Cure tool assembly, method and system for composite manufacturing

Abstract

To improve resin impregnation into dry fabric laminates in composite manufacturing.SOLUTION: A curing tool assembly (100) includes a curing tool (102) and a compression pressure chamber (110). The curing tool (102) has a tool face (104) on which a dry fabric laminate (106) rests. The compression pressure chamber (110) is disposed over the dry fabric laminate (106). The compression pressure chamber (110) receives pressurized fluid (112) from a compressed fluid source (114) during resin impregnation of the dry fabric laminate (106). The pressurized fluid (112) is received at a compression pressure higher than standard atmospheric pressure, and the dry fabric laminate (106) is enclosed in an enclosed space (134). The dry fabric laminate (106) is impregnated with liquid resin (116) in response to the resin pressure and the compression pressure.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates generally to dispersing liquid resin in a curing tool at resin pressures higher than standard atmospheric pressure in composite manufacturing, and more specifically to applying a compressive pressure higher than resin pressure to a layup during resin infiltration using a curing tool assembly. Various techniques have been considered for delivering the liquid resin. Various techniques have also been considered for applying resin pressure to the liquid resin and compressive pressure to the layup. [Background technology]

[0002] As composite parts become larger and more complex, the infusion duration may be longer, potentially exceeding the resin's processing time or exceeding the cycle time required by the manufacturing system. This may require that composite parts that would otherwise be produced by resin infusion or dry fiber processing be produced using alternative, suboptimal processing methods. The most common method of increasing the infusion pressure is resin transfer molding (RTM), where tooling is matched on both sides of the part. The tooling is held together by a press. This requires that the thickness and contour of the part be contained within the tooling on both sides of the part, which can lead to excessive tooling and equipment costs. In addition, RTM molding is difficult to apply to components with large surface areas because of the need to maintain tight tolerances under high pressure, and is generally limited to small structures.

[0003] Therefore, those skilled in the art continue to conduct research and development efforts to improve techniques related to resin impregnation in composite manufacturing. Summary of the Invention

[0004] Disclosed herein are examples of curing tool assemblies, methods, and systems for composite manufacturing. The following examples are non-exclusive examples of the subject matter of the present disclosure, and may include those that are or are not claimed.

[0005] In one embodiment, a curing tool assembly for composite manufacturing of the present disclosure includes a curing tool and a compression pressure chamber. The curing tool has a tool face configured for placement of a dry fabric laminate. The compression pressure chamber is configured to overlie the dry fabric laminate placed on the tool face of the curing tool. The compression pressure chamber is further configured to receive pressurized fluid from at least one compressed fluid source during resin impregnation of the dry fabric laminate. The pressurized fluid is received at a compression pressure greater than standard atmospheric pressure.

[0006] In one embodiment, the method for composite manufacturing of the present disclosure includes (1) subjecting liquid resin in at least one liquid resin source to a resin pressure greater than standard atmospheric pressure; and (2) flowing the liquid resin from the at least one liquid resin source in response to the resin pressure onto a dry fabric laminate disposed on a tool face of a curing tool. The dry fabric laminate is enclosed in an enclosed space. A compression pressure greater than the resin pressure is applied to the enclosed space. This embodiment further includes (3) impregnating the dry fabric laminate with the liquid resin in response to the resin pressure and the compression pressure.

[0007] In another embodiment, a method for composite manufacturing of the present disclosure includes: (1) placing a dry fabric laminate on a tool face of a curing tool; (2) placing a compression pressure chamber over the dry fabric laminate; (3) sealing the compression pressure chamber against the tool face over the dry fabric laminate to form an enclosed space between the compression pressure chamber and the tool face; and (4) supplying pressurized fluid from at least one compressed fluid source to the compression pressure chamber, the pressurized fluid being supplied at a compression pressure greater than standard atmospheric pressure. This embodiment further includes: (5) supplying liquid resin from at least one liquid resin source to the enclosed space; (6) subjecting the liquid resin to a resin pressure greater than standard atmospheric pressure and less than the compression pressure; (7) flowing the liquid resin from the at least one liquid resin source into the dry fabric laminate in response to the resin pressure; and (8) impregnating the dry fabric laminate with the liquid resin in response to the resin pressure and the compression pressure.

[0008] In one embodiment, the system for composite manufacturing of the present disclosure includes at least one compressed fluid source and a curing tool assembly. The curing tool assembly includes a curing tool, a fluid impermeable membrane, and a compression pressure chamber. The curing tool has a tool face configured for placing a dry fabric laminate. The fluid impermeable membrane is configured to overlie the dry fabric laminate placed on the tool face of the curing tool. The compression pressure chamber is configured to overlie the fluid impermeable membrane. The compression pressure chamber is further configured to receive pressurized fluid from the at least one compressed fluid source during resin impregnation of the dry fabric laminate. The pressurized fluid is received at a compression pressure greater than standard atmospheric pressure.

[0009] Other examples of cure tool assemblies, methods, and systems for composite manufacturing according to the present disclosure 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 functional diagram illustrating an example of a curing tool assembly for composite manufacturing. [Diagram 2] FIG. 13 is a functional diagram illustrating another example of a cure tool assembly including an exemplary inflatable bladder within a compression pressure chamber. [Diagram 3] FIG. 13 is a functional diagram illustrating yet another example of a curing tool assembly including a curing plate, a fluid impermeable membrane, and a seal that form a resin pressure chamber and a compression pressure chamber. [Figure 4] FIG. 13 is a functional diagram illustrating yet another example of a curing tool assembly including an exemplary inflatable bladder within a resin pressure chamber. [Diagram 5] FIG. 1 is a flow diagram illustrating an example method for composite manufacturing. [Figure 6] FIG. 6 is a flow diagram illustrating an example of a method for composite manufacturing in conjunction with FIG. [Figure 7] FIG. 6 is a flow diagram illustrating yet another example of a method for manufacturing a composite material in conjunction with FIG. [Figure 8] FIG. 6 is a flow diagram illustrating yet another example of a method for manufacturing a composite material in conjunction with FIG. [Figure 9] FIG. 9 is a flow diagram illustrating yet another example of a method for manufacturing a composite material in conjunction with FIGS. [Figure 10] FIG. 9 is a flow diagram illustrating yet another example of a method for manufacturing a composite material in conjunction with FIGS. [Figure 11] FIG. 9 is a flow diagram illustrating yet another example of a method for manufacturing a composite material in conjunction with FIGS. [Figure 12] FIG. 13 is a flow diagram illustrating yet another example of a method for composite manufacturing in conjunction with FIGS. [Figure 13] FIG. 13 is a flow diagram illustrating yet another example of a method for composite manufacturing in conjunction with FIGS. [Figure 14] FIG. 1 is a functional diagram illustrating an example of a system for composite manufacturing. [Figure 15]FIG. 1 shows a cross section of an example of a preformed dry fabric laminate, a wing skin / stringer panel preform, ready for resin impregnation with an exemplary curing tool assembly. [Figure 16] FIG. 13 shows a cross-section of an example of a preformed dry fabric laminate for an airfoil section with internal reinforcements, ready for resin impregnation with another example curing tool assembly. [Figure 17] FIG. 1 is a flow diagram illustrating another example of a method for composite manufacturing. [Figure 18] FIG. 1 is a block diagram illustrating an aircraft manufacturing and service method in which one or more example methods for composite manufacturing of the present disclosure may be implemented. [Figure 19] FIG. 1 illustrates a schematic diagram of an aircraft including one or more parts manufactured using one or more examples of the curing tool assemblies, methods, and systems for composite manufacturing of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Various embodiments of the curing tool assemblies, methods, and systems for composite manufacturing disclosed herein provide a technique for applying a compressive pressure to a dry fabric laminate during resin impregnation that is greater than standard atmospheric pressure, allowing for a resin pressure greater than standard atmospheric pressure and less than the compressive pressure to be applied to the liquid resin during resin impregnation, resulting in a more rapid and efficient resin impregnation compared to techniques that use lower compressive and resin pressures.

[0012] With reference to Figures 1-4, 15, and 16, the present disclosure relates to, by way of example, a curing tool assembly 100 for composite manufacturing. Figures 1-4 show several examples of curing tool assemblies 100. Figure 15 shows an example of a preform dry fabric layup for a wing skin / stringer panel, shown ready for resin impregnation. Figure 16 shows an example of a preform dry fabric layup for an airfoil section with internal stiffeners, shown ready for resin impregnation.

[0013] 1-4, 15, and 16, in one or more embodiments, a curing tool assembly 100 for composite manufacturing includes a curing tool 102 and a compression pressure chamber 110. The curing tool 102 has a tool face 104 configured for placement of a dry fabric laminate 106. The compression pressure chamber 110 is configured to cover the dry fabric laminate 106 placed on the tool face 104 of the curing tool 102. The compression pressure chamber 110 is further configured to receive a pressurized fluid 112 from at least one compressed fluid source 114 during resin impregnation of the dry fabric laminate 106. The pressurized fluid 112 is received at a compression pressure 148 that is greater than standard atmospheric pressure 150, which is a unit representing a typical mean atmospheric pressure at sea level. The standard atmospheric pressure 150 may be expressed as 14.696 psi, for example.

[0014] In another embodiment of the cure tool assembly 100, the dry fabric layup 106 comprises a preformed dry fabric layup. In yet another embodiment, the preformed dry fabric layup comprises multiple plies of dry fabric bonded together using a localized melted thermoplastic veil. In yet another embodiment, the preformed dry fabric layup is for a wing skin / stringer panel 1502 (FIG. 15). In yet another embodiment, the preformed dry fabric layup is for an airfoil section 1602 (FIG. 16) with internal stiffeners.

[0015] In yet another embodiment of the curing tool assembly 100, the compressed pressure 148 when the pressurized fluid 112 is received from the at least one compressed fluid source 114 is greater than about two times standard atmospheric pressure, greater than about three times standard atmospheric pressure, greater than about four times standard atmospheric pressure, or any other suitable pressure greater than standard atmospheric pressure 150. For example, a pressure of two times standard atmospheric pressure may be expressed as 29.392 psi, a pressure of three times standard atmospheric pressure may be expressed as 44.088 psi, and a pressure of four times standard atmospheric pressure may be expressed as 58.784 psi. In yet another embodiment, the compressed pressure 148 when the pressurized fluid 112 is received from the at least one compressed fluid source 114 is greater than a resin pressure 152 applied to the liquid resin 116 during resin impregnation of the dry fabric laminate 106. In yet another embodiment of the curing tool assembly 100, the pressurized fluid 112 may include compressed air, compressed nitrogen, compressed inert gas, or any other suitable pressurized fluid in any suitable combination.

[0016] In yet another embodiment, the curing tool assembly 100 further includes a fluid impermeable membrane 108 configured to cover the dry fabric laminate 106 placed on the tool face 104 of the curing tool 102. The fluid impermeable membrane 108 is disposed between the dry fabric laminate 106 and the compression pressure chamber 110.

