Composite material molding
The method addresses wrinkling and bulk issues in composite material molding by using a vacuum envelope and forming machine to create a consistent molded shape, enhancing the molding process for composite materials.
Patent Information
- Application Number
- JP2025022007
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-02-23
- Filing Date
- 2025-02-14
- Publication Date
- 2025-09-04
AI Technical Summary
Existing molding processes for composite materials, such as dry carbon fabrics and non-crimp fabrics, often result in inconsistencies like wrinkling due to bulk limitations and tooling constraints.
A method involving a composite layup sealed within a vacuum envelope, where the layup is molded onto a tool under vacuum, debulked, and processed using a forming machine with a sweeper to reduce wrinkling and bulk, while applying controlled vacuum and heat to maintain the molded shape.
The method effectively reduces wrinkling and bulk in composite materials, ensuring consistent molding and facilitating further processing steps like resin infusion.
Smart Images
Figure 2025129132000001_ABST
Abstract
Description
[Technical Field]
[0001]
[0001] The present disclosure relates generally to molding composite materials, and more particularly to methods for molding composite materials with reduced wrinkling. [Background technology]
[0002]
[0002] Dry carbon fabrics can be used in resin infusion applications. Dry carbon fabrics are often molded into part shapes before infusion and curing. Due to the bulk of dry composite fabrics, tooling options can be limited. During some molding methods, inconsistencies such as wrinkles can occur.
[0003]
[0003] A number of other materials, including non-crimp fabrics (NCF) and unidirectional prepreg laminates, are also molded, and it is desirable to reduce inconsistencies during the molding process.
[0004]
[0004] Therefore, it would be desirable to have methods and apparatus that address at least some of the above-mentioned problems, as well as other potential problems. For example, it would be desirable to provide additional methods for forming dry composite fabrics. Furthermore, it would be desirable to reduce or prevent wrinkling during forming of the composite material. Summary of the Invention
[0005]
[0005] One embodiment of the present disclosure provides a method for molding a composite structure. A composite layup is sealed within a vacuum envelope. The composite layup includes at least one of a resin or a thermoplastic material. While the composite layup is held under vacuum within the vacuum envelope, the composite layup is molded onto a tool to create a molded shape for the composite layup.
[0006] Another embodiment of the present disclosure provides a method for forming a composite layup with reduced wrinkling. The composite layup is debulked within a vacuum envelope. The composite layup is formed onto a tool while the composite layup is under vacuum within the vacuum envelope to create a formed shape for the composite layup. The composite layup is processed while in the formed shape.
[0007] A further embodiment of the present disclosure provides a method of forming a composite layup. The composite layup, under vacuum in a vacuum envelope, is loaded into a forming machine. The composite layup, under vacuum in the vacuum envelope, is swept over a tool using a sweeper of the forming machine.
[0008]
[0008] A still further embodiment of the present disclosure provides a method for forming a composite layup. Multiple layers of material are arranged to form the composite layup. The composite layup includes at least one of a resin or a thermoplastic material. The composite layup is reduced in bulk by applying a vacuum within a vacuum envelope prior to forming. The composite layup is molded onto a tool while the composite layup is under vacuum within the vacuum envelope to create a molded shape for the composite layup. The composite layup is heated while under vacuum to maintain the molded shape for the composite layup by tacking the composite layup.
[0009]
[0009] These features and functions may be realized individually in various embodiments of the present disclosure or may be combined in further embodiments, further details of which can be understood by reference to the following description and drawings.
[0010]
[0010] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, as well as preferred modes of use, further objects and features, will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]
[0011] [Figure 1]
[0011] FIG. 1 is an illustration of an aircraft in accordance with an illustrative embodiment. [Figure 2]
[0012] FIG. 1 is a block diagram of a manufacturing environment in accordance with an illustrative embodiment. [Figure 3]
[0013] 1 is an illustration of a flowchart of steps for forming a composite layup in accordance with an illustrative embodiment; [Figure 4]
[0014] FIG. 1 is an illustration of a front view of a composite layup sealed within a vacuum envelope in a forming machine in accordance with an illustrative embodiment; [Figure 5]
[0015] 1 is a flowchart of a method for forming a composite structure in accordance with an illustrative embodiment. [Figure 6]
[0016] 1 is a flowchart of a method for forming a composite structure in accordance with an illustrative embodiment. [Figure 7]
[0017] 1 is a flowchart of a method for forming a composite structure in accordance with an illustrative embodiment. [Figure 8]
[0018] 1 is a flowchart of a method for forming a composite structure in accordance with an illustrative embodiment. [Figure 9]
[0019] FIG. 1 is an illustration of an aircraft manufacturing and service methodology in the form of a block diagram in accordance with an illustrative embodiment; [Figure 10]
[0020] 1 is an illustration of an aircraft in the form of a block diagram in which an illustrative embodiment may be implemented; DETAILED DESCRIPTION OF THE INVENTION
[0012]
[0021] Referring now to Figure 1, an illustration of an aircraft is shown in accordance with an illustrative embodiment. Aircraft 100 has wings 102 and 104 attached to fuselage 106. Aircraft 100 includes engines 108 and 110 attached to wing 102 and wing 104, respectively.
[0013]
[0022] The fuselage 106 has a tail section 112. A horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118 are attached to the tail section 112 of the fuselage 106.
