a coordinate system of a final product may be employed during any one or more of the stages of manufacturing and service method 2800. For example, components or subassemblies corresponding to manufacturing of components and subassemblies (block 2806) may be fabricated or manufactured similarly to components or subassemblies manufactured during operation of aircraft 2900 (block 2812). Also, one or more embodiments of one or more systems, one or more methods, or combinations thereof may be utilized during the manufacturing stage (blocks 2806 and 2808), for example, by substantially streamlining or reducing the cost of assembling aircraft 2900. Similarly, one or more embodiments implementing a system or method, or combinations thereof, may be utilized during operation of aircraft 2900 (block 2812) and / or during maintenance and service (block 2814), for example, without limitation.

[0069]

[0097] Features, advantages, and characteristics described in one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will appreciate that the embodiments described herein may be practiced without one or more of the specific features or advantages of a particular embodiment. In other cases, additional features and advantages may be recognized in some embodiments that are not present in all embodiments. Furthermore, while various embodiments of the curing tool assembly 100, 1800, methods 700, 800, 900, 1000, 1100, 1200, 1300, 1900, 2700, and systems 1400, 1500, 1600, 1700 for composite manufacturing have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

1. A curing tool assembly (100) for composite manufacturing, comprising: a curing tool (102) including a tool surface (104) defining a resin channel (202) having a channel axis (106); and a cover plate (108) overlying at least a portion of the resin channel (202) along the channel axis (106) and defining a plurality of openings (110) in fluid communication with the resin channel (202), the plurality of openings (110) being positioned to provide different flow rates through different portions of the cover plate (108) along the channel axis (106); a hardened tool assembly including:

2. 2. The cure tool assembly of claim 1, wherein the cover plate (108) is parallel to the channel axis (106) and is customized based on predetermined resin flow requirements of a dry fabric layup (1404) associated with molding a composite part.

3. 2. The hardening tool assembly of claim 1, wherein each opening (110) of the plurality of openings (110) defines a cross-sectional opening area, and a cumulative cross-sectional opening area varies at the different portions of the cover plate (108) along the channel axis (106) to provide a differential flow rate along the cover plate (108).

4. 4. The hardened tool assembly of claim 3, wherein the cumulative cross-sectional open area of ​​a given portion relative to a maximum cumulative cross-sectional open area of ​​the given portion is equal to or less than at least one of about 100%, about 90%, about 80%, about 70%, about 60%, about 50%, about 40%, about 30%, about 20% and about 10%.

5. 4. The hardening tool assembly of claim 3, wherein the difference in cumulative cross-sectional open area of ​​the different portions of the cover plate (108) is based on the difference in cumulative cross-sectional open area of ​​a group of openings (110) of the plurality of openings (110) along the channel axis (106).

6. The cure tool assembly of claim 5 , wherein the differences in the groups of openings (110) are based on differences in predetermined resin flow requirements at corresponding locations of a dry fabric layup (1404) associated with molding a composite part.

7. 6. The hardening tool assembly of claim 5, wherein the cumulative cross-sectional open area of ​​the distinct portions of the cover plate (108) is defined by a cumulative cross-sectional open area of ​​a group of openings (110) in a corresponding portion, the cumulative cross-sectional open area of ​​a group of openings (110) being defined by a dimension of a particular opening in the corresponding group.

8. 8. The hardening tool assembly of claim 7, wherein the different cumulative cross-sectional open areas of the different portions of the cover plate are due to at least one of a difference in size of a particular opening from at least a portion of an adjacent group and a difference in quantity of the particular opening from at least a portion of an adjacent group.

9. The cure tool assembly of claim 1 , wherein at least one dimension of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

10. 10. The cure tool assembly of claim 9, wherein the difference in the at least one dimension of the plurality of openings (110) is based on a difference in a predetermined resin flow requirement at a corresponding location of a dry fabric layup (1404) associated with molding a composite part.

11. The cure tool assembly of claim 9, wherein the at least one dimension of the plurality of openings (110) varies by at least one of width, length, angle, diameter, and depth.