[0017] In yet another embodiment, the fluid impermeable membrane 108 comprises a rubber material, a thermoplastic elastomer material, a reinforced polyimide, a fiber reinforced elastomer material, a fiberglass material, a silicone material, or any other suitable material in any suitable combination. In yet another embodiment, the fluid impermeable membrane 108 comprises a vacuum bag. In yet another embodiment of the curing tool assembly 100, the compression pressure chamber 110 is configured to apply a compressive force to the fluid impermeable membrane 108 and the dry fabric laminate 106 during resin impregnation in response to receiving the pressurized fluid 112.

[0018] In yet another embodiment, the curing tool assembly 100 further includes a curing plate 118 having a plate surface 120 facing the tool surface 104 of the curing tool 102. The curing plate 118 is configured to be clamped against the curing tool 102 during resin impregnation of the dry fabric laminate 106 to enclose the fluid impermeable membrane 108 and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. The curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate surface 120. In yet another embodiment, the curing plate 118 includes a metallic material. In yet another embodiment, the metallic material may be, for example, steel, stainless steel, cobalt chromium alloy, or any other suitable metallic material in any suitable combination.

[0019] In yet another embodiment, the curing tool assembly 100 further includes a seal 124 configured to be disposed between a peripheral portion 126 of the plate face 120 of the curing plate 118 and an adjacent portion 128 of the fluid impermeable membrane 108 during resin infiltration. The plate face 120, the seal 124, and the fluid impermeable membrane 108 cooperate with a cavity 122 defined by the curing plate 118 to form a compression pressure chamber 110. The curing plate 118 is configured to receive pressurized fluid 112 from at least one compressed fluid source 114 during resin infiltration and to supply pressurized fluid 112 to the compression pressure chamber 110 during resin infiltration.

[0020] In yet another embodiment of the stiffening tool assembly 100, the compression pressure chamber 110 includes at least one inflatable bladder 202, as shown in Figure 2. The stiffening plate 118 is configured to receive pressurized fluid 112 from the at least one compressed fluid source 114 and to supply pressurized fluid 112 to each of the at least one inflatable bladder 202.

[0021] In yet another embodiment of the curing tool assembly 100, the tool face 104 of the curing tool 102 includes one or more resin supply areas 302 that define at least one resin well 304, as shown in FIG. 3. The one or more resin supply areas 302 on the tool face 104 are spaced apart from a composite part area 306 also on the tool face 104. Each resin well 304 is configured to hold and supply liquid resin 116 during resin impregnation. The composite part area 306 is an area configured for receiving the dry fabric laminate 106.

[0022] In yet another embodiment, the curing tool assembly 100 further includes at least one resin pressure chamber 308 configured to overlie the at least one resin reservoir 304 of the curing tool 102. The at least one resin pressure chamber 308 is further configured to receive a second pressurized fluid 310 from the at least one compressed fluid source 114 during resin impregnation of the dry fabric laminate 106. The second pressurized fluid 310 is received at a resin pressure 152 that is greater than the standard atmospheric pressure 150 and less than the compression pressure 148 of the pressurized fluid 112 associated with the compression pressure chamber 110. The standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, the standard atmospheric pressure 150 is expressed as 14.696 psi.

[0023] In yet another embodiment, the curing tool assembly 100 further includes a curing plate 118 having a plate face 120 opposing the tool face 104 of the curing tool 102. The curing plate 118 is configured to be clamped against the curing tool 102 during resin infiltration of the dry fabric laminate 106 to enclose the fluid impermeable membrane 108, at least one resin pressure chamber 308, and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. The curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate face 120.

[0024] In yet another alternative embodiment, the curing tool assembly 100 includes a seal 124 and a second seal 312, as shown in FIG. 3. The seal 124 is configured to be disposed between a peripheral portion 126 of the plate surface 120 of the curing plate 118 and an adjacent portion 128 of the fluid impermeable membrane 108 during resin infiltration. The second seal 312 is configured to be disposed between the plate surface 120 of the curing plate 118 and the fluid impermeable membrane 108 to separate the at least one resin pressure chamber 308 from the compression pressure chamber 110 during resin infiltration. The plate surface 120, the seal 124, the second seal 312, and the fluid impermeable membrane 108 form the at least one resin pressure chamber 308 and the compression pressure chamber 110. The curing plate 118 is configured to receive the pressurized fluid 112 from the at least one compressed fluid source 114 and to supply the pressurized fluid 112 to the compression pressure chamber 110 during resin infiltration. The stiffening plate 118 is configured to receive a second pressurized fluid 310 from the at least one compressed fluid source 114 and is configured to supply the second pressurized fluid 310 to the at least one resin pressure chamber 308.

[0025] In yet another alternative embodiment of the curing tool assembly 100, the at least one resin pressure chamber 308 includes an expandable bladder 402, as shown in Figure 4. The curing plate 118 is configured to receive the second pressurized fluid 310 from the at least one compressed fluid source 114 and to supply the second pressurized fluid 310 to the expandable bladder 402.

[0026] 1, the curing tool assembly 100 further includes a seal 130 configured to be disposed between a peripheral portion 132 of the tool face 104 of the curing tool 102 and an adjacent portion 128 of the fluid impermeable membrane 108 during resin impregnation to form an enclosed space 134 around the dry fabric laminate 106. In yet another embodiment, the curing tool 102 is configured to receive the liquid resin 116 from at least one liquid resin source 136 during resin impregnation and to supply the liquid resin 116 to the enclosed space 134 during resin impregnation.

[0027] In yet another embodiment of the curing tool assembly 100, the liquid resin 116 is received at a resin pressure 152 that is greater than standard atmospheric pressure 150 and less than the compression pressure 148 of the pressurized fluid 112 associated with the compression pressure chamber 110. Standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, standard atmospheric pressure 150 is expressed as 14.696 psi. In yet another alternative embodiment, the at least one liquid resin source 136 includes one or more resin pressure pots 138, one or more resin injectors, or any other suitable source of liquid resin in any suitable combination.

[0028] In yet another embodiment of the curing tool assembly 100, the curing tool 102 is configured in fluid communication with at least one vacuum pump 140 to draw a vacuum on the enclosed space 134 during resin impregnation. In yet another alternative embodiment, the curing tool assembly 100 is configured to utilize a vacuum to draw the liquid resin 116 into the enclosed space 134 during resin impregnation. In yet another alternative embodiment, the curing tool assembly 100 is configured to utilize a vacuum to draw excess resin from the enclosed space 134 towards the at least one vacuum pump 140 for collection in a resin waste bin 142 during resin impregnation.

[0029] 1 and 17, the present disclosure relates, by way of example, to a method 1700 for composite manufacturing. Figure 1 illustrates an example of a curing tool assembly 100. Figure 17 illustrates a method 1700 for composite manufacturing.

[0030] 1 and 17, in one or more embodiments, a method 1700 for composite manufacturing includes applying 1702 a resin pressure 152 higher than standard atmospheric pressure 150 to liquid resin 116 in at least one liquid resin source 136. At 1704, the liquid resin 116 is caused to flow from the at least one liquid resin source 136 to a dry fabric laminate 106 disposed on a tool face 104 of a curing tool 102 in response to the resin pressure 152. At this time, the dry fabric laminate 106 is enclosed in an enclosed space 134. Also, a compression pressure 148 higher than the resin pressure 152 is applied to the enclosed space 134. At 1706, the dry fabric laminate 106 is impregnated with the liquid resin 116 in response to the resin pressure 152 and the compression pressure 148. Standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, 150 standard atmospheric pressure is expressed as 14.696 psi.

[0031] In other embodiments of the method 1700, the resin pressure 152 applied to the liquid resin 116 is greater than or equal to about 1.5 times standard atmospheric pressure, greater than or equal to about 2.5 times standard atmospheric pressure, greater than or equal to about 3.5 times standard atmospheric pressure, or any other suitable pressure greater than standard atmospheric pressure 150. For example, 1.5 times standard atmospheric pressure may be expressed as 22.044 psi, 2.5 times standard atmospheric pressure may be expressed as 36.74 psi, and 3.5 times standard atmospheric pressure may be expressed as 51.436 psi. In yet other embodiments of the method 1700, the compression pressure 148 applied to the enclosed space 134 is greater than or equal to about 2 times standard atmospheric pressure, greater than or equal to about 3 times standard atmospheric pressure, greater than or equal to about 4 times standard atmospheric pressure, or any other suitable pressure greater than standard atmospheric pressure 150. For example, two times standard atmospheric pressure can be represented as 29.392 psi, three times standard atmospheric pressure can be represented as 44.088 psi, and four times standard atmospheric pressure can be represented as 58.784 psi.

[0032] In yet another embodiment, the method 1700 further includes drawing 1708 a vacuum on the enclosed space 134. At 1710, excess resin that does not impregnate the dry fabric laminate 106 is drawn from the enclosed space 134 in response to the vacuum and collected in a waste resin bin 142.

[0033] Referring primarily to Figures 1-13, the present disclosure relates to methods 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300 for composite manufacturing, by way of example. Figures 1-4 show some examples of a curing tool assembly 100. Figure 5 shows a method 500 for composite manufacturing. Figure 6 shows a method 600 for composite manufacturing in conjunction with Figure 5. Figure 7 shows a method 700 for composite manufacturing in conjunction with Figure 5. Figure 8 shows a method 800 for composite manufacturing in conjunction with Figure 5. Figure 9 shows a method 900 for composite manufacturing in conjunction with Figures 5 and 8. Figure 10 shows a method 1000 for composite manufacturing in conjunction with Figures 5 and 8. Figure 11 shows a method 1100 for composite manufacturing in conjunction with Figures 5 and 8. Figure 12 illustrates a method 1200 for composite manufacturing in conjunction with Figures 5, 8, and 11. Figure 13 illustrates a method 1300 for composite manufacturing in conjunction with Figures 5, 8, and 11.

[0034] 1 and 5, in one or more embodiments, a method 500 for composite manufacturing includes placing 502 a dry fabric laminate 106 on a tool face 104 of a curing tool 102. At 504, a compression pressure chamber 110 is placed over the dry fabric laminate 106. At 506, the compression pressure chamber 110 is sealed against the tool face 104 above the dry fabric laminate 106 to form an enclosed space 134 between the compression pressure chamber 110 and the tool face 104. At 508, pressurized fluid 112 is provided from at least one compressed fluid source 114 to the compression pressure chamber 110, where the pressurized fluid 112 is provided at a compression pressure 148 that is greater than standard atmospheric pressure 150. At 510, liquid resin 116 is provided from at least one liquid resin source 136 to the enclosed space 134. At 512, the liquid resin 116 is subjected to a resin pressure 152 that is greater than the standard atmospheric pressure 150 and less than the compression pressure 148. At 514, the liquid resin 116 is caused to flow from at least one liquid resin source 136 to the dry fabric laminate 106 in response to the resin pressure 152. At 516, the dry fabric laminate 106 is impregnated with the liquid resin 116 in response to the resin pressure 152 and the compression pressure 148. The standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, the standard atmospheric pressure 150 is expressed as 14.696 psi.