[0014]
[0023] Aircraft 100 is one example of an aircraft that may have composite components molded using exemplary embodiments. A portion of at least one of wing 102, wing 104, fuselage 106, horizontal stabilizer 114, horizontal stabilizer 116, or vertical stabilizer 118 may be manufactured using exemplary embodiments. In some exemplary embodiments, stiffeners for at least one of wing 102, wing 104, fuselage 106, horizontal stabilizer 114, horizontal stabilizer 116, or vertical stabilizer 118 may be manufactured using exemplary embodiments.
[0015]
[0024] With reference now to Figure 2, a block diagram of a manufacturing environment is depicted in accordance with an illustrative embodiment. A portion of aircraft 100 in Figure 1 may be manufactured in manufacturing environment 200. A composite layup 202 may be formed against a tool 204 in manufacturing environment 200.
[0016]
[0025] The composite layup 202 is debulked prior to forming the composite layup 202 on the tool 204. Debulking 244 the composite layup 202 prior to forming 246 is performed by applying a vacuum 206 within a vacuum envelope 208 prior to forming 246. The vacuum envelope 208 is formed of an impermeable material, such as a vacuum bag. The vacuum 206 is applied to the composite layup 202 to reduce the bulk of the composite layup 202. By applying the vacuum 206 to the composite layup 202, the composite layup 202 is sealed within the vacuum envelope 208. In some illustrative examples, applying the vacuum 206 to the composite layup 202 within the vacuum envelope 208 reduces a thickness 210 of the composite layup 202.
[0017]
[0026] Composite layup 202 may take any desired form. Composite layup 202 includes multiple layers 252 of material 254. Material 254 may take the form of either composite prepreg 212 or dry fabric 214. Multiple layers 252 of material are arranged to form composite layup 202. In some illustrative embodiments, composite layup 202 is substantially flat.
[0018]
[0027] Composite layup 202 includes at least one of resin 221 or thermoplastic material 216. Thermoplastic material 216 may be present with dry fabric 214 or composite prepreg 212. In some exemplary embodiments, thermoplastic material 216 takes the form of at least one of thermoplastic veil 218 or thermoplastic stitching 220. In these exemplary embodiments, resin 221 is part of composite prepreg 212. In some exemplary embodiments, composite layup 202 includes one of a preform of dry fabric 214 or a laminate formed with composite prepreg 212. The preform of dry fabric 214 is non-impregnated. In some exemplary embodiments, composite layup 202 includes composite prepreg 212. In some exemplary embodiments, composite layup 202 includes dry fabric 214. In some exemplary embodiments, composite layup 202 includes thermoplastic material 216. In some illustrative embodiments, thermoplastic material 216 includes one of thermoplastic veil 218 or thermoplastic stitching 220. In some illustrative embodiments, one of thermoplastic veil 218 or thermoplastic stitching 220 is used with dry fabric 214 to form composite layup 202.
[0019]
[0028] Composite layup 202 is formed onto tool 204 while it is held under vacuum 206 within vacuum envelope 208. Forming 246 composite layup 202 onto tool 204 creates a formed shape 222 for composite layup 202. By forming composite layup 202 onto tool 204 while it is held under vacuum 206, wrinkling is reduced.
[0020]
[0029] Tool 204 can have any desired cross-sectional shape. In some exemplary embodiments, tool 204 has a planar surface. In some exemplary embodiments, tool 204 can have a bend, twist, curve, or other type of change in direction. In some exemplary embodiments, vacuum envelope 208 can stretch to accommodate a bend, twist, curve, or other type of feature in tool 204.
[0021]
[0030] In some illustrative embodiments, a forming machine 226 is used to sweep the composite layup 202 over the tool 204 to form the composite layup 202 over the tool 204. In some illustrative embodiments, a sweeper 228 of the forming machine 226 sweeps the composite layup 202 over the tool 204. In some illustrative embodiments, the composite layup 202 sealed in the vacuum envelope 208 is loaded into the forming machine 226, and the forming machine 226 sweeps the composite layup 202 over the tool 204, thereby forming the composite layup 202 over the tool 204.
[0022]
[0031] In some illustrative embodiments, sweeper 228 may take the form of an inflatable bladder 229 or a compliant wiper 231. In some illustrative embodiments, compliant wiper 231 may take the form of a finger, a squeegee, or any other desired form of sweeper. Sweeper 228 is configured to press composite layup 202 sealed within vacuum envelope 208 against tool 204. Pressing composite layup 202 against tool 204 changes the shape of composite layup 202 to create formed shape 222 for composite layup 202.
[0023]
[0032] Inflatable bladder 229 can be filled with any desired type of material. Inflatable bladder 229 can be filled with at least one of air, a different gas, a fluid, a gel, a polymer, or any other desired material. In some exemplary embodiments, silicone is present in inflatable bladder 229.
[0024]
[0033] In some illustrative embodiments, the pressure applied by sweeper 228 applies high pressure to composite layup 202 during forming 246. High pressure during forming 246 controls wrinkles and bulk.