12. 10. The hardening tool assembly of claim 9, wherein the at least one dimension is a width of the plurality of openings (110), the width ranging from at least one of about 0.50 inches to about 2.25 inches, about 0.75 inches to about 2.00 inches, about 1.00 inches to about 1.75 inches, and about 1.25 inches to about 1.5 inches.

13. 13. The curing tool assembly of claim 12, wherein the width of the plurality of openings (110) is based on predetermined resin flow requirements of a dry fabric layup (1404) associated with molding a composite part to improve resin infusion rate and mitigate trap-off.

14. 10. The hardening tool assembly of claim 9, wherein the at least one dimension is a length of the plurality of openings (110), the length ranging from at least one of about 0.50 inches to about 2.25 inches, about 0.75 inches to about 2.00 inches, about 1.00 inches to about 1.75 inches, and about 1.25 inches to about 1.5 inches.

15. 10. The hardening tool assembly of claim 9, wherein the at least one dimension is an angle of the plurality of openings (110), the angle ranging from at least one of about 5 degrees to about 175 degrees, about 25 degrees to about 155 degrees, about 45 degrees to about 135 degrees, about 65 degrees to about 115 degrees, and about 85 degrees to about 95 degrees.

16. 10. The hardened tool assembly of claim 9, wherein the at least one dimension is a diameter of the plurality of openings (110), the diameter ranging from at least one of about 0.050 inches to about 0.750 inches, about 0.100 inches to about 0.700 inches, about 0.150 inches to about 0.650 inches, about 0.200 inches to about 0.600 inches, about 0.250 inches to about 0.550 inches, about 0.300 inches to about 0.500 inches, and about 0.350 inches to about 0.450 inches.

17. 10. The hardening tool assembly of claim 9, wherein the at least one dimension is a depth of the plurality of openings (110), the depth ranging from at least one of about 0.040 inches to about 0.100 inches, about 0.050 inches to about 0.090 inches, and about 0.060 inches to about 0.080 inches.

18. The cure tool assembly of claim 1 , wherein positions of the openings (110) in the cover plate (108) vary along the channel axis (106).

19. 20. The cure tool assembly of claim 18, wherein the differences in location of the plurality of openings (110) are based on differences in predetermined resin flow requirements at corresponding locations of a dry fabric layup (1404) associated with molding a composite part.

20. The cure tool assembly of claim 18, wherein the locations of the plurality of openings (110) are based on different amounts of openings in different portions of the cover plate (108) along the channel axis (106).

21. 21. The hardened tool assembly of claim 20, wherein the amount of openings in a given portion relative to a maximum amount of openings in the given portion is equal to or less than at least one of about 100%, about 90%, about 80%, about 70%, about 60%, about 50%, about 40%, about 30%, about 20% and about 10%.

22. 20. The hardening tool assembly of claim 18, wherein the locations of the plurality of openings (110) are based on an array of rows across and columns along the channel axis (106), and different locations are formed by varying an amount of openings from row to row for at least a portion of the array of rows.

23. The cure tool assembly of claim 1 , wherein the shapes of the openings (110) in the cover plate (108) vary along the channel axis (106).

24. 24. The cure tool assembly of claim 23, wherein the difference in shape of the plurality of openings (110) is based on a difference in predetermined resin flow requirements at corresponding locations of a dry fabric layup (1404) associated with molding a composite part.

25. 24. The hardening tool assembly of claim 23, wherein the shape of the plurality of openings (110) comprises at least one of a rectangular shape, a square shape, a circular shape, an oval shape, a triangular shape, a hexagonal shape, an octagonal shape, a pentagonal shape, an elongated shape, a parallelogram shape, a trapezoidal shape, and a curved slit shape.

26. 24. The hardening tool assembly of claim 23, wherein at least a portion of the plurality of openings (110) comprise curved slit openings defined by at least one radius of curvature, at least one width, and at least one length.

27. 27. The hardened tool assembly of claim 26, wherein the at least one radius of curvature of the curved slit opening ranges from at least one of about 0.050 inches to about 0.750 inches, about 0.100 inches to about 0.700 inches, about 0.150 inches to about 0.650 inches, about 0.200 inches to about 0.600 inches, about 0.250 inches to about 0.550 inches, about 0.300 inches to about 0.500 inches, and about 0.350 inches to about 0.450 inches.