[0035] 1, 5, and 6, in one or more embodiments, a method 600 for composite manufacturing includes the method 500 shown in FIG 5, which continues from 508 at 602, applying a compressive force to the dry fabric laminate 106 in response to supplying a pressurized fluid 112 to the compression pressure chamber 110. 602 of the method 600 then proceeds to 510 of FIG 5.

[0036] 1 and 5, in yet another embodiment of the method 500, the compression pressure 148 when the pressurized fluid 112 is provided to the compression pressure chamber 110 is greater than or equal to about two times standard atmospheric pressure, greater than or equal to about three times standard atmospheric pressure, greater than or equal to about four times standard atmospheric pressure, or any other suitable pressure greater than standard atmospheric pressure 150. For example, two times standard atmospheric pressure may be expressed as 29.392 psi, three times standard atmospheric pressure may be expressed as 44.088 psi, and four times standard atmospheric pressure may be expressed as 58.784 psi. In yet another embodiment, the compression pressure 148 when the pressurized fluid 112 is provided from the at least one compressed fluid source 114 is greater than a resin pressure 152 applied to the liquid resin 116 during resin impregnation of the dry fabric laminate 106. In yet another embodiment of the method 500, the at least one liquid resin source 136 includes one or more resin pressure pots 138. In yet another embodiment of the method 500, the at least one liquid resin source 136 includes one or more resin injectors.

[0037] 1, 5, and 7, in one or more embodiments, a method 700 for composite manufacturing includes the method 500 of FIG. 5, continuing from 516 to 702. Here, impregnating 516 with liquid resin 116 includes drawing 702 a vacuum on the enclosed space 134 during resin impregnation. Also, at 704, impregnating 516 with liquid resin further includes drawing 704 the liquid resin 116 into the enclosed space 134 during resin impregnation based at least in part on drawing 702. Also, at 706, impregnating 516 with liquid resin further includes drawing 706 excess resin from the enclosed space 134 towards at least one vacuum pump 140 for collection in waste resin bin 142 during resin impregnation.

[0038] 1, 5, and 8, in one or more embodiments, a method 800 for composite manufacturing includes the method 500 shown in FIG. 5, where at 802, continuing from 504, the method includes disposing a fluid impermeable membrane 108 over the dry fabric laminate 106 prior to disposing 504 a compression pressure chamber 110 over the dry fabric laminate 106. At 804, the fluid impermeable membrane 108 is sealed to the tool face 104 over the dry fabric laminate 106 to form an enclosed space 134 between the fluid impermeable membrane 108 and the tool face 104. At 806, the compression pressure chamber 110 is sealed to the fluid impermeable membrane 108 over the dry fabric laminate 106. 806 of the method 800 then proceeds to 508 of FIG. 5.

[0039] 1, 5, 8, and 9, in one or more embodiments, a method 900 for composite manufacturing includes the method 500 shown in FIG. 5 and the method 800 shown in FIG. 8, and continues from 802 at 902, the method includes placing a release film 144 on the dry fabric laminate 106 before placing 802 the fluid impermeable membrane 108, such that the release film 144 is located between the dry fabric laminate 106 and the fluid impermeable membrane 108. The release film 144 is also referred to as a peel layer. In another embodiment, the method 900 includes placing 904 a breathable cloth 146 on the release film 144 before placing 802 the fluid impermeable membrane 108, such that the breathable cloth 146 is located between the release film 144 and the fluid impermeable membrane 108. The breathable cloth 146 is also referred to as a resin flow control medium. The method 900 then proceeds from 904 to 804 of Figure 8. In another embodiment, the method 900 continues from 802 to 906 of Figure 8, where the method 900 includes, prior to placing 802 the fluid impermeable membrane 108, placing 906 a breathable cloth 146 over the dry fabric laminate 106 such that the breathable cloth 146 is positioned between the dry fabric laminate 106 and the fluid impermeable membrane 108. 906 of the method 900 then proceeds to 804 of Figure 8.

[0040] 1, 5, 8, and 10, in one or more embodiments, a method 1000 for composite manufacturing includes the method 500 shown in FIG. 5 and the method 800 shown in FIG. 8, continuing from 806, at 1002, the plate surface 120 of the curing plate 118 is positioned over the compression pressure chamber 110. The plate surface 120 faces the tool surface 104 of the curing tool 102. At 1004, the curing plate 118 is clamped against the curing tool 102 to enclose the dry fabric laminate 106, the fluid impermeable membrane 108, and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. The curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate surface 120.

[0041] In yet another embodiment, the method 1000 further includes sealing 1006 a peripheral portion 126 of the plate surface 120 of the stiffening plate 118 to an adjacent portion 128 of the fluid impermeable membrane 108. Based on the sealing 1006, the plate surface 120 and the fluid impermeable membrane 108 cooperate with the cavity 122 defined by the stiffening plate 118 to form a compressed pressure chamber 110. At 1008, pressurized fluid 112 is received at the stiffening plate 118 from at least one compressed fluid source 114. At 1010, the pressurized fluid 112 is delivered to the compressed pressure chamber 110 via the stiffening plate 118. The method 1000 1010 then proceeds to 508 of FIG. 5 .

[0042] In yet another embodiment of the method 1000, the compressed pressure chamber 110 includes at least one inflatable bladder 202 (FIG. 2). In this embodiment, the method 1000 continues from 1004 at 1012 with receiving pressurized fluid 112 at the stiffening plate 118 from at least one compressed fluid source 114. At 1014, the pressurized fluid 112 is delivered to each of the at least one inflatable bladder 202 via the stiffening plate 118. The method 1000 at 1014 then proceeds to 508 of FIG.

[0043] 1, 3, 5 and 8, in another embodiment of the method 800, the at least one liquid resin source 136 includes one or more resin reservoirs 304 defined by the tool face 104 of the curing tool 102, the resin reservoirs being included in one or more resin supply areas 302 on the tool face 104 spaced apart from composite part areas 306 on the tool face 104. Each resin reservoir 304 is configured to hold and supply liquid resin 116 to the dry fabric laminate 106 during resin impregnation. The dry fabric laminate 106 is disposed in the composite part area 306 on the tool face 104 of the curing tool 102.

[0044] Referring again to Figures 1, 3, 5, 8, and 11, in one or more embodiments, a method 1100 for composite manufacturing includes the method 500 shown in Figure 5 and the method 800 shown in Figure 8, and continues from 806 at 1102 by disposing at least one resin pressure chamber 308 above the at least one resin reservoir 304 of the curing tool 102. In another embodiment, the method 1100 further includes supplying 1104 a second pressurized fluid 310 from the at least one compressed fluid source 114 to the at least one resin pressure chamber 308. The second pressurized fluid 310 is supplied at a resin pressure 152 that is higher than standard atmospheric pressure 150 and lower than the compression pressure 148 of the pressurized fluid 112 supplied to the compression pressure chamber 110. Standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, standard atmospheric pressure 150 is expressed as 14.696 psi. In yet another embodiment, the method 1100 further includes positioning 1106 a plate surface 120 of a curing plate 118 over the at least one resin pressure chamber 308 and the compression pressure chamber 110. The plate surface 120 faces the tool surface 104 of the curing tool 102. At 1108, the curing plate 118 is clamped against the curing tool 102 to enclose the dry fabric laminate 106, the fluid impermeable membrane 108, the at least one resin pressure chamber 308, and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. In so doing, the curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate surface 120. The method 1100 at 1108 then proceeds to 510 of FIG.

[0045] 1 , 3 , 5 , 8 , 11 , and 12 , in one or more embodiments, a method 1200 for composite manufacturing includes method 500 shown in FIG 5 , method 800 shown in FIG 8 , and method 1100 shown in FIG 11 , and includes, at 1202, continuing from 1108, sealing a peripheral portion 126 of the plate surface 120 of the stiffening plate 118 to an adjacent portion 128 of the fluid impermeable membrane 108. At 1204, a central portion 314 of the plate surface 120 of the stiffening plate 118 to an adjacent portion 128 of the fluid impermeable membrane 108 to separate at least one resin pressure chamber 308 from the compression pressure chamber 110. Based on the seal 1202 of the periphery 126 and the seal 1204 of the central portion 314, the plate surface 120 and the fluid impermeable membrane 108 form a compression pressure chamber 110 over the dry fabric laminate 106 and at least one resin pressure chamber 308 over the at least one resin reservoir 304 and separate the at least one resin reservoir 304 from the compression pressure chamber 110. The compression pressure chamber 110 and the at least one resin pressure chamber 308 are formed in cooperation with the cavity 122 defined by the stiffening plate 118. At 1206, a pressurized fluid 112 is received at the stiffening plate 118 from the at least one compressed fluid source 114. At 1208, the pressurized fluid 112 is supplied to the compression pressure chamber 110 through the stiffening plate 118. At 1210, a second pressurized fluid 310 is received at the stiffening plate 118 from the at least one compressed fluid source 114. At 1212, the second pressurized fluid 310 is supplied to the at least one resin pressure chamber 308 through the stiffening plate 118. The method 1200 at 1212 then proceeds to 510 of FIG.

[0046] 1, 3, 5, 8, 11, and 13, in one or more embodiments, a method 1300 for composite manufacturing includes the method 500 shown in FIG. 5, the method 800 shown in FIG. 8, and the method 1100 shown in FIG. 11. In the method 1300, the at least one resin pressure chamber 308 includes an expandable bladder 402. The method 1300 continues from 1108 of FIG. 11 at 1302 with receiving a second pressurized fluid 310 from at least one compressed fluid source 114 at the stiffening plate 118. At 1304, the second pressurized fluid 310 is delivered to the expandable bladder 402 through the stiffening plate 118. The method 1300 1304 then proceeds to 510 shown in FIG. 5.

[0047] Referring primarily to Figures 1-4 and 14, the present disclosure relates to, by way of example, a system 1400 for composite manufacturing. Figures 1-4 show several examples of cured tool assemblies 100. Figure 14 shows the system 1400 for composite manufacturing.

[0048] 1-4 and 14, in one or more embodiments, a system 1400 for composite manufacturing includes at least one compressed fluid source 114 and a curing tool assembly 100. The curing tool assembly 100 includes a curing tool 102, a fluid impermeable membrane 108, and a compression pressure chamber 110. The curing tool 102 has a tool face 104 configured for placing a dry fabric laminate 106. The fluid impermeable membrane 108 is configured to overlie the dry fabric laminate 106 placed on the tool face 104 of the curing tool 102. The compression pressure chamber 110 is configured to overlie the fluid impermeable membrane 108. The compression pressure chamber 110 is further configured to receive a pressurized fluid 112 from the at least one compressed fluid source 114 during resin impregnation of the dry fabric laminate 106. The pressurized fluid 112 is received at a compression pressure 148 that is greater than standard atmospheric pressure 150. Standard atmospheric pressure 150 is a unit of average atmospheric pressure at sea level. For example, standard atmospheric pressure 150 is expressed as 14.696 psi.