[0025]
[0034] In some illustrative embodiments, the level of vacuum 206 in the vacuum envelope 208 is controlled during forming 246 of the composite layup 202 onto the tool 204 to control the forming 246 of the composite layup 202. By controlling the level of vacuum 206 in the vacuum envelope 208, the stiffness 224 of the composite layup 202 within the vacuum envelope 208 may be controlled. By increasing the vacuum 206, the stiffness 224 of the composite layup 202 within the vacuum envelope 208 may be increased. By decreasing the vacuum 206, the stiffness 224 of the composite layup 202 within the vacuum envelope 208 may be decreased. In some illustrative embodiments, decreasing the vacuum 206 decreases the stiffness 224, making the composite layup 202 easier to form onto the tool 204. In some illustrative embodiments, decreasing stiffness 224 may allow multiple plies of composite layup 202 to slide more relative to one another.
[0026]
[0035] After forming 246, processing 248 is performed on composite layup 202. In some illustrative embodiments, processing 248 is performed on composite layup 202 within vacuum envelope 208. Processing 248 includes further steps for manufacturing. Processing 248 may include at least one of heating 250 or resin infusion 236.
[0027]
[0036] In some illustrative embodiments, the composite layup 202 is heated while under vacuum 206 to maintain the formed shape 222 of the composite layup 202. In some illustrative embodiments, heating 250 the composite layup 202 at least one of melts and softens the thermoplastic material 216. In some illustrative embodiments, the thermoplastic material 216 is at least softened in order to tack the composite layup 202.
[0028]
[0037] In some illustrative embodiments, composite layup 202 is molded with dry fabric 214 and heating 250 is performed prior to removing composite layup 202 from vacuum envelope 208. In some illustrative embodiments, composite layup 202 is molded with composite prepreg 212 and composite layup 202 is removed from vacuum envelope 208 without heating 250.
[0029]
[0038] In some illustrative embodiments, heating 250 the composite layup 202 includes melting at least one of the thermoplastic veil 218 or the thermoplastic stitching 220 in the composite layup 202. In some illustrative embodiments, melting at least one of the thermoplastic veil 218 or the thermoplastic stitching 220 holds the composite layup 202 together. In some illustrative embodiments, the thermoplastic veil 218 stiffens the composite layup 202. In some illustrative embodiments, the thermoplastic stitching 220 tacks and holds the composite layup 202 together.
[0030]
[0039] In some illustrative embodiments, heating 250 the composite layup 202 includes heating 250 the composite layup 202 on the tool 204 in an oven 232. In some illustrative embodiments, heating 250 the composite layup 202 includes applying directional heat to the composite layup 202 while a sweeper 228 of the forming machine 226 presses the composite layup 202 against the tool 204. In some illustrative embodiments, heating 250 the composite layup 202 includes applying directional heat using a heater 230. In some illustrative embodiments, the heater 230 may comprise at least one of a blower, a conductive heater within the tool 204, or any other type of directional heater. In some illustrative embodiments, the heater 230 comprises a heating element integrated into one of the forming machine 226 or the tool 204. In some illustrative embodiments, the composite layup 202 is heated by a blower or other type of heater 230 that is movable relative to the forming machine 226 .
[0031]
[0040] In some illustrative embodiments, the composite layup 202 within the vacuum envelope 208 having the formed shape 222 is placed on or in at least one of a second tool 238 before heating 250 the composite layup 202. In some illustrative embodiments, the composite layup 202 within the vacuum envelope 208 is placed in a matched metal mold 240 before heating 250 the composite layup 202. In some illustrative embodiments, the composite layup 202 within the vacuum envelope 208 is placed on a mandrel 242 before heating 250 the composite layup 202. In other illustrative embodiments, heating 250 the composite layup 202 is performed before removing the composite layup 202 from the vacuum envelope 208.
[0032]
[0041] In some illustrative embodiments, after removing the composite layup 202 having the shaped shape 222 from the vacuum envelope 208, the composite layup 202 having the shaped shape 222 is placed into or on at least one of a second tool 238. In some illustrative embodiments, the second tool 238 may take the form of one of a mating mold 240 or a mandrel 242.
[0033]
[0042] In some illustrative embodiments, the vacuum envelope 208 is sealed to the tool 204. In some illustrative embodiments, resin infusion 236 is performed with the vacuum envelope 208 sealed to the tool 204. In some illustrative embodiments, resin 234 is infused into the composite layup 202 while the vacuum envelope 208 is sealed to the tool 204. In some illustrative embodiments, resin infusion 236 of the composite layup 202 is performed within the vacuum envelope 208. In other illustrative embodiments, resin infusion 236 may be performed on the composite layup 202 having the molded shape 222 outside of the vacuum envelope 208. In some illustrative embodiments, resin infusion 236 may be performed on the composite layup 202 in a mating mold 240.
[0034]
[0043] The illustration of manufacturing environment 200 in FIG. 2 is not meant to impose physical or architectural limitations on the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary. Also, blocks are presented to illustrate some functional components. When implemented in an illustrative embodiment, one or more of these blocks may be combined, divided, or combined or divided into different blocks.
[0035]
[0044] With reference now to Figure 3, an illustration of a flowchart of steps for forming a composite layup is shown in accordance with an illustrative embodiment. Flowchart 300 may be implemented within manufacturing environment 200 in Figure 2. Method 300 may be performed to form a composite section for aircraft 100 in Figure 1.
[0036]
[0045] In step 302, a composite layup is placed. The composite layup includes one of a prepreg 310 or a dry preform 312. In step 304, a vacuum is applied to the composite layup to reduce its bulk.