28. 27. The cure tool assembly of claim 26, wherein the at least one width of the curved slit opening ranges from at least one of about 0.50 inches to about 2.25 inches, about 0.75 inches to about 2.00 inches, about 1.00 inches to about 1.75 inches, and about 1.25 inches to about 1.5 inches.

29. 27. The cure tool assembly of claim 26, wherein the at least one length of the curved slit opening ranges from about 0.50 inches to approximately the length of the resin channel (202), from about 1 inch to about 120 inches, from about 2 inches to about 96 inches, from about 4 inches to about 72 inches, from about 6 inches to about 48 inches, and from about 8 inches to about 24 inches.

30. The cure tool assembly of claim 1, wherein a pitch of sidewalls (208) of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

31. 31. The cure tool assembly of claim 30, wherein the difference in pitch of the sidewalls (208) of the plurality of openings (110) is based on a difference in predetermined resin flow requirements at corresponding locations of a dry fabric layup (1404) associated with molding a composite part.

32. 31. The hardening tool assembly of claim 30, wherein the pitch of the sidewalls (208) of the plurality of openings (110) varies by at least one of an angle of the sidewalls (208), a slope of the sidewalls (208), and a depth of the sidewalls (208).

33. 31. The hardening tool assembly of claim 30, wherein the pitch of the sidewalls (208) of the plurality of openings (110) ranges from at least one of about 45 degrees to about 90 degrees, about 50 degrees to about 85 degrees, about 55 degrees to about 80 degrees, about 60 degrees to about 75 degrees, and about 65 degrees to about 70 degrees.

34. The cure tool assembly of claim 1 , wherein the spacing between adjacent ones of the plurality of openings (110) is greater than about 0.0375 inches.

35. 2. The cure tool assembly of claim 1, wherein the resin channel (202) has a channel depth (204) ranging from at least one of about 0.15 inches to about 0.60 inches, about 0.20 inches to about 0.50 inches, about 0.25 inches to about 0.45 inches, and about 0.30 inches to about 0.40 inches.

36. The cure tool assembly of claim 1, wherein the resin channel (202) has a channel width (206) ranging from at least one of about 0.20 inches to about 0.80 inches, about 0.30 inches to about 0.70 inches, and about 0.40 inches to about 0.60 inches.

37. The cure tool assembly of claim 1 , wherein a position of the resin channel (202) relative to the cure tool (102) is based on predetermined resin flow requirements of a dry fabric layup (1404) associated with molding a composite part.

38. 2. The curing tool assembly of claim 1, wherein the resin channel (202) has a channel width (206), the cover plate (108) has a plate width greater than the channel width (206), and at least a portion of the plurality of openings (110) extend beyond the channel width (206).

39. 40. The hardening tool assembly of claim 38, wherein the plate width is at least one of: up to 400 percent of the channel width, up to 350 percent of the channel width, up to 300 percent of the channel width, up to 250 percent of the channel width, up to 200 percent of the channel width, and up to 150 percent of the channel width.

40. 2. The cure tool assembly of claim 1, wherein the cure tool includes shoulders along either side of the resin channel on the tool surface for aligning the cover plate with the resin channel.

41. The hardened tool assembly of claim 40, wherein the cover plate (108) overlaps at least a portion of the shoulder (402) such that a plate surface (404) of the cover plate (108) is substantially flush with the tool surface (104).

42. 42. The cure tool assembly of claim 41, wherein the resin channel (202) has a channel width (206), the cover plate (108) includes a support member (406) that elevates the plate surface (404) above the shoulder (402), and at least a portion of the plurality of openings (110) extend beyond the channel width (206) above the shoulder (402).

43. 43. The cure tool assembly of claim 42, wherein the cover plate (108) provides a fluid path from the resin channel (202) through the portions of the plurality of openings (110) that extend beyond the channel width (206), the fluid path being along the shoulder (402) and through corresponding openings (110).