[0049] In another embodiment of the system 1400, the dry fabric laminate 106 comprises a preformed dry fabric laminate. In yet another embodiment, the preformed dry fabric laminate comprises a plurality of plies of dry fabric bonded together using a localized melting thermoplastic veil. In yet another embodiment of the system 1400, the fluid impermeable membrane 108 comprises a rubber material, a thermoplastic elastomer material, a reinforced polyimide, a fiber reinforced elastomer material, a fiberglass material, a silicone material, or any other suitable material in any suitable combination. In yet another embodiment of the system 1400, the fluid impermeable membrane 108 comprises a vacuum bag. In yet another embodiment of the system 1400, the compression pressure chamber 110 is configured to apply a compression force to the fluid impermeable membrane 108 and the dry fabric laminate 106 during resin impregnation in response to receiving the pressurized fluid 112.

[0050] In yet another embodiment of the system 1400, the compressed pressure 148 when the pressurized fluid 112 is received from the at least one compressed fluid source 114 is greater than about two times standard atmospheric pressure, greater than about three times standard atmospheric pressure, greater than about four times standard atmospheric pressure, or any other suitable pressure greater than standard atmospheric pressure 150. For example, two times standard atmospheric pressure may be expressed as 29.392 psi, three times standard atmospheric pressure may be expressed as 44.088 psi, and four times standard atmospheric pressure may be expressed as 58.784 psi. In yet another embodiment, the compressed pressure 148 when the pressurized fluid 112 is received from the at least one compressed fluid source 114 is greater than the resin pressure applied to the liquid resin 116 during resin impregnation of the dry fabric laminate 106. The pressurized fluid 112 in the system 1400 in yet another embodiment may include compressed air, compressed nitrogen, compressed inert gas, or any other suitable pressurized fluid in any suitable combination.

[0051] In yet another embodiment of the system 1400, the curing tool assembly 100 further includes a release film 144 configured to be placed over the dry fabric laminate 106 before the fluid impermeable membrane 108 is placed over the dry fabric laminate 106. In yet another embodiment of the system 1400, the curing tool assembly 100 further includes a breathable cloth 146 ( FIG. 1 ) configured to be placed over the dry fabric laminate 106 before the fluid impermeable membrane 108 is placed over the dry fabric laminate 106.

[0052] In yet another embodiment of the system 1400, the curing tool assembly 100 further includes a curing plate 118 having a plate surface 120 opposing the tool surface 104 of the curing tool 102. The curing plate 118 is configured to be clamped against the curing tool 102 during resin impregnation of the dry fabric laminate 106 to enclose the fluid impermeable membrane 108 and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. The curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate surface 120. In yet another embodiment, the curing plate 118 includes a metallic material. In yet another embodiment, the metallic material includes, for example, steel, stainless steel, cobalt chromium alloy, or any other suitable metallic material in any suitable combination.

[0053] In yet another embodiment, the curing tool assembly 100 further includes a seal 124 configured to be disposed between a peripheral portion 126 of the plate surface 120 of the curing plate 118 and an adjacent portion 128 of the fluid impermeable membrane 108 during resin infiltration. The plate surface 120, the seal 124, and the fluid impermeable membrane 108 cooperate with a cavity 122 defined by the curing plate 118 to form a compression pressure chamber 110. The curing plate 118 is configured to receive pressurized fluid 112 from at least one compressed fluid source 114 during resin infiltration and to supply pressurized fluid 112 to the compression pressure chamber 110 during resin infiltration.

[0054] In yet another embodiment, the compressed pressure chamber 110 includes at least one inflatable bladder 202. The stiffening plate 118 is configured to receive pressurized fluid 112 from the at least one compressed fluid source 114 and to supply the pressurized fluid 112 to each of the at least one inflatable bladder 202.

[0055] In yet another embodiment of the system 1400, the tool face 104 of the curing tool 102 includes one or more resin supply areas 302 that define at least one resin reservoir 304. The one or more resin supply areas 302 are spaced apart from a composite part area 306 on the tool face 104. Each resin reservoir 304 is configured to hold and supply liquid resin 116 during resin impregnation. The composite part area 306 is an area configured for placement of the dry fabric laminate 106.

[0056] In yet another embodiment, the curing tool assembly 100 further includes at least one resin pressure chamber 308 configured to cover the at least one resin reservoir 304 of the curing tool 102. The at least one resin pressure chamber 308 is further configured to receive a second pressurized fluid 310 from the at least one compressed fluid source 114 during resin impregnation of the dry fabric laminate 106. The second pressurized fluid 310 is received at a resin pressure that is greater than the standard atmospheric pressure 150 and less than the compression pressure 148 of the pressurized fluid 112 associated with the compression pressure chamber 110. The standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, the standard atmospheric pressure 150 is expressed as 14.696 psi.

[0057] In yet another embodiment, the curing tool assembly 100 further includes a curing plate 118 having a plate face 120 opposing the tool face 104 of the curing tool 102. The curing plate 118 is configured to be clamped against the curing tool 102 during resin infiltration of the dry fabric laminate 106 to enclose the fluid impermeable membrane 108, at least one resin pressure chamber 308, and the compression pressure chamber 110 between the curing tool 102 and the curing plate 118. The curing plate 118 defines a cavity 122 between the fluid impermeable membrane 108 and the plate face 120.

[0058] In yet another embodiment, the curing tool assembly 100 includes a seal 124 and a second seal 312. The seal 124 is configured to be disposed between a peripheral portion 126 of the plate surface 120 of the curing plate 118 and an adjacent portion 128 of the fluid impermeable membrane 108 during resin infusion. The second seal 312 is configured to be disposed between the plate surface 120 of the curing plate 118 and the fluid impermeable membrane 108 during resin impregnation to separate the at least one resin pressure chamber 308 from the compression pressure chamber 110. The plate surface 120, the seal 124, the second seal 312, and the fluid impermeable membrane 108 form the at least one resin pressure chamber 308 and the compression pressure chamber 110. The curing plate 118 is configured to receive the pressurized fluid 112 from the at least one compressed fluid source 114 and to supply the pressurized fluid 112 to the compression pressure chamber 110. The stiffening plate 118 is configured to receive a second pressurized fluid 310 from the at least one compressed fluid source 114 and is configured to supply the second pressurized fluid 310 to the at least one resin pressure chamber 308.

[0059] In yet another embodiment, the at least one resin pressure chamber 308 includes an expandable bladder 402. The stiffening plate 118 is configured to receive the second pressurized fluid 310 from the at least one compressed fluid source 114 and to supply the second pressurized fluid 310 to the expandable bladder 402.

[0060] In yet another embodiment of the system 1400, the curing tool assembly 100 further includes a seal 130 that is configured to be positioned between a peripheral portion 132 of the tool face 104 of the curing tool 102 and an adjacent portion 128 of the fluid-impermeable membrane 108 during resin impregnation to form a sealed space 134 around the dry fabric laminate 106.

[0061] In yet another embodiment, the system 1400 further includes at least one liquid resin source 136 configured to supply liquid resin 116 to the curing tool 102 during resin impregnation. The curing tool 102 is configured to supply liquid resin 116 from the at least one liquid resin source 136 to the enclosed space 134 during resin impregnation.

[0062] In yet another embodiment, the liquid resin 116 is received at a resin pressure that is greater than standard atmospheric pressure 150 and less than the compression pressure 148 of the pressurized fluid 112 associated with the compression pressure chamber 110. Standard atmospheric pressure 150 is a unit that represents the average atmospheric pressure at sea level. For example, standard atmospheric pressure 150 is expressed as 14.696 psi. In yet another embodiment, the at least one source of liquid resin 136 includes one or more resin pressure pots 138, one or more resin injectors, or any other suitable source of liquid resin in any suitable combination.

[0063] In yet another embodiment, the system 1400 further includes at least one vacuum pump 140 in fluid communication with the curing tool 102 and configured to evacuate the enclosed space 134 during resin impregnation. In yet another embodiment, the system 1400 is configured to utilize a vacuum to draw the liquid resin 116 into the enclosed space 134 during resin impregnation. In yet another embodiment, the system 1400 further includes a waste resin container 142 in fluid communication with the at least one vacuum pump 140 and the curing tool 102 and configured to receive and collect excess resin from the enclosed space 134 in response to the evacuation of the enclosed space 134.

[0064] Each of the embodiments of the curing tool assembly 100, methods 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1700, and system 1400 for composite manufacturing may be used in connection with the manufacture of aircraft. Although an aircraft example is described, the embodiments and principles disclosed herein may be applicable to other products in the aerospace industry, as well as products in other industries, such as automotive, space, construction, design and manufacturing, etc. Thus, in addition to aircraft, the embodiments and principles disclosed herein may be applicable to the use of composite members in the manufacture of various types of vehicles and in the construction of various types of buildings.

[0065] In the above detailed description, reference is made to the accompanying drawings, which show certain examples of the present disclosure. However, other embodiments, including different structures and processes, do not depart from the scope of the present disclosure. Also, the same reference numerals may be used for the same features, elements, or parts in different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually or collectively as the items and may be referred to using the same reference numerals. In addition, in the present disclosure, a feature, element, part, or step described in the singular does not necessarily exclude a plurality of features, elements, parts, or steps, unless specifically stated otherwise.

[0066] The above description is illustrative and non-exclusive examples of the subject matter of the present disclosure, including, but not limited to, those described in the claims. In this context, "example" means that one or more features, structures, elements, components, properties, and / or process steps described in connection with an example are included in at least one aspect, embodiment, and / or implementation of the subject matter of the present disclosure. Thus, throughout this disclosure, phrases such as "one example," "another example," "one or more examples," and the like may, but are not required to, refer to the same example. Also, subject matter characterizing any one example may, but is not required to, include subject matter characterizing any other example. In addition, subject matter characterizing any one example may, but is not required to, be combined with subject matter representing any other example.

[0067] As used herein, a system, apparatus, device, structure, article, element, part, or hardware that is "configured" to perform a particular function refers to one that can perform the particular function without any modification, and not one that could be modified to perform the particular function. In other words, a system, apparatus, device, structure, article, element, part, or hardware that is "configured" to perform a particular function refers to one that is specifically selected, made, implemented, utilized, programmed, and / or designed to perform the particular function. As used herein, "configured" refers to a characteristic that the system, apparatus, structure, article, element, part, or hardware already possesses that enables the system, apparatus, structure, article, element, part, or hardware to perform the particular function without any modification. In this disclosure, a system, apparatus, device, structure, article, element, part, or hardware that is "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operable" to perform the particular function.