[0037]
[0046] In step 306, the composite layup is shaped while applying a vacuum to the composite layup. The composite layup is shaped by molding the composite layup onto a tool. Molding the composite layup onto the tool creates a shaped shape for the composite layup. High pressure is applied by molding the composite layup while the composite layup is under vacuum. High pressure can be used to control wrinkling and bulk in the composite layup.
[0038]
[0047] After forming in step 306, the composite layup undergoes processing in step 308. In some illustrative embodiments, at least one processing procedure may be completed with the composite layup within the vacuum envelope. In some illustrative embodiments, at least one procedure in step 308 is performed with the composite layup outside the vacuum envelope. In some illustrative embodiments, the processing in step 308 includes at least one of heating 314 or resin infusion 316. In other illustrative embodiments, step 308 includes placing the composite layup in or on at least one of a second tool.
[0039]
[0048] Referring now to FIG. 4 , a front view of a composite layup sealed in a vacuum envelope within a forming machine is shown in accordance with an illustrative embodiment. In the view 400 of the forming machine 402, a composite layup 408 sealed in a vacuum envelope is loaded into the forming machine 402. The forming machine 402 is one physical implementation of the forming machine 226 of FIG. 2 . The forming machine 402 uses a sweeper 404 to form the composite layup 408 sealed in the vacuum envelope onto a tool 406. In this illustrative example, the sweeper 404 takes the form of an inflatable bladder. In other illustrative examples, the sweeper 404 may take the form of a compliant wiper, such as a finger, a squeegee, or any other desired form of sweeper. The sweeper 404 is configured to press the composite layup 408 sealed in the vacuum envelope against the tool 406. Forcing composite layup 408 against tool 406 alters the shape of composite layup 408 to create a molded shape for composite layup 408 .
[0040]
[0049] Referring now to Figure 5, an illustration of a flowchart of a method for forming a composite structure is shown in accordance with an illustrative embodiment. Method 500 may be performed to fabricate a composite component of aircraft 100. Method 500 may be performed on composite layup 202 within vacuum envelope 208 of Figure 2. Method 500 may include the steps of flowchart 300 of Figure 3. Method 500 may be performed using forming machine 402 of Figure 4.
[0041]
[0050] The method 500 includes sealing a composite layup in a vacuum envelope, the composite layup including at least one of a resin or a thermoplastic material (step 502). The method 500 also includes molding the composite layup onto a tool while the composite layup is held under vacuum in the vacuum envelope to create a molded shape for the composite layup (step 504). The method 500 then ends.
[0042]
[0051] In some illustrative embodiments, the method 500 reduces the bulk of the composite layup before forming by applying a vacuum within a vacuum envelope prior to forming (step 506). In some illustrative embodiments, applying a vacuum within the vacuum envelope reduces the thickness of the composite layup.
[0043]
[0052] In some exemplary embodiments, method 500 includes loading the composite layup sealed in the vacuum envelope into a forming machine, and forming the composite layup over a tool by sweeping the composite layup over the tool with the forming machine (step 508). The forming machine may include any desired type of sweeper. In some exemplary embodiments, the forming machine sweeper includes at least one of an inflatable bladder or a compliant wiper. The compliant wiper may take the form of a finger, a squeegee, or any other desired type of sweeper.
[0044]
[0053] In some exemplary embodiments, the method 500 varies the level of vacuum in the vacuum envelope while the composite layup is being formed on the tool to control the forming of the composite layup (step 510). In some exemplary embodiments, varying the level of vacuum in the vacuum envelope changes the stiffness of the composite layup and the vacuum envelope. In some exemplary embodiments, when a greater vacuum is applied to the composite layup, the composite layup has a greater stiffness. In some exemplary embodiments, the vacuum is reduced to reduce the stiffness of the composite layup during some portions of the forming.
[0045]
[0054] In some exemplary embodiments, the method 500 heats the composite layup while under vacuum to maintain the formed shape of the composite layup (step 512). In some exemplary embodiments, heating the composite layup is performed in an oven. In some exemplary embodiments, heating the composite layup is performed by a directional heat source.
[0046]
[0055] In some exemplary embodiments, heating the composite layup includes melting at least one of a thermoplastic veil or thermoplastic stitching in the composite layup (step 514). In some exemplary embodiments, melting at least one of the thermoplastic veil or thermoplastic stitching holds the composite layup together. In some exemplary embodiments, the thermoplastic veil stiffens the material. In some exemplary embodiments, the thermoplastic stitching tacks and holds the composite layup together.
[0047]
[0056] In some illustrative embodiments, heating the composite lay-up includes heating the composite lay-up on the tool in an oven (Step 516). In these illustrative embodiments, the tool and composite lay-up may be moved into the oven. In some of these illustrative embodiments, a vacuum envelope is sealed to the tool prior to heating.
[0048]
[0057] In some illustrative examples, heating the composite layup includes applying directional heat to the composite layup while a sweeper of the forming machine presses the composite layup against the tool (step 518). In some illustrative examples, the directional heat may include at least one of infrared heaters above and / or below the layup, induction heaters above and / or below the layup, induction heating in the tool, a blower, a conductive heater in the tool, or any other type of directional heater.
[0049]
[0058] In some example embodiments, the method 500 seals the vacuum envelope to the tool (step 520). In some example embodiments, the method 500 injects resin into the composite layup while sealing the vacuum envelope to the tool (step 522).