44. 2. The cure tool assembly of claim 1, wherein the cure tool includes chamfers along either side of the resin channel on the tool surface for aligning the cover plate with the resin channel.

45. 45. The hardened tool assembly of claim 44, wherein the cover plate (108) overlaps at least a portion of the chamfer (502) such that a plate surface (404) of the cover plate (108) is substantially flush with the tool surface (104).

46. 46. ​​The curing tool assembly of claim 45, wherein the resin channel (202) has a channel width (206), at least a portion of the plurality of openings (110) extend beyond the channel width (206) over the chamfer (502), and the cover plate (108) provides a fluid path from the resin channel (202) through the portions of the plurality of openings (110) that extend beyond the channel width (206), the fluid path being along the chamfer (502) and through a corresponding one of the openings (110).

47. a second cover plate (602) configured to overlie a second portion of the resin channel (202) along the channel axis (106) and defining a second plurality of openings (604) in fluid communication with the resin channel (202), the second plurality of openings (604) being positioned to provide different flow rates through different portions of the second cover plate (602) along the channel axis (106); The cure tool assembly of claim 1 further comprising:

48. The cure tool assembly of claim 47, wherein the cover plate (108) and the second cover plate (602) overlap different portions of the resin channel (202) along the channel axis (106).

49. 48. The cure tool assembly of claim 47, wherein a difference in flow rates through the different portions of the second cover plate (602) is based on a difference in predetermined resin flow requirements at corresponding locations of a dry fabric layup (1404) associated with molding a composite part.

50. a second cover plate (602) configured to overlap at least the portion of the resin channel (202) along the channel axis (106) and defining a second plurality of openings (604) in fluid communication with the resin channel (202), the second plurality of openings (604) being positioned to provide different flow rates through different portions of the second cover plate (602) along the channel axis (106); The cure tool assembly of claim 1 further comprising:

51. The cure tool assembly of claim 50, wherein the cover plate (108) and the second cover plate (602) are interchangeable relative to the cure tool (102) and the resin channel (202).

52. The cure tool assembly of claim 50, wherein the difference in flow rates through the different portions of the second cover plate (602) is based on a difference in predetermined resin flow requirements at corresponding locations of a second dry fabric layup (1404) associated with molding a second composite part.

53. The cure tool assembly of claim 1 , wherein the cover plate (108) is reusable in connection with molding multiple composite parts.

54. The cure tool assembly of claim 1 , wherein the cover plate (108) is not consumable in connection with forming a plurality of composite parts.

55. 1. A method (2700) for composite manufacturing, comprising: Flowing (2702) a wavefront of resin through a resin channel (202); flowing (2704) the wave front of resin from the resin channel (202) onto a cover plate (108); flowing (2706) the resin wave front through an opening (110) in the cover plate (108); and Allowing the resin wave front to flow (2708) through the opening (110) in the cover plate (108) into the dry fabric lay-up (1404) until impregnation is achieved. The method includes:

56. 56. The method of claim 55, wherein the cover plate (108) comprises a slotted cover and the opening (110) comprises a slot.

57. 56. The method of claim 55, wherein the dry fabric layup (1402) comprises a dry preform.

58. 1. A method (1900) for composite manufacturing, comprising: Placing (1902) a dry fabric layup (1404) having a pad-up region (1405) on a tool surface (104) of a curing tool (102), the tool surface (104) defining a plurality of interconnected resin channels (202) having a channel width (206) and a channel axis (106), the interconnected plurality of resin channels (202) defining strategic paths for distributing resin to the dry fabric layup (1404), the dry fabric layup (1404) having the pad-up region (1405) being formed by applying a plurality of cover plates (206) overlying the interconnected plurality of resin channels (202). and placing (1902) a dry fabric layup (1404) over a pad-up region (1405) of the dry fabric layup (1404), each cover plate (108) having a plate width extending beyond the channel width (206), each cover plate (108) including a plurality of openings (110) at least a portion of which extends beyond the channel width (206), the plurality of openings (110) in each cover plate (108) further defining strategic paths for distributing the resin to the dry fabric layup (1404), the plate widths of the plurality of cover plates (108) being strategically wider in the pad-up region (1405) than in other regions; placing (1904) a fluid impermeable layer (1406) over the dry fabric lay-up (1404) facing the tool surface (104); sealing (1906) the fluid impermeable layer (1406) to a tool surface (104) over the dry fabric lay-up (1404) to form a sealed volume between the fluid impermeable layer (1406) and the tool surface (104); supplying (1908) liquid resin from a resin source (1402) to the enclosed volume; providing a pressure differential across the enclosed volume to cause the liquid resin to flow from the resin source (1402) into the enclosed volume (1910); directing (1912) the liquid resin within the enclosed volume into the plurality of interconnected resin channels (202) in response to the pressure differential; further directing (1914) the liquid resin from the plurality of interconnected resin channels (202) through the plurality of openings (110) in the plurality of cover plates (108) and into the dry fabric lay-up (1404) having the pad-up area (1405) in response to the pressure differential; The method includes:

59. A method (700) for composite manufacturing, comprising: placing (702) a dry fabric layup (1404) on a tool surface (104) of a curing tool (102), the tool surface (104) defining a resin channel (202) having a channel axis (106), the dry fabric layup (1404) being disposed on a cover plate (108) overlapping the resin channel (202); placing (704) a fluid impermeable layer (1406) facing the tool surface (104) over the dry fabric lay-up (1404); sealing (706) the fluid impermeable layer (1406) to the tool surface (104) over the dry fabric lay-up (1404) to form a sealed volume between the fluid impermeable layer (1406) and the tool surface (104); supplying (708) liquid resin to the enclosed volume from a resin source (1402); providing a pressure differential across the enclosed volume to cause the liquid resin to flow from the resin source (1402) into the enclosed volume (710); directing (712) the liquid resin within the enclosed volume into the resin channel (202) in response to the pressure differential; further directing (714) the liquid resin from the resin channel (202) through a plurality of openings (110) in the cover plate (108) and into the dry fabric lay-up (1404) in further response to the pressure differential, the plurality of openings (110) in the cover plate (108) being positioned to provide different flow rates through different portions of the cover plate (108) to corresponding portions of the dry fabric lay-up (1404); The method includes:

60. 60. The method of claim 59, wherein the dry fabric layup (1404) comprises a preform dry fabric layup (1404).

61. 61. The method of claim 60, wherein the preform dry fabric layup (1404) comprises a plurality of tacked dry fabric plies.

62. 60. The method of claim 59, wherein the dry fabric layup (1404) comprises a stack of dry fabric plies.

63. 63. The method of claim 62, wherein the dry fabric plies in the stack are tacked.

64. the fluid impermeable layer (1406) comprises a vacuum bag (1502), the pressure differential is a vacuum, and the method further comprises: placing (802) the vacuum bag (1502) over the dry fabric lay-up (1404); sealing (804) the vacuum bag (1502) to the tool surface (104) over the dry fabric lay-up (1404) to form the sealed volume between the vacuum bag (1502) and the tool surface (104); 60. The method of claim 59, further comprising:

65. Placing (806) a release film (1410) on said dry fabric (1404) prior to placing (802) a vacuum bag (1502).

65. The method of claim 64, further comprising:

66. placing (808) a breather cloth (1412) over the release film (1410) prior to placing (802) the vacuum bag (1502); 66. The method of claim 65, further comprising:

67. Placing (810) a breather cloth (1412) over the dry fabric lay-up (1404) prior to placing (802) the vacuum bag (1502).

65. The method of claim 64, further comprising:

68. the fluid impermeable layer (1406) includes a second tool (1602) having a second surface (1604) opposing the tool surface (104) of the hardening tool (102), the pressure differential is positive, and the method further comprises: placing (902) the second tool (1602) on the dry fabric lay-up (1404); sealing (904) the second surface (1604) to the tool surface (104) over the dry fabric lay-up (1404) to form a sealed volume between the second surface (1604) and the tool surface (104); 60. The method (900) of claim 59, further comprising:

69. placing (906) a release film (1410) on the dry fabric lay-up (1404) prior to placing (902) the second tool (1602); 69. The method of claim 68, further comprising:

70. Placing (812) a release film (1410) on the tool surface (104) of the curing tool (102) prior to placing (702) the dry fabric layup (1404) on the tool surface (104).