[0068] Unless otherwise specified, the terms "first," "second," "third," etc., used herein are merely used as labels and do not impose any order, position, or hierarchical requirements on the elements to which they refer. In addition, referring to an element as, for example, a "second" does not require or exclude the presence of a lower ordinal item, such as, for example, a "first," or a higher ordinal item, such as, for example, a "third."

[0069] In this specification, the phrase "at least one of" is used in reference to a list of items to mean that one or more of the listed items may be used in various combinations, and that only one of each of the listed items may be required. For example, the phrase "at least one of item A, item B, and item C" includes, but is not limited to, item A, or item A and item B. It also includes item A, item B, and item C, or item B and item C. In other examples, "at least one of" includes, but is not limited to, 2 item A, 1 item B, and 10 item C, 4 item B, and 7 item C, or other suitable combinations. In this specification, when the term "and / or" or the symbol " / " is used, all combinations of one or more of the listed items are included.

[0070] In this disclosure, terms such as "connected," "connect," and the like, mean that two or more elements are joined, coupled, fixed, attached, connected, placed in communication with one another, or otherwise associated with one another (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various embodiments, the elements are associated directly or indirectly. In one example, element A is directly associated with element B. In another example, element A is indirectly associated with element B, e.g., through another element C. It is noted that not all associations are shown between the various disclosed elements. Thus, connections other than those shown may be included.

[0071] In this specification, the term "about" refers to a state that is not exactly the same as the described state, but is close to the described state and can perform the desired function or achieve the desired result. For example, the term "about" refers to a state that is within an acceptable range of a certain tolerance or precision, for example, within 10% of the described state. However, the term "about" does not exclude a state that is exactly the same as the described state. In this specification, the term "substantially" refers to a state that is essentially the same as the described state and can perform the desired function or achieve the desired result.

[0072] 1-4 and 14-17 referred to in the above description may depict functional elements, features, or components, but this does not necessarily imply a particular structure. Thus, modifications, additions, and / or omissions may be made to the depicted structures. In addition, as will be appreciated by those skilled in the art, not all of the elements, features, and / or components depicted and described in FIGS. 1-4 and 14-17 are necessarily included in every embodiment, and not all of the described elements, features, and / or components are necessarily depicted in every embodiment. Thus, some of the elements, features, and / or components depicted and described in FIGS. 1-4 and 14-17 may be combined in various ways, whether or not explicitly shown herein, without necessarily including other elements, features, and / or components depicted and described in FIGS. 1-4 and 14-17. Similarly, some or all of the features depicted and described herein may be combined with additional features, not limited to the embodiments presented herein. Unless otherwise stated, the schematic embodiments shown in FIGS. 1-4 and 14-17 referred to in the above description do not imply any structural limitations with respect to these exemplary embodiments. Rather, it should be understood that exemplary structures are shown, but that the structures can be modified as appropriate. Thus, the illustrated structures can be modified, added, and / or omitted. Furthermore, in each of FIGS. 1-4 and 14-17, elements, features, and / or parts that perform similar or at least substantially similar purposes are labeled with the same reference numerals, and in addition, detailed descriptions of such elements, features, and / or parts with reference to each of FIGS. 1-4 and 14-17 may be omitted. Similarly, not all elements, features, and / or parts are labeled with reference numerals in FIGS. 1-4 and 14-17, but may still be labeled with reference numerals for consistency in the relevant descriptions.

[0073] The blocks in FIG. 5-FIG. 13 and FIG. 17 referred to in the above description represent processes, steps, and / or portions of processes or steps, but the lines connecting the various blocks do not imply a particular order or dependency relationship between the related processes or portions of processes. It should be noted that not all dependencies between the various processes disclosed are necessarily shown. The descriptions in FIG. 5-FIG. 13 and FIG. 17 and the description of the processes of the method described herein do not necessarily dictate the order in which these processes are performed. Rather, one exemplary order is shown, but it should be understood that the order in which these processes are performed can be changed as appropriate. Thus, the illustrated processes can be modified, added, and / or omitted, and some processes can be performed in a different order or simultaneously. In addition, it will be understood by those skilled in the art that not all processes need to be performed.

[0074] Furthermore, references to features and advantages and similar language throughout this specification do not imply that all features and advantages achieved by the embodiments disclosed herein are or should be included in any one embodiment. Rather, when a particular feature, advantage, or characteristic is described in connection with an embodiment, it means that the feature, advantage, or characteristic is included in at least one embodiment. Thus, descriptions of features and advantages and similar language used throughout this disclosure may, but do not necessarily, refer to the same embodiment.

[0075] An embodiment of the subject matter of the present disclosure may be described in conjunction with an aircraft manufacturing and maintenance method 1800 shown in FIG. 18 and an aircraft 1900 shown in FIG. 19. In one or more examples, the methods and systems of the present disclosure may be used in the manufacture of aircraft. Before production begins, the maintenance method 1800 includes the steps of specification and design (block 1802) and material procurement (block 1804) of the aircraft 1900. During production, parts and subassemblies of the aircraft 1900 are manufactured (block 1806) and systems integrated (block 1808). The aircraft 1900 then undergoes certification and delivery (block 1810) and enters a period of service (block 1812). While in service, the aircraft 1900 undergoes routine maintenance and maintenance (block 1814). The routine maintenance and maintenance may include upgrading, reconfiguring, modifying, etc., one or more systems of the aircraft 1900.

[0076] Each step in aircraft maintenance method 1800 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). 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 include, but is not limited to, an airline, a leasing company, a military entity, a service organization, and the like.

[0077] As shown in FIG. 19 , the aircraft 1900 produced by the maintenance method 1800 includes an airframe 1902 with a number of high level systems 1904 and an interior 1906. Examples of the high level systems 1904 include one or more of a propulsion system 1908, an electrical system 1910, a hydraulic system 1912, and an environmental system 1914, as well as any number of other systems. It should be noted that while an example aerospace application has been described, the principles of the present disclosure may be applied to other industries, such as the automotive industry. Thus, the principles disclosed herein may be applied not only to the aircraft 1900, but also to other types of vehicles, such as land vehicles, watercraft, and spacecraft, for example.

[0078] Methods and systems of the present disclosure may be employed during any one or more stages of aircraft manufacturing and service method 1800. For example, parts or subassemblies corresponding to parts and subassemblies manufacturing (block 1806) may be manufactured or produced in the same manner as parts or subassemblies produced during the in-service life of aircraft 1900 (block 1812). Also, one or more example systems, methods, or combinations thereof may be used during the production stage (blocks 1806 and 1808), which may, for example, significantly improve the speed and cost of assembly of aircraft 1900. Similarly, one or more example systems, method embodiments, or combinations thereof may be used during, for example, but not limited to, the in-service life of aircraft 1900 (block 1812) and during maintenance and service (block 1814).

[0079] Features, advantages, and characteristics described in this disclosure with respect to one embodiment may be combined in any suitable manner in one or more other embodiments. Additionally, 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. Additionally, not all embodiments may include additional features and advantages included in a particular embodiment. Additionally, while various embodiments of the curing tool assembly 100, methods 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, and 1700, and system 1400 for composite manufacturing have been shown and disclosed, various modifications will occur to those skilled in the art in light of this disclosure. The present application is intended to include such modifications and is limited only by the scope of the appended claims.

[0080] The present disclosure also includes the following notes:

[0081] Appendix 1. a curing tool (102) having a tool face (104) configured for placement of a dry fabric laminate (106); a compression pressure chamber (110) configured to cover the dry fabric laminate (106) placed on the tool face (104) of the curing tool (102), the compression pressure chamber (110) further configured to receive pressurized fluid (112) from at least one compressed fluid source (114) during resin impregnation of the dry fabric laminate (106), the pressurized fluid (112) being received at a compression pressure (148) greater than standard atmospheric pressure (150).

[0082] Appendix 2. 2. The curing tool assembly of claim 1, wherein the dry fabric laminate (106) comprises a preformed dry fabric laminate.

[0083] Appendix 3. 3. The curing tool assembly of claim 2, wherein the preformed dry fabric laminate comprises a plurality of plies of dry fabric bonded together using a locally melted thermoplastic veil.

[0084] Appendix 4. 3. The cure tool assembly of claim 2, wherein the preformed dry fabric laminate is for a wing skin / stringer panel (1502).

[0085] Appendix 5. 3. The curing tool assembly of claim 2, wherein the preformed dry fabric laminate is for an airfoil section with internal reinforcements (1602).

[0086] Appendix 6. 2. The hardening tool assembly of claim 1, wherein the compressed pressure (148) when the pressurized fluid (112) is received from the at least one compressed fluid source (114) is at least one of: greater than or equal to about two times standard atmospheric pressure, greater than or equal to about three times standard atmospheric pressure, and greater than or equal to about four times standard atmospheric pressure.

[0087] Appendix 7. 7. The curing tool assembly of claim 6, wherein the compression pressure (148) when the pressurized fluid (112) is received from the at least one compressed fluid source (114) is higher than a resin pressure (152) applied to a liquid resin (116) during resin impregnation into the dry fabric laminate (106).

[0088] Appendix 8. 2. The hardening tool assembly of claim 1, wherein the pressurized fluid (112) comprises at least one of compressed air, compressed nitrogen, and compressed inert gas.

[0089] Appendix 9. 2. The hardening tool assembly of claim 1, further comprising a fluid-impermeable membrane (108) configured to cover the dry fabric laminate (106) placed on the tool face (104) of the hardening tool (102), the fluid-impermeable membrane (108) being disposed between the dry fabric laminate (106) and the compression pressure chamber (110).

[0090] Appendix 10. 10. The curing tool assembly of claim 9, wherein the fluid impermeable membrane (108) comprises at least one of a rubber material, a thermoplastic elastomer material, a reinforced polyimide, a fiber reinforced elastomer material, a fiberglass material, and a silicone material.

[0091] Appendix 11. 10. The curing tool assembly of claim 9, wherein the fluid impermeable membrane (108) comprises a vacuum bag.

[0092] Appendix 12. 10. The curing tool assembly of claim 9, wherein the compression pressure chamber (110) is configured to apply a compressive force to the fluid impermeable membrane (108) and the dry fabric laminate (106) in response to receiving the pressurized fluid (112) during the resin impregnation.

[0093] Appendix 13. 10. The curing tool assembly of claim 9, further comprising a curing plate (118) having a plate surface (120) facing the tool surface (104) of the curing tool (102), the curing plate (118) configured to be clamped against the curing tool (102) during resin impregnation of the dry fabric laminate (106) to enclose the fluid-impermeable membrane (108) and the compression pressure chamber (110) between the curing tool (102) and the curing plate (118), the curing plate (118) defining a cavity (122) between the fluid-impermeable membrane (108) and the plate surface (120).

[0094] Appendix 14. 14. The hardening tool assembly of claim 13, wherein the hardening plate (118) comprises a metallic material.