[0050]
[0059] In some illustrative embodiments, the method 500 resin infuses the composite layup within the vacuum envelope (step 524). Any desired equipment may be used to perform the resin infusion. In some illustrative embodiments, additional tooling or additional vacuum bags may be placed around the vacuum envelope.
[0051]
[0060] In some exemplary embodiments, the method 500 removes the composite layup having the shaped configuration from the vacuum envelope (step 526). In some exemplary embodiments, the composite layup having the shaped configuration is removed from the vacuum envelope after heat treating. In some exemplary embodiments, the composite layup having the shaped configuration is removed from the vacuum envelope before heat treating.
[0052]
[0061] In some exemplary embodiments, the method 500 places the composite layup having the shaped configuration into or on at least one of a second tool (step 528). In some exemplary embodiments, the second tool takes the form of a matching mold. In some exemplary embodiments, the second tool takes the form of a second mandrel. In some exemplary embodiments, the thermoplastic material takes the form of at least one of a thermoplastic veil or a thermoplastic stitching (step 530).
[0053]
[0062] Referring now to Figure 6, an illustration of a flowchart of a method for forming a composite structure is shown in accordance with an illustrative embodiment. Method 600 may be performed to fabricate a composite component of aircraft 100. Method 600 may be performed on composite layup 202 within vacuum envelope 208 of Figure 2. Method 600 may include the steps of flowchart 300 of Figure 3. Method 600 may be performed using forming machine 402 of Figure 4.
[0054]
[0063] The method 600 debulks the composite layup within the vacuum envelope (step 602). The method 600 molds the composite layup onto a tool while the composite layup is under vacuum within the vacuum envelope to create a molded shape for the composite layup (step 604). The method 600 processes the composite layup while in the molded shape (step 606). Thereafter, the method 600 ends.
[0055]
[0064] In some illustrative examples, forming the composite layup includes sweeping the composite layup over a tool with a forming machine (step 608). The forming machine may include any desired type of sweeper to perform the sweeping. In some illustrative examples, the forming machine sweeper includes at least one of an inflatable bladder or a compliant wiper. In some illustrative examples, the compliant wiper includes a squeegee, a finger, or any other desired type of sweeper.
[0056]
[0065] In some illustrative examples, the method 600 controls 610 the vacuum applied to the composite layup to facilitate forming the composite layup. Controlling the level of vacuum within the vacuum envelope can control the stiffness of the composite layup within the vacuum envelope. Increasing the vacuum can increase the stiffness of the composite layup within the vacuum envelope. Decreasing the vacuum can decrease the stiffness of the composite layup within the vacuum envelope. In some illustrative examples, decreasing the vacuum reduces the stiffness, making the composite layup easier to form on the tool. In some illustrative examples, decreasing the stiffness can increase the sliding of multiple layers of the composite layup relative to each other.
[0057]
[0066] In some illustrative examples, treating the composite layup includes resin infusing the composite layup having the molded shape within the vacuum envelope (Step 612). In some illustrative examples, treating the composite layup includes heating the composite layup to maintain the molded shape as the composite layup (Step 614). In some illustrative examples, heating the composite layup includes heating the composite layup while a sweeper holds the composite layup against the tool to maintain the molded shape of the composite layup. In some illustrative examples, heating the composite layup includes heating the composite layup on the tool using an oven. In some illustrative examples, heating the composite layup melts at least one of the thermoplastic veil or the thermoplastic stitching.
[0058]
[0067] In some illustrative examples, the method 600 increases the vacuum in the vacuum envelope after forming the composite layup on the tool to maintain the formed shape (step 616). Increasing the vacuum in the vacuum envelope increases the stiffness of the composite layup.
[0059]
[0068] In some illustrative examples, processing the composite layup includes removing the composite layup with the formed shape from the vacuum envelope and placing the composite layup with the formed shape into or on at least one of a second tool (step 618). The second tool may take any desired form. In some illustrative examples, the second tool may take the form of at least one of a matching mold or a mandrel.
[0060]
[0069] Referring now to Figure 7, an illustration of a flowchart of a method for forming a composite structure is shown in accordance with an illustrative embodiment. Method 700 may be performed to fabricate a composite component of aircraft 100. Method 700 may be performed on composite layup 202 within vacuum envelope 208 of Figure 2. Method 700 may include the steps of flowchart 300 of Figure 3. Method 700 may be performed using forming machine 402 of Figure 4.
[0061]
[0070] The method 700 loads the composite layup, which is under vacuum in a vacuum envelope, into a forming machine (step 702). The method 700 then uses a sweeper of the forming machine to sweep the composite layup, which is under vacuum in the vacuum envelope, over a tool (step 704). The method 700 then ends.
[0062]
[0071] In some illustrative embodiments, the method 700 heats the composite layup while the sweeper holds the composite layup against the tool to maintain the formed shape of the composite layup (step 706). In some illustrative embodiments, the composite layup is heated by a heating element integrated into one of the forming machine or the tool. In some illustrative embodiments, the composite layup is heated by a blower or other type of heater that is movable relative to the forming machine.
[0063]
[0072] In some exemplary embodiments, the method 700 heats the composite layup on the tool using an oven (step 708). In some exemplary embodiments, heating the composite layup melts at least one of the thermoplastic veil or the thermoplastic stitching (step 710). In some exemplary embodiments, melting at least one of the thermoplastic veil or the thermoplastic stitching holds the composite layup together. In some exemplary embodiments, the thermoplastic veil stiffens the composite layup. In some exemplary embodiments, the thermoplastic stitching tacks and holds the composite layup together.