60. The method of claim 59, further comprising:

71. placing (814) a breather cloth (1412) over the release film (1410) prior to placing (702) the dry fabric layup (1404); 71. The method of claim 70, further comprising:

72. Placing (816) a breather cloth (1412) on the tool surface (104) of the curing tool (102) prior to placing (702) the dry fabric layup (1404) on the tool surface (104).

60. The method of claim 59, further comprising:

73. 60. The method of claim 59, wherein each opening (110) of the plurality of openings (110) defines a cross-sectional opening area, and wherein a cumulative cross-sectional opening area varies at the different portions of the cover plate (108) along the channel axis (106) to provide a differential in flow rate along the cover plate (108).

74. and further directing (714) the liquid resin based on a difference in the cumulative cross-sectional open area of ​​the different portions of the cover plate (108) based on a difference in the cumulative cross-sectional open area of ​​openings (110) of the plurality of openings (110) along the channel axis (106). directing (1002) the liquid resin from the resin channel (202) along the channel axis (106) through the differing cumulative cross-sectional open areas of the openings (110) into the dry fabric lay-up (1404); 74. The method (1000) of claim 73, comprising:

75. 75. The method of claim 74, wherein the difference in the groups of openings (110) is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with forming a composite part.

76. 60. The method of claim 59, wherein at least one dimension of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

77. 77. The method of claim 76, wherein the difference in the at least one dimension of the plurality of openings (110) is based on a difference in a predetermined resin flow requirement at a corresponding location of the dry fabric layup (1404) associated with forming a composite part.

78. 60. The method of claim 59, wherein positions of the openings (110) in the cover plate (108) vary along the channel axis (106).

79. 80. The method of claim 78, wherein the differences in location of the plurality of openings (110) are based on differences in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with molding a composite part.

80. 60. The method of claim 59, wherein a shape of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

81. 81. The method of claim 80, wherein the difference in shape of the plurality of openings (110) is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with forming a composite part.

82. 81. The method of claim 80, wherein at least a portion of the plurality of openings (110) comprise curved slit openings defined by at least one radius of curvature, at least one width, and at least one length.

83. 60. The method of claim 59, wherein a pitch of sidewalls (208) of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

84. 84. The method of claim 83, wherein the difference in pitch of the sidewalls (208) of the plurality of openings (110) is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with molding a composite part.

85. 60. The method of claim 59, wherein the resin channel (202) has a channel width (206), the cover plate (108) has a plate width greater than the channel width (206), and at least a portion of the plurality of openings (110) extend beyond the channel width (206).

86. the resin channel (202) has a channel width (206), the curing tool (102) includes shoulders (402) along both sides (210) of the resin channel (202) on the tool surface (104), and the cover plate (108) provides a fluid path from the resin channel (202) through a portion of the plurality of openings (110) that extend beyond the channel width (206) of the resin channel (202), the fluid path being along the shoulders (402) and through corresponding openings (110) to further direct (714) the liquid resin; directing (1102) the liquid resin from the resin channel (202), through the portion of the plurality of openings (110) that extends beyond the channel width (206), through the fluid path along the shoulder (402), and onto the dry fabric lay-up (1404); 60. The method of claim 59, comprising:

87. the resin channel (202) has a channel width (206), the curing tool (102) includes chamfers (502) along both sides (210) of the resin channel (202) on the tool surface (104), and the cover plate (108) provides a fluid path from the resin channel (202) through a portion of the plurality of openings (110) that extends beyond the channel width (206) of the resin channel (202), the fluid path being along the chamfers (502) and through a corresponding one of the openings (110) to further direct (714) the liquid resin; directing (1202) the liquid resin from the resin channel (202), through the portion of the plurality of openings (110) that extends beyond the channel width (206), through the fluid path along the chamfer (502), and onto the dry fabric lay-up (1404); 60. The method of claim 59, comprising:

88. The dry fabric lay-up (1404) is also disposed over a second cover plate (602) overlying a second portion of the resin channel (202) along the channel axis (106), and further directing (714) the liquid resin; and directing (1302) the liquid resin from the resin channel (202) through a second plurality of openings (604) in the second cover plate (602) to the dry fabric lay-up (1404) in further response to the pressure differential, the second plurality of openings (604) being positioned to provide different flow rates through different portions of the second cover plate (602) along the channel axis (106).