[0095] Appendix 15. 15. The hardened tool assembly of claim 14, wherein the metallic material comprises at least one of steel, stainless steel, and cobalt chromium alloy.

[0096] Appendix 16. a seal (124) configured to be disposed between a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) and an adjacent portion (128) of the fluid-impermeable membrane (108) during the resin impregnation; 14. The curing tool assembly of claim 13, wherein the plate surface (120), the seal (124), and the fluid-impermeable membrane (108) cooperate with the cavity (122) defined by the curing plate (118) to form the compression pressure chamber (110), the curing plate (118) being configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) during the resin impregnation and to supply the pressurized fluid (112) to the compression pressure chamber (110) during the resin impregnation.

[0097] Appendix 17. The compression pressure chamber (110) 14. The hardening tool assembly of claim 13, comprising at least one inflatable bladder (202), wherein the hardening plate (118) is configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) and to supply the pressurized fluid (112) to each of the at least one inflatable bladder (202).

[0098] Appendix 18. The tool face (104) of the hardening tool (102) is 10. The curing tool assembly of claim 9, comprising one or more resin supply areas (302) defining at least one resin reservoir (304), the one or more resin supply areas (302) on the tool face (104) spaced apart from a composite part area (306) on the tool face (104), each resin reservoir (304) configured to hold and supply liquid resin (116) during the resin impregnation, the composite part area (306) configured to receive the dry fabric laminate (106).

[0099] Appendix 19. 19. The curing tool assembly of claim 18, further comprising at least one resin pressure chamber (308) configured to cover the at least one resin reservoir (304) of the curing tool (102), the at least one resin pressure chamber (308) being further configured to receive a second pressurized fluid (310) from the at least one compressed fluid source (114) during resin impregnation of the dry fabric laminate (106), the second pressurized fluid (310) being received at a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148) of the pressurized fluid (112) associated with the compression pressure chamber (110).

[0100] Appendix 20. 20. The curing tool assembly of claim 19, further comprising a curing plate (118) having a plate surface (120) facing the tool surface (104) of the curing tool (102), the curing plate (118) configured to be clamped against the curing tool (102) during resin impregnation of the dry fabric laminate (106) to enclose the fluid impermeable membrane (108), the at least one resin pressure chamber (308), and the compression pressure chamber (110) between the curing tool (102) and the curing plate (118), the curing plate (118) defining a cavity (122) between the fluid impermeable membrane (108) and the plate surface (120).

[0101] Appendix 21. a seal (124) configured to be disposed between a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) and an adjacent portion (128) of the fluid-impermeable membrane (108) during the resin impregnation; a second seal (312) configured to be disposed between the plate face (120) of the curing plate (118) and the fluid impermeable membrane (108) during the resin impregnation to separate the at least one resin pressure chamber (308) from the compression pressure chamber (110); 21. The curing tool assembly of claim 20, wherein the plate face (120), the seal (124), the second seal (312), and the fluid impermeable membrane (108) form the at least one resin pressure chamber (308) and the compression pressure chamber (110), the curing plate (118) is configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) and supply the pressurized fluid (112) to the compression pressure chamber (110), and the curing plate (118) is configured to receive the second pressurized fluid (310) from the at least one compressed fluid source (114) and supply the second pressurized fluid (310) to the at least one resin pressure chamber (308).

[0102] Appendix 22. The at least one resin pressure chamber (308) 21. The hardening tool assembly of claim 20, comprising an inflatable bladder (402), wherein the hardening plate (118) is configured to receive the second pressurized fluid (310) from the at least one compressed fluid source (114) and to supply the second pressurized fluid (310) to the inflatable bladder (402).

[0103] Appendix 23. 10. The curing tool assembly of claim 9, further comprising a seal (130) configured to be disposed between a peripheral portion (132) of the tool face (104) of the curing tool (102) and an adjacent portion (128) of the fluid-impermeable membrane (108) during the resin impregnation to form an enclosed space (134) around the dry fabric laminate (106).

[0104] Appendix 24. 24. The curing tool assembly of claim 23, wherein the curing tool (102) is configured to receive liquid resin (116) from at least one liquid resin source (136) during the resin impregnation and to supply the liquid resin (116) to the enclosed space (134) during the resin impregnation.

[0105] Appendix 25. 25. The curing tool assembly of claim 24, wherein the liquid resin (116) is received at a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148) of the pressurized fluid (112) associated with the compression pressure chamber (110).

[0106] Appendix 26. 26. The curing tool assembly of claim 25, wherein the at least one liquid resin source (136) includes at least one of: one or more resin pressure pots (138) and one or more resin injectors.

[0107] Appendix 27. 25. The curing tool assembly of claim 24, wherein the curing tool (102) is in fluid communication with at least one vacuum pump (140) configured to evacuate the sealed space (134) during the resin impregnation.

[0108] Appendix 28. 28. The curing tool assembly of claim 27, wherein the curing tool assembly (100) is configured to utilize the vacuum to draw the liquid resin (116) into the enclosed space (134) during the resin impregnation.

[0109] Appendix 29. 28. The curing tool assembly of claim 27, wherein the curing tool assembly (100) is configured to use the vacuum to draw excess resin from the enclosed space (134) toward the at least one vacuum pump (140) during the resin impregnation and collect it in a waste resin container (142).

[0110] Appendix 30. applying (1702) a resin pressure (152) to liquid resin (116) in at least one liquid resin source (136) that is greater than standard atmospheric pressure (150); flowing the liquid resin (116) from the at least one liquid resin source (136) into a dry fabric laminate (106) disposed on a tool face (104) of a curing tool (102) in response to the resin pressure (152), wherein the dry fabric laminate (106) is enclosed (1704) in an enclosed space (134) to which a compressive pressure (148) higher than the resin pressure (152) is applied; and impregnating (1706) the dry fabric laminate (106) with the liquid resin (116) in response to the resin pressure (152) and the compaction pressure (148).

[0111] Appendix 31. 31. The method of claim 30, wherein the resin pressure (152) applied to the liquid resin (116) is at least one of about 1.5 times standard atmospheric pressure or more, about 2.5 times standard atmospheric pressure or more, and about 3.5 times standard atmospheric pressure or more.

[0112] Appendix 32. 31. The method of claim 30, wherein the compressive pressure (148) applied to the enclosed space (134) is at least one of about two times standard atmospheric pressure or more, about three times standard atmospheric pressure or more, and about four times standard atmospheric pressure or more.

[0113] Appendix 33. drawing a vacuum (1708) from the enclosed space (134); 31. The method of claim 30, further comprising: drawing (1710) excess resin that is not impregnated into the dry fabric laminate (106) from the enclosed space (134) in response to the vacuum and collecting it in a waste resin bin (142).

[0114] Appendix 34. Placing (502) a dry fabric laminate (106) on a tool face (104) of a curing tool (102); placing (504) a compression pressure chamber (110) over the dry fabric laminate (106); sealing (506) the compression pressure chamber (110) against the tool face (104) above the dry fabric laminate (106) to form an enclosed space (134) between the compression pressure chamber (110) and the tool face (104); providing (508) pressurized fluid (112) from at least one compressed fluid source (114) to the compression pressure chamber (110), the pressurized fluid (112) being provided at a compression pressure (148) greater than standard atmospheric pressure (150); providing (510) liquid resin (116) from at least one liquid resin source (136) to the enclosed space (134); subjecting the liquid resin (116) to a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148); flowing (514) the liquid resin (116) from the at least one liquid resin source (136) onto a dry fabric laminate (106) in response to the resin pressure (152); and impregnating (516) the dry fabric laminate (106) with the liquid resin (116) in response to the resin pressure (152) and the compaction pressure (148).

[0115] Appendix 35. 35. The method (600) of claim 34, further comprising applying a compressive force (602) to the dry fabric laminate (106) in response to providing the pressurized fluid (112) to the compression pressure chamber (110).

[0116] Appendix 36. 35. The method of claim 34, wherein the compression pressure (148) when the pressurized fluid (112) is supplied to the compression pressure chamber (110) is at least one of: greater than or equal to about two times standard atmospheric pressure, greater than or equal to about three times standard atmospheric pressure, and greater than or equal to about four times standard atmospheric pressure.

[0117] Appendix 37. 37. The method of claim 36, wherein the compression pressure (148) when the pressurized fluid (112) is supplied from the at least one compressed fluid source (114) is higher than the resin pressure (152) applied to the liquid resin (116) for resin impregnation into the dry fabric laminate (106).

[0118] Appendix 38. 35. The method of claim 34, wherein the at least one liquid resin source (136) includes one or more resin pressure pots (138).

[0119] Appendix 39. 40. The method of claim 38, wherein the at least one liquid resin source (136) comprises one or more resin injectors.

[0120] Appendix 40. 35. The method (700) of claim 34, wherein impregnating (516) the liquid resin (116) includes drawing a vacuum (702) in the sealed space (134) during resin impregnation.

[0121] Appendix 41. The impregnation (516) of the liquid resin (116) includes: 41. The method of claim 40, further comprising drawing (704) the liquid resin (116) into the enclosed space (134) during the resin impregnation based at least in part on the drawing (702).

[0122] Appendix 42. The impregnation (516) of the liquid resin (116) includes: 41. The method of claim 40, further comprising drawing (706) excess resin from the enclosed space (134) during the resin impregnation towards at least one vacuum pump (140) for collection in a waste resin bin (142).

[0123] Appendix 43. placing (802) a fluid impermeable membrane (108) over the dry fabric laminate (106) prior to placing (504) the compression pressure chamber (110) over the dry fabric laminate (106); sealing (804) the fluid impermeable membrane (108) against the tool face (104) over the dry fabric laminate (106) to form the enclosed space (134) between the fluid impermeable membrane (108) and the tool face (104); 35. The method (800) of claim 34, further comprising sealing (806) the compression pressure chamber (110) against the fluid impermeable membrane (108) above the dry fabric laminate (106).

[0124] Appendix 44. 44. The method (900) of claim 43, further comprising, prior to placing (802) the fluid-impermeable membrane (108), placing (902) a release film (144) on the dry fabric laminate (106) such that the release film (144) is located between the dry fabric laminate (106) and the fluid-impermeable membrane (108).

[0125] Note 45. 45. The method of claim 44, further comprising, prior to placing (802) the fluid-impermeable membrane (108), placing (904) a breathable cloth (146) on the release film (144) such that the breathable cloth (146) is located between the release film (144) and the fluid-impermeable membrane (108).

[0126] Appendix 46. 44. The method of claim 43, further comprising, prior to placing (802) the fluid-impermeable membrane (108), placing (906) a breathable cloth (146) on the dry fabric laminate (106) such that the breathable cloth (146) is located between the dry fabric laminate (106) and the fluid-impermeable membrane (108).