[0064]
[0073] In some illustrative embodiments, the method 700 injects resin into the composite layup within the vacuum envelope after sweeping the composite layup over the tool (step 712). Any desired equipment may be used to perform the resin infusion. In some illustrative embodiments, additional tooling or additional vacuum bags may be placed around the vacuum envelope.
[0065]
[0074] In some illustrative examples, the sweeper of the molding machine takes the form of an inflatable bladder or a compliant wiper, and sweeping the composite layup under vacuum within the vacuum envelope against the tool includes using the inflatable bladder or compliant wiper to sweep the composite layup against the tool to add pressure and reduce the occurrence of wrinkles during the sweep (step 714).
[0066]
[0075] Referring now to Figure 8 , an illustration of a flowchart of a method for forming a composite structure is shown in accordance with an illustrative embodiment. Method 800 may be performed to fabricate a composite component of aircraft 100. Method 800 may be performed on composite layup 202 within vacuum envelope 208 of Figure 2. Method 800 may include the steps of flowchart 300 of Figure 3. Method 800 may be performed using forming machine 402 of Figure 4.
[0067]
[0076] Method 800 arranges multiple layers of material to form a composite layup, the composite layup including at least one of a resin or a thermoplastic material (step 802). Method 800 reduces the bulk of the composite layup by applying a vacuum within a vacuum envelope prior to forming (step 804). Method 800 forms the composite layup on a tool while the composite layup is under vacuum within the vacuum envelope to create a formed shape for the composite layup (step 806). Method 800 heats the composite layup while under vacuum to maintain the formed shape for the composite layup by tacking the composite layup (step 808). Method 800 then ends.
[0068]
[0077] In some illustrative embodiments, the method 800 controls the vacuum applied to the composite layup to control slippage of the layers of material in the composite layup (step 810). In some illustrative embodiments, the vacuum applied to the composite layup is reduced to increase slippage of the layers of material relative to each other during forming of the composite layup.
[0069]
[0078] In some exemplary embodiments, the thermoplastic material takes the form of at least one of a thermoplastic veil or thermoplastic stitching (step 811). In some exemplary embodiments, the method 800 stitches multiple layers of material together using thermoplastic stitching (step 812) before arranging the multiple layers to form a composite layup. In some exemplary embodiments, the multiple layers of material are stitched into several separate stitched sets. Each stitched set can include any desired number of multiple layers of material.
[0070]
[0079] In some illustrative embodiments, after molding the composite layup, the method 800 resin infuses the composite layup within the vacuum envelope (step 814). In some illustrative embodiments, the vacuum envelope is vacuum sealed to the tool prior to resin infus- ing the composite layup.
[0071]
[0080] In some illustrative examples, forming the composite layup includes sweeping the composite layup under vacuum in a vacuum envelope against a tool using a sweeper of the forming machine, the sweeper of the forming machine taking the form of an inflatable bladder or a compliant wiper, and sweeping the composite layup under vacuum in a vacuum envelope against a tool includes sweeping the composite layup against the tool using the inflatable bladder or compliant wiper to apply pressure and reduce wrinkling during the sweep (step 816). In some illustrative examples, higher pressures may be present in the inflatable bladder of the forming machine when forming the composite layup under vacuum than when forming a composite prepreg without vacuum.
[0072]
[0081] As used herein, the phrase "at least one of" used in conjunction with enumerated items means that various combinations of one or more of the enumerated items may be used, and that only one of each enumerated item may be required. For example, without limitation, "at least one of item A, item B, and item C" may include item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In other examples, "at least one of" may be, for example, without limitation, "two items A, one item B, and ten items C," "four items B and seven items C," or other suitable combinations. An item may be a specific object, thing, or category. In other words, "at least one of" means that any combination of items, and some items, may be used from the list, but not all of the listed items are required.
[0073]
[0082] As used herein, the term "a number of," when used in connection with items, means one or more items.
[0074]
[0083] The flowcharts and block diagrams in the various illustrated embodiments illustrate the structure, functionality, and operation of some possible implementations of apparatus and methods in an illustrative embodiment. In this regard, each block in a flowchart or block diagram may represent at least one of a module, a segment, a function, or a portion of an operation or step.
[0075]
[0084] In some alternative implementations of an exemplary embodiment, one or more functions noted in a block may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in reverse order, depending on the functionality involved. Also, other blocks may be added in addition to the blocks shown in a flowchart or block diagram. Some blocks may be optional. For example, steps 506 through 528 may be optional. For example, steps 608 through 620 may be optional. For example, steps 706 through 712 may be optional. For example, steps 810 through 816 may be optional.
[0076]
[0085] An exemplary embodiment of the present disclosure may be described in the context of aircraft manufacturing and service method 900 shown in Figure 9 and aircraft 1000 shown in Figure 10. Referring initially to Figure 9, an aircraft manufacturing and service method is illustrated in the form of a block diagram in accordance with an illustrative embodiment. Aircraft manufacturing and service method 900 may include specification and design 902 and material procurement 904 of aircraft 1000 in Figure 10 during pre-production.