60. The method of claim 59, comprising:

89. 90. The method of claim 88, wherein the cover plate (108) and the second cover plate (602) overlap different portions of the resin channel (202) along the channel axis (106).

90. 90. The method of claim 88, wherein the difference in flow rates through the different portions of the second cover plate (602) is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with molding a composite part.

91. 1. A system (1400) for composite manufacturing, comprising: a curing tool (102) including a tool surface (104) defining a resin channel (202) having a channel axis (106), the resin channel (202) configured to receive liquid resin from a resin source (1402); a cover plate (108) overlying at least a portion of the resin channel (202) along the channel axis (106) and defining a plurality of openings (110) in fluid communication with the resin channel (202), the plurality of openings (110) being arranged to provide different flow rates through different portions of the cover plate (108) along the channel axis (106), the cover plate (108) and the tool surface (104) being configured to receive a dry fabric layup (1404); a fluid-impermeable layer (1406) facing the tool surface (104) and configured to overlay the dry fabric layup (1404) after the dry fabric layup (1404) is disposed on the tool surface (104) and the cover plate (108), the fluid-impermeable layer (1406) configured to be sealed to the tool surface (104) over the dry fabric layup (1404) to form a sealed volume between the fluid-impermeable layer (1406) and the tool surface (104); a differential pressure generator (1408) configured to establish a differential pressure within the sealed volume to cause the liquid resin to flow from the resin source (1402) into the sealed volume, configured to direct the liquid resin in the sealed volume to the resin channel (202), and further configured to direct the liquid resin from the resin channel (202) through the plurality of openings (110) in the cover plate (108) to the dry fabric lay-up (1404), the plurality of openings (110) being positioned to provide different flow rates through the different portions of the cover plate (108) to corresponding portions of the dry fabric lay-up (1404); A system including:

92. the pressure difference being a vacuum, and the fluid impermeable layer (1406) a vacuum bag (1502) configured to overlay the dry fabric layup (1404) and to be sealed to the tool surface (104) over the dry fabric layup (1404) to form a sealed volume between the vacuum bag (1502) and the tool surface (104); 92. The system of claim 91, comprising:

93. a release film (1410) configured to be placed over the dry fabric lay-up (1404) prior to placing the vacuum bag (1502) over the dry fabric lay-up (1404); 93. The system of claim 92, further comprising:

94. a breather cloth (1412) configured to be placed over the dry fabric layup (1404) prior to placing the vacuum bag (1502) over the dry fabric layup (1404); 93. The system of claim 92, further comprising:

95. The differential pressure generator (1408) a vacuum pump (1504) configured to establish a vacuum inside the sealed volume between the vacuum bag (1502) and the tool surface (104) to cause the liquid resin to flow from the resin source into the sealed volume, configured to direct the liquid resin in the sealed volume into the resin channel (202), and further direct the liquid resin from the resin channel (202) through the plurality of openings (110) in the cover plate (108) to the dry fabric lay-up (1404), and configured to direct resin waste from the sealed volume to a resin collector (1506); 93. The system of claim 92, comprising:

96. The pressure difference is positive, and the fluid impermeable layer (1406) a second tool (1602) having a second surface (1604) facing the tool surface (104) of the curing tool (102) and configured to overlay the dry fabric lay-up (1404), the second surface (1604) configured to be sealed to the tool surface (104) over the dry fabric lay-up (1404) to form the sealed volume between the second surface (1604) and the tool surface (104); 92. The system of claim 91, comprising:

97. a release film (1410) configured to be placed over the dry fabric layup (1404) prior to placing the second tool (1602) over the dry fabric layup (1404); 97. The system of claim 96, further comprising:

98. The differential pressure generator (1408) a resin pump (1702) configured to establish a positive pressure inside the sealed volume between the second surface (1604) and the tool surface (104) to cause the liquid resin to flow from the resin source into the sealed volume, configured to direct the liquid resin in the sealed volume to the resin channel (202), and further direct the liquid resin from the resin channel (202) through the plurality of openings (110) in the cover plate (108) to the dry fabric lay-up (1404), and configured to direct resin waste from the sealed volume to a resin collector (1506); 97. The system of claim 96, comprising:

99. 92. The system of claim 91, wherein each opening (110) of the plurality of openings (110) defines a cross-sectional opening area, the cumulative cross-sectional opening area being different at the different portions of the cover plate (108) along the channel axis (106) to provide a differential flow rate along the cover plate (108).

100. 92. The system of claim 91, wherein at least one dimension of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

101. 92. The system of claim 91, wherein positions of the openings (110) in the cover plate (108) vary along the channel axis (106).

102. 92. The system of claim 91, wherein a shape of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

103. 92. The system of claim 91, wherein a pitch of sidewalls (208) of the plurality of openings (110) in the cover plate (108) varies along the channel axis (106).

104. 92. The system of claim 91, wherein the resin channel (202) has a channel width (206), the cover plate (108) has a plate width greater than the channel width (206), and at least a portion of the plurality of openings (110) extend beyond the channel width (206).

105. The resin channel (202) has a channel width (206), and the curing tool (102) comprises: shoulders (402) along either side (210) of the resin channel (202) on the tool surface (104), wherein the cover plate (108) provides a fluid path from the resin channel (202) through a portion of the plurality of openings (110) that extends beyond the channel width (206) of the resin channel (202), the fluid path being along the shoulders (402) and through corresponding openings (110); Including, the pressure differential generator (1408) is configured to direct the liquid resin from the resin channel (202), through the portion of the plurality of openings (110) that extends beyond the channel width (206), through the fluid path along the shoulder (402), and onto the dry fabric lay-up (1404).

92. The system of claim 91.

106. The resin channel (202) has a channel width (206), and the curing tool (102) comprises: chamfers (502) along either side (210) of the resin channel (202) on the tool surface (104), wherein the cover plate (108) provides a fluid path from the resin channel (202) through a portion of the plurality of openings (110) that extends beyond the channel width (206) of the resin channel (202), the fluid path being along the chamfers (502) and through a corresponding one of the openings (110); Including, the pressure differential generator (1408) is configured to direct the liquid resin from the resin channel (202), through the portion of the plurality of openings (110) that extends beyond the channel width (206), through the fluid path along the chamfer (402), and onto the dry fabric lay-up (1404).

92. The system of claim 91.

107. a second cover plate (602) configured to overlie a second portion of the resin channel (202) along the channel axis (106) and defining a second plurality of openings (604) in fluid communication with the resin channel (202), the second plurality of openings (604) being positioned to provide different flow rates through different portions of the second cover plate (602) along the channel axis (106); 92. The system of claim 91, further comprising:

108. 108. The system of claim 107, wherein the cover plate (108) and the second cover plate (602) overlap different portions of the resin channel (202) along the channel axis (106).

109. 108. The system of claim 107, wherein the difference in flow rates through the different portions of the second cover plate (602) is based on a difference in predetermined resin flow requirements at corresponding locations of the dry fabric layup (1404) associated with molding a composite part.

110. a second cover plate (602) configured to overlap at least the portion of the resin channel (202) along the channel axis (106) and defining a second plurality of openings (604) in fluid communication with the resin channel (202), the second plurality of openings (604) being positioned to provide different flow rates through different portions of the second cover plate (602) along the channel axis (106); 92. The system of claim 91, further comprising:

111. The system of claim 110, wherein the cover plate (108) and the second cover plate (602) are interchangeable relative to the curing tool (102) and the resin channel (202).

112. The system of claim 110, wherein the difference in flow rates through the different portions of the second cover plate (602) is based on a difference in predetermined resin flow requirements at corresponding locations of a second dry fabric layup (1404) associated with molding a second composite part.

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