[0127] Appendix 47. Positioning (1002) a plate surface (120) of a hardening plate (118) over the compression pressure chamber (110) such that the plate surface (120) faces the tool surface (104) of the hardening tool (102); 44. The method (1000) of claim 43, further comprising clamping the stiffening plate (118) against the stiffening tool (102) to enclose (1004) the dry fabric laminate (106), the fluid impermeable membrane (108), and the compression pressure chamber (110) between the stiffening tool (102) and the stiffening plate (118), wherein the stiffening plate (118) forms a cavity (122) between the fluid impermeable membrane (108) and the plate surface (120).

[0128] Note 48. sealing (1006) a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) to an adjacent portion (128) of the fluid-impermeable membrane (108), the plate surface (120) and the fluid-impermeable membrane (108) forming the compression pressure chamber (110) in cooperation with the cavity (122) defined by the stiffening plate (118) based on the sealing (1006); receiving (1008) the pressurized fluid (112) at the stiffening plate (118) from the at least one compressed fluid source (114); 48. The method of claim 47, further comprising: supplying (1010) the pressurized fluid (112) to the compression pressure chamber (110) through the stiffening plate (118).

[0129] Appendix 49. The compression pressure chamber (110) comprises at least one inflatable bladder (202), and the method further comprises: receiving (1012) the pressurized fluid (112) at the stiffening plate (118) from the at least one compressed fluid source (114); 48. The method of claim 47, further comprising: supplying (1014) the pressurized fluid (112) to each of the at least one inflatable bladder (202) through the stiffening plate (118).

[0130] Note 50. 44. The method of claim 43, wherein the at least one liquid resin source (136) includes at least one resin reservoir (304) defined by one or more resin supply areas (302) on the tool face (104) of the curing tool (102) spaced apart from a composite part area (306) on the tool face (104), each resin reservoir (304) configured to hold and supply the liquid resin (116) to the dry fabric laminate (106) during resin impregnation, the dry fabric laminate (106) being disposed in the composite part area (306) on the tool face (104) of the curing tool (102).

[0131] Note 51. 51. The method (1100) of claim 50, further comprising disposing (1102) at least one resin pressure chamber (308) above the at least one resin reservoir (304) of the curing tool (102).

[0132] Appendix 52. 52. The method of claim 51, further comprising supplying (1104) a second pressurized fluid (310) from the at least one compressed fluid source (114) to the at least one resin pressure chamber (308), wherein the second pressurized fluid (310) is supplied at a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148) of the pressurized fluid (112) supplied to the compression pressure chamber (110).

[0133] Note 53. placing (1106) a plate surface (120) of a curing plate (118) over the at least one resin pressure chamber (308) and the compression pressure chamber (110) such that the plate surface (120) faces the tool surface (104) of the curing tool (102); 53. The method of claim 52, further comprising clamping the curing plate (118) against the curing tool (102) to enclose (1108) the dry fabric laminate (106), the fluid impermeable membrane (108), the at least one resin pressure chamber (308), and the compression pressure chamber (110) between the curing tool (102) and the curing plate (118), wherein the curing plate (118) forms a cavity (122) between the fluid impermeable membrane (108) and the plate surface (120).

[0134] Note 54. sealing (1202) a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) to an adjacent portion (128) of the fluid impermeable membrane (108); sealing (1204) a central portion (314) of the plate surface (120) of the stiffening plate (118) against the adjacent portion (128) of the fluid-impermeable membrane (108) to isolate the at least one resin pressure chamber (308) from the compression pressure chamber (110), whereby the plate surface (120) and the fluid-impermeable membrane (108) are sealed against the dry fabrication process based on the sealing (1202) of the peripheral portion (126) and the sealing (1204) of the central portion (314). forming the compression pressure chamber (110) on the elastomeric laminate (106), forming the at least one resin pressure chamber (308) on the at least one resin reservoir (304), and isolating the at least one resin reservoir (304) from the compression pressure chamber (110), the compression pressure chamber (110) and the at least one resin pressure chamber (308) being formed in cooperation with the cavity (122) defined by the stiffening plate (118); receiving (1206) the pressurized fluid (112) from the at least one compressed fluid source (114) at the stiffening plate (118); providing (1208) the pressurized fluid (112) to the compression pressure chamber (110) through the stiffening plate (118); receiving (1210) the second pressurized fluid (310) from the at least one compressed fluid source (114) at the stiffening plate (118); 54. The method (1200) of claim 53, further comprising: supplying (1212) the second pressurized fluid (310) to the at least one resin pressure chamber (308) through the stiffening plate (118).

[0135] Note 55. The at least one resin pressure chamber (308) includes an inflatable bladder (402), and the method further comprises: receiving (1302) the second pressurized fluid (310) at the stiffening plate (118) from the at least one compressed fluid source (114); 54. The method (1300) of claim 53, further comprising: supplying (1304) the second pressurized fluid (310) to the inflatable bladder (402) through the stiffening plate (118).

[0136] Note 56. 1. A system (1400) for composite manufacturing, comprising: at least one compressed fluid source (114); and a hardening tool assembly (100), the hardening tool assembly comprising: a curing tool (102) having a tool face (104) configured for placement of a dry fabric laminate (106); a fluid impermeable membrane (108) configured to cover the dry fabric laminate (106) placed on the tool face (104) of the curing tool (102); a compression pressure chamber (110) configured to cover the fluid impermeable membrane (108), the compression pressure chamber (110) being further configured to receive pressurized fluid (112) from the at least one compressed fluid source (114) during resin impregnation of the dry fabric laminate (106), the pressurized fluid (112) being received at a compression pressure (148) greater than standard atmospheric pressure (150).

[0137] Note 57. 57. The system of claim 56, wherein the dry fabric laminate (106) comprises a preformed dry fabric laminate.

[0138] Note 58. 58. The system of claim 57, wherein the preformed dry fabric laminate comprises a plurality of plies of dry fabric bonded together using a locally melted thermoplastic veil.

[0139] Note 59. 57. The system of claim 56, wherein the fluid-impermeable membrane (108) comprises at least one of a rubber material, a thermoplastic elastomer material, a reinforced polyimide, a fiber reinforced elastomer material, a fiberglass material, and a silicone material.

[0140] Note 60. 57. The system of claim 56, wherein the fluid impermeable membrane (108) comprises a vacuum bag.

[0141] Appendix 61. 57. The system of claim 56, wherein the compression pressure chamber (110) is configured to apply a compressive force to the fluid impermeable membrane (108) and the dry fabric laminate (106) in response to receiving the pressurized fluid (112) during the resin impregnation.

[0142] Appendix 62. 57. The system of claim 56, wherein the compressed pressure (148) when the pressurized fluid (112) is received from the at least one compressed fluid source (114) is at least one of: greater than or equal to about two times standard atmospheric pressure, greater than or equal to about three times standard atmospheric pressure, and greater than or equal to about four times standard atmospheric pressure.

[0143] Appendix 63. 63. The system of claim 62, wherein the compression pressure (148) when the pressurized fluid (112) is received from the at least one compressed fluid source (114) is higher than a resin pressure (152) applied to a liquid resin (116) during resin impregnation into the dry fabric laminate (106).

[0144] Note 64. 57. The system of claim 56, wherein the pressurized fluid (112) comprises at least one of compressed air, compressed nitrogen, and compressed inert gas.

[0145] Note 65. The hardening tool assembly (100) comprises: 57. The system of claim 56, further comprising a release film (144) configured to be placed on the dry fabric laminate (106) before the fluid-impermeable membrane (108) is placed on the dry fabric laminate (106).

[0146] Note 66. The hardening tool assembly (100) comprises: 57. The system of claim 56, further comprising a breathable cloth (146) configured to be placed over the dry fabric laminate (106) before the fluid impermeable membrane (108) is placed over the dry fabric laminate (106).

[0147] Note 67. The hardening tool assembly (100) comprises: 57. The system of claim 56, further comprising a hardening plate (118) having a plate surface (120) facing the tool surface (104) of the hardening tool (102), the hardening plate (118) configured to be clamped against the hardening tool (102) during resin impregnation of the dry fabric laminate (106) to enclose the fluid-impermeable membrane (108) and the compression pressure chamber (110) between the hardening tool (102) and the hardening plate (118), the hardening plate (118) defining a cavity (122) between the fluid-impermeable membrane (108) and the plate surface (120).

[0148] Note 68. 68. The system of claim 67, wherein the stiffening plate (118) comprises a metallic material.

[0149] Note 69. 70. The system of claim 68, wherein the metallic material comprises at least one of steel, stainless steel, and cobalt chromium alloy.

[0150] Appendix 70. The hardening tool assembly (100) comprises: a seal (124) configured to be disposed between a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) and an adjacent portion (128) of the fluid impermeable membrane (108) during the resin impregnation; 68. The system of claim 67, wherein the plate surface (120), the seal (124), and the fluid-impermeable membrane (108) cooperate with the cavity (122) defined by the stiffening plate (118) to form the compression pressure chamber (110), the stiffening plate (118) being configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) during the resin impregnation and to supply the pressurized fluid (112) to the compression pressure chamber (110) during the resin impregnation.

[0151] Appendix 71. The compression pressure chamber (110) 68. The system of claim 67, comprising at least one inflatable bladder (202), wherein the stiffening plate (118) is configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) and to supply the pressurized fluid (112) to each of the at least one inflatable bladder (202).

[0152] Appendix 72. The tool face (104) of the hardening tool (102) is 57. The system of claim 56, comprising one or more resin supply areas (302) defining at least one resin reservoir (304), the one or more resin supply areas (302) spaced apart from a composite part area (306) on the tool face (104), each resin reservoir (304) configured to hold and supply liquid resin (116) during the resin impregnation, the composite part area (306) configured to receive the dry fabric laminate (106).

[0153] Appendix 73. The hardening tool assembly (100) comprises: 73. The system of claim 72, further comprising at least one resin pressure chamber (308) configured to overlie the at least one resin reservoir (304) of the curing tool (102), the at least one resin pressure chamber (308) further configured to receive a second pressurized fluid (310) from the at least one compressed fluid source (114) during resin impregnation of the dry fabric laminate (106), the second pressurized fluid (310) being received at a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148) of the pressurized fluid (112) associated with the compression pressure chamber (110).

[0154] Note 74. The hardening tool assembly (100) comprises: 74. The system of claim 73, further comprising a hardening plate (118) having a plate surface (120) facing the tool surface (104) of the hardening tool (102), the hardening plate (118) configured to be clamped against the hardening tool (102) during resin impregnation of the dry fabric laminate (106) to enclose the fluid-impermeable membrane (108), the at least one resin pressure chamber (308), and the compression pressure chamber (110) between the hardening tool (102) and the hardening plate (118), the hardening plate (118) defining a cavity (122) between the fluid-impermeable membrane (108) and the plate surface (120).