[0077]
[0086] During production, component and subassembly manufacturing 906 and system integration 908 of the aircraft 1000 takes place. The aircraft 1000 may then undergo certification and delivery 910 and be placed into service 912. While in customer service 912, the aircraft 1000 is scheduled for routine maintenance and service 914, which may include modification, reconfiguration, refurbishment, or other maintenance and service.
[0078]
[0087] Each process of aircraft manufacturing and service method 900 may be performed or implemented by a system integrator, a third party, and / or an operator. In these examples, the operator may be the customer. As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an entity may be an airline, a leasing company, a military organization, a service organization, etc.
[0079]
[0088] Referring now to Figure 10, an aircraft in the form of a block diagram is shown in which an illustrative embodiment may be implemented. In this example, aircraft 1000 is manufactured via aircraft manufacturing and service method 900 in Figure 9 and may include an airframe 1002 having a number of systems 1004 and an interior 1006. Examples of systems 1004 include one or more of a propulsion system 1008, an electrical system 1010, a hydraulic system 1012, and an environmental system 1014. Any number of other systems may also be included.
[0080]
[0089] Apparatus and methods embodied herein may be used during at least one stage of aircraft manufacturing and service method 900. One or more illustrative embodiments may be manufactured or used during at least one of component and subassembly manufacturing 906, system integration 908, service 912, or maintenance and service 914 in Figure 9 .
[0081]
[0090] Exemplary embodiments utilize forming under vacuum in a new process for dry materials. Vacuum bags are used to remove bulk from a composite layup, such as a dry laminate. The composite layup is formed against a tool. In some exemplary embodiments, the composite layup may be formed using a forming machine. In some exemplary embodiments, the forming machine may use an inflatable bladder to add pressure, control wrinkles, and further control bulk.
[0082]
[0091] Exemplary embodiments control the wrinkling and bulk behavior of composite materials for molding processes. Exemplary embodiments control the wrinkling and bulk behavior during subsequent steps after forming the composite layup on a mandrel under vacuum. For example, exemplary embodiments control the wrinkling and bulk behavior during subsequent steps even with closed die tooling approaches. With closed die tooling, bulk can be tightly controlled to allow the tool to close and prevent or reduce misalignment.
[0083]
[0092] In exemplary embodiments, a vacuum bag is used to enclose the composite layup, along with a sweeper that applies pressure to achieve high pressures above vacuum pressure. In some exemplary embodiments, the molding pressure is applied by an inflatable bladder within the molding machine. In some exemplary embodiments, integrated heating is used during molding to further assist in controlling bulk. In other exemplary embodiments, heat may be applied to the composite layup after molding. High pressure is used during molding to control wrinkles and bulk. Temperature control may be used to tuck the material during and / or after molding to substantially reduce bulk.
[0084]
[0093] The description of the various exemplary embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Many modifications and variations will be apparent to those skilled in the art. Furthermore, various exemplary embodiments may offer different features as compared to other exemplary embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments and to facilitate an understanding by others skilled in the art of the disclosure of the various embodiments and various modifications suitable for the particular applications contemplated.
Claims
1. A method (500) for forming a composite structure (246, 306), comprising: sealing (502) a composite layup (202, 408) in a vacuum envelope (208), the composite layup (202, 408) comprising at least one of a resin (221) or a thermoplastic material (216); and shaping (246, 306, 504) the composite layup (202, 408) onto a tool (204, 406) while the composite layup (202, 408) is held under vacuum (206) within the vacuum envelope (208) to create a shaped shape (222) for the composite layup (202, 408).
2. 10. The method of claim 1, further comprising: varying a level of the vacuum within the vacuum envelope during forming of the composite layup onto the tool to control the forming of the composite layup.
3. 10. The method of claim 1, further comprising heating the composite layup while under the vacuum to maintain the formed shape of the composite layup.
4. 4. The method of claim 3, wherein heating the composite layup comprises melting at least one of a thermoplastic veil or a thermoplastic stitching within the composite layup.
5. 4. The method of claim 3, wherein heating the composite layup comprises heating the composite layup on the tool in an oven.
6. 4. The method of claim 3, wherein heating the composite layup comprises applying directional heat to the composite layup while a sweeper of a forming machine presses the composite layup against the tool.
7. sealing (520) the vacuum envelope (208) to the tool (204, 406); and 10. The method of claim 1, further comprising infusing a resin into the composite layup while the vacuum envelope is sealed to the tool.
8. 2. The method of claim 1, further comprising loading the composite layup sealed in the vacuum envelope into a forming machine, wherein forming the composite layup onto the tool is performed by sweeping the composite layup over the tool with the forming machine.
9. The method (500) of claim 1, further comprising resin infusing (236, 524) the composite layup (202, 408) within the vacuum envelope (208).
10. 10. The method of claim 1, further comprising debulking the composite layup prior to forming by applying the vacuum within the vacuum envelope prior to forming.
11. removing (526) the composite lay-up (202, 408) having the formed shape (222) from the vacuum envelope (208); and 10. The method of claim 1, further comprising placing the composite layup having the shaped shape in at least one of a first tool and a second tool.
12. The method (500) of claim 1, wherein the thermoplastic material (216) takes the form of at least one of a thermoplastic veil (218) or a thermoplastic stitching (220).