[0155] Appendix 75. The hardening tool assembly (100) comprises: a seal (124) configured to be disposed between a peripheral portion (126) of the plate surface (120) of the stiffening plate (118) and an adjacent portion (128) of the fluid-impermeable membrane (108) during the resin impregnation; a second seal (312) configured to be disposed between the plate face (120) of the curing plate (118) and the fluid impermeable membrane (108) during the resin impregnation to separate the at least one resin pressure chamber (308) from the compression pressure chamber (110); 75. The system of claim 74, wherein the plate face (120), the seal (124), the second seal (312), and the fluid-impermeable membrane (108) form the at least one resin pressure chamber (308) and the compression pressure chamber (110), the stiffening plate (118) is configured to receive the pressurized fluid (112) from the at least one compressed fluid source (114) and supply the pressurized fluid (112) to the compression pressure chamber (110), and the stiffening plate (118) is configured to receive the second pressurized fluid (310) from the at least one compressed fluid source (114) and supply the second pressurized fluid (310) to the at least one resin pressure chamber (308).

[0156] Appendix 76. The at least one resin pressure chamber (308) 75. The system of claim 74, further comprising an inflatable bladder (402), wherein the stiffening plate (118) is configured to receive the second pressurized fluid (310) from the at least one compressed fluid source (114) and to supply the second pressurized fluid (310) to the inflatable bladder (402).

[0157] Appendix 77. The hardening tool assembly (100) comprises: 57. The system of claim 56, further comprising a seal (130) configured to be disposed between a peripheral portion (132) of the tool face (104) of the curing tool (102) and an adjacent portion (128) of the fluid-impermeable membrane (108) during the resin impregnation to form an enclosed space (134) around the dry fabric laminate (106).

[0158] Appendix 78. 78. The system of claim 77, further comprising at least one liquid resin source (136) configured to supply liquid resin (116) to the curing tool (102) during the resin impregnation, the curing tool (102) configured to supply the liquid resin (116) from the at least one liquid resin source (136) to the enclosed space (134) during the resin impregnation.

[0159] Appendix 79. 80. The system of claim 78, wherein the liquid resin (116) is received at a resin pressure (152) that is greater than the standard atmospheric pressure (150) and less than the compression pressure (148) of the pressurized fluid (112) associated with the compression pressure chamber (110).

[0160] Note 80. 80. The system of claim 79, wherein the at least one liquid resin source (136) includes at least one of: one or more resin pressure pots (138) and one or more resin injectors.

[0161] Appendix 81. 80. The system of claim 78, further comprising at least one vacuum pump (140) in fluid communication with the curing tool (102) and configured to evacuate the enclosed space (134) during the resin impregnation.

[0162] Note 82. 82. The system of claim 81, wherein the system (1400) is configured to use the vacuum to draw the liquid resin (116) into the enclosed space (134) during the resin impregnation.

[0163] Note 83. 82. The system of claim 81, further comprising a waste resin container (142) in fluid communication with the at least one vacuum pump (140) and the curing tool (102) and configured to receive and collect excess resin from the enclosed space (134) in response to drawing a vacuum in the enclosed space (134).

Claims

1. a curing tool having a tool face configured for placement of a dry fabric laminate; a compression pressure chamber configured to cover the dry fabric laminate placed on the tool face of the curing tool, the compression pressure chamber further configured to receive pressurized fluid from at least one compressed fluid source during resin impregnation of the dry fabric laminate, the pressurized fluid being received at a compression pressure greater than standard atmospheric pressure.

2. The curing tool assembly of claim 1 , wherein the dry fabric laminate comprises a preformed dry fabric laminate.

3. The cure tool assembly of claim 2 , wherein the preformed dry fabric laminate comprises a plurality of plies of dry fabric bonded together with a locally melted thermoplastic veil.

4. The curing tool assembly of claim 1 , wherein the compression pressure when the pressurized fluid is received from the at least one compressed fluid source is higher than a resin pressure applied to liquid resin during resin impregnation into the dry fabric laminate.

5. The curing tool assembly of claim 1 , wherein the pressurized fluid comprises at least one of compressed air, compressed nitrogen, and compressed inert gas.

6. 2. The curing tool assembly of claim 1, further comprising a fluid impermeable membrane configured to cover the dry fabric laminate placed on the tool face of the curing tool, the fluid impermeable membrane being disposed between the dry fabric laminate and the compression pressure chamber.

7. The cure tool assembly of claim 6 , wherein the fluid impermeable membrane comprises a vacuum bag.

8. The cure tool assembly of claim 6 , wherein the compressive pressure chamber is configured to apply a compressive force to the fluid impermeable membrane and the dry fabric laminate in response to receiving the pressurized fluid during the resin impregnation.

9. 7. The curing tool assembly of claim 6, further comprising a curing plate having a plate surface opposite the tool surface of the curing tool, the curing plate configured to be clamped against the curing tool during resin impregnation of the dry fabric laminate to enclose the fluid impermeable membrane and the compression pressure chamber between the curing tool and the curing plate, the curing plate defining a cavity between the fluid impermeable membrane and the plate surface.

10. a seal configured to be disposed between a peripheral edge of the plate surface of the curing plate and an adjacent portion of the fluid-impermeable membrane during the resin impregnation; 10. The curing tool assembly of claim 9, wherein the plate faces, the seals and the fluid impermeable membrane cooperate with the cavity defined by the stiffening plate to form the compression pressure chamber, the stiffening plate being configured to receive the pressurized fluid from the at least one compressed fluid source during the resin impregnation and to supply the pressurized fluid to the compression pressure chamber during the resin impregnation.

11. The compression pressure chamber comprises:

10. The curing tool assembly of claim 9, including at least one inflatable bladder, the curing plate configured to receive the pressurized fluid from the at least one compressed fluid source and configured to supply the pressurized fluid to each of the at least one inflatable bladder.

12. The tool face of the hardening tool comprises:

7. The cure tool assembly of claim 6, comprising one or more resin supply areas defining at least one resin reservoir, the one or more resin supply areas on the tool face spaced apart from a composite part area on the tool face, each resin reservoir configured to hold and supply liquid resin during the resin impregnation, the composite part area configured to receive the dry fabric laminate.

13. 13. The curing tool assembly of claim 12, further comprising at least one resin pressure chamber configured to overlie the at least one resin reservoir of the curing tool, the at least one resin pressure chamber further configured to receive a second pressurized fluid from the at least one compressed fluid source during resin impregnation of the dry fabric laminate, the second pressurized fluid being received at a resin pressure that is higher than the standard atmospheric pressure and lower than the compression pressure of the pressurized fluid associated with the compressed pressure chamber.

14. 14. The curing tool assembly of claim 13, further comprising a curing plate having a plate surface opposite the tool surface of the curing tool, the curing plate configured to be clamped against the curing tool during resin impregnation of the dry fabric laminate to enclose the fluid impermeable membrane, the at least one resin pressure chamber, and the compression pressure chamber between the curing tool and the curing plate, the curing plate defining a cavity between the fluid impermeable membrane and the plate surface.

15. a seal configured to be disposed between a peripheral edge of the plate surface of the curing plate and an adjacent portion of the fluid impermeable membrane during the resin impregnation; a second seal configured to be disposed between the plate face of the curing plate and the fluid impermeable membrane during the resin impregnation to separate the at least one resin pressure chamber from the compression pressure chamber; 15. The curing tool assembly of claim 14, wherein the plate face, the seal, the second seal, and the fluid impermeable membrane define the at least one resin pressure chamber and the compression pressure chamber, the curing plate configured to receive the pressurized fluid from the at least one compressed fluid source and supply the pressurized fluid to the compression pressure chamber, and the curing plate configured to receive the second pressurized fluid from the at least one compressed fluid source and supply the second pressurized fluid to the at least one resin pressure chamber.

16. The at least one resin pressure chamber comprises:

15. The curing tool assembly of claim 14 including an inflatable bladder, the curing plate configured to receive the second pressurized fluid from the at least one compressed fluid source and to supply the second pressurized fluid to the inflatable bladder.

17. 7. The curing tool assembly of claim 6, further comprising a seal configured to be disposed between a peripheral edge of the tool face of the curing tool and an adjacent portion of the fluid impermeable membrane during the resin impregnation to form an enclosed space around the dry fabric laminate.

18. 20. The curing tool assembly of claim 17, wherein the curing tool is configured to receive liquid resin from at least one liquid resin source during the resin impregnation and to supply the liquid resin to the enclosed space during the resin impregnation.

19. The curing tool assembly of claim 18 , wherein the liquid resin is received at a resin pressure that is greater than the standard atmospheric pressure and less than the compression pressure of the pressurized fluid associated with the compression pressure chamber.

20. The curing tool assembly of claim 19 , wherein the at least one source of liquid resin comprises at least one of: one or more resin pressure pots; and one or more resin injectors.

21. The curing tool assembly of claim 18 , wherein the curing tool is in fluid communication with at least one vacuum pump configured to draw a vacuum in the enclosed space during the resin impregnation.

22. The curing tool assembly of claim 21 , wherein the curing tool assembly is configured to utilize the vacuum to draw the liquid resin into the enclosed space during the resin impregnation.

23. 22. The curing tool assembly of claim 21, wherein the curing tool assembly is configured to utilize the vacuum during the resin impregnation to draw excess resin from the enclosed space towards the at least one vacuum pump for collection in a waste resin bin.

24. applying a resin pressure to the liquid resin in at least one liquid resin source that is greater than standard atmospheric pressure; Flowing the liquid resin from the at least one liquid resin source onto a dry fabric laminate disposed on a tool face of a curing tool in response to the resin pressure, wherein the dry fabric laminate is enclosed in an enclosed space to which a compression pressure higher than the resin pressure is applied; and impregnating the dry fabric laminate with the liquid resin in response to the resin pressure and the compression pressure.

25. placing a dry fabric laminate on a tool face of a curing tool; placing a compression pressure chamber over the dry fabric laminate; sealing the compression pressure chamber against the tool face above the dry fabric laminate to form an enclosed space between the compression pressure chamber and the tool face; providing pressurized fluid from at least one compressed fluid source to the compressed pressure chamber, the pressurized fluid being provided at a compressed pressure greater than standard atmospheric pressure; providing liquid resin from at least one source of liquid resin to the enclosed space; applying a resin pressure to the liquid resin that is higher than the standard atmospheric pressure and lower than the compression pressure; flowing the liquid resin from the at least one liquid resin source onto a dry fabric laminate in response to the resin pressure; and impregnating the dry fabric laminate with the liquid resin in response to the resin pressure and the compression pressure.

26. 1. A system for composite manufacturing, comprising: at least one compressed fluid source; and a hardening tool assembly, the hardening tool assembly comprising: a curing tool having a tool face configured for placement of a dry fabric laminate; a fluid impermeable membrane configured to cover the dry fabric laminate placed on the tool face of the curing tool; a compression pressure chamber configured to cover the fluid impermeable membrane, the compression pressure chamber further configured to receive pressurized fluid from the at least one compressed fluid source during resin impregnation of the dry fabric laminate, the pressurized fluid being received at a compression pressure greater than standard atmospheric pressure.

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