13. 1. A method (600) for forming a composite layup (202, 408) having reduced wrinkles, comprising: debulking (244, 602) said composite layup (202, 408) within a vacuum envelope (208); forming (246, 306, 604) the composite layup (202, 408) onto a tool (204, 406) while the composite layup (202, 408) is under a vacuum (206) within the vacuum envelope (208) to create a formed shape (222) for the composite layup (202, 408); and A method (600) comprising processing (248, 606) the composite layup (202, 408) while in the formed shape (222).
14. 14. The method of claim 13, wherein processing the composite layup includes infusing the composite layup having the molded shape within the vacuum envelope with resin.
15. 14. The method (600) of claim 13, wherein forming (246, 306) the composite layup (202, 408) onto the tool (204, 406) comprises sweeping (608) the composite layup (202, 408) onto the tool (204, 406) with a forming machine (226, 402).
16. 14. The method of claim 13, wherein treating the composite layup includes heating the composite layup to maintain the formed shape of the composite layup.
17. 14. The method (600) of claim 13, further comprising increasing (616) the vacuum (206) within the vacuum envelope (208) after forming (246, 306) the composite layup (202, 408) onto the tool (204, 406) to maintain the formed shape (222).
18. 14. The method (600) of claim 13, further comprising controlling (610) the vacuum (206) applied to the composite layup (202, 408) to facilitate the shaping (246, 306) of the composite layup (202, 408).
19. Processing (248) the composite layup (202, 408) comprises: removing the composite lay-up (202, 408) having the formed shape (222) from the vacuum envelope (208); and 14. The method (600) of claim 13, comprising placing (618) the composite layup (202, 408) having the shaped shape (222) into or on at least one of a second tool (204, 406) (238).
20. A method (700) for forming (246, 306) a composite layup (202, 408), comprising: loading (702) the composite layup (202, 408) under vacuum (206) within a vacuum envelope (208) into a forming machine (226, 402); and A method (700) comprising: using a sweeper (228, 404) of the forming machine (226, 402) to sweep (704) the composite layup (202, 408) under the vacuum (206) within the vacuum envelope (208) against a tool (204, 406).
21. 21. The method (700) of claim 20, further comprising heating (706) the composite layup (202, 408) while the sweeper (228, 404) holds the composite layup (202, 408) against the tool (204, 406) to maintain the formed shape (222) of the composite layup (202, 408).
22. The method (700) of claim 20, further comprising heating (708) the composite lay-up (202, 408) on the tool (204, 406) using an oven (232).
23. 21. The method (700) of claim 20, wherein heating the composite layup (202, 408) melts (710) at least one of a thermoplastic veil (218) or a thermoplastic stitching (220).
24. 21. The method (700) of claim 20, further comprising injecting (236, 712) a resin (234) into the composite layup (202, 408) within the vacuum envelope (208) after sweeping the composite layup (202, 408) over the tool (204, 406).
25. 21. The method of claim 20, wherein the sweeper of the forming machine takes the form of an inflatable bladder or a compliant wiper, and wherein sweeping the composite layup under the vacuum within the vacuum envelope against the tool includes using the inflatable bladder to apply pressure to reduce wrinkles during the sweep.
26. A method (800) for forming (246, 306) a composite layup (202, 408), comprising: disposing (802) multiple layers (252) of material (254) to form the composite layup (202, 408) including at least one of a resin (221) or a thermoplastic material (216); debulking (244, 804) the composite lay-up (202, 408) by applying a vacuum (206) within a vacuum envelope (208) prior to said molding (246, 306); forming (246, 306, 806) the composite layup (202, 408) onto a tool (204, 406) while the composite layup (202, 408) is under the vacuum (206) within the vacuum envelope (208) to create a formed shape (222) for the composite layup (202, 408); and heating (250, 314, 808) the composite layup (202, 408) while under the vacuum (206) to maintain the formed shape (222) of the composite layup (202, 408) by tacking the composite layup (202, 408).
27. 27. The method (800) of claim 26, further comprising controlling (810) the vacuum (206) applied to the composite layup (202, 408) to control slippage of multiple layers (252) of the material (254) of the composite layup (202, 408).
28. 27. The method (800) of claim 26, further comprising resin infusing (236, 814) the composite layup (202, 408) within the vacuum envelope (208) after molding the composite layup (202, 408).
29. Shaping the composite layup (202, 408) includes sweeping (704) the composite layup (202, 408) under the vacuum (206) within the vacuum envelope (208) against the tool (204, 406) using a sweeper (228, 404) of a forming machine (226, 402), the sweeper (228, 404) of the forming machine (226, 402) taking the form of an inflatable bladder (229) or a compliant wiper (231), and the vacuum envelope (208) is 27. The method (800) of claim 26, wherein sweeping (704) the composite layup (202, 408) under the vacuum (206) within an envelope (208) against the tool (204, 406) includes (816) sweeping the composite layup (202, 408) against the tool (204, 406) using the inflatable bladder (229) or the compliant wiper (231) to apply pressure to reduce the occurrence of wrinkles during the sweeping.
30. 27. The method (800) of claim 26, wherein the thermoplastic material (216) takes the form of at least one of a thermoplastic veil (218) or a thermoplastic stitching (220).
31. 31. The method (800) of claim 30, further comprising stitching (812) the multiple layers (252) of the material (254) together using thermoplastic stitching (220) prior to placing (802) the multiple layers (252) of the material (254) to form the composite layup (202, 408).