Composite stringer package, and system and method for manufacturing a composite stringer package.

Abstract

This invention provides a system for manufacturing composite stringer packages. [Solution] The system includes a tray, a lid, a deformable membrane, and a vacuum rig. The tray includes a receptacle. The lid is configured to move relative to the tray between an open and a closed state. The deformable membrane is configured to be positioned on the tray. The vacuum rig is coupled to the tray. When the lid is in the closed state, the lid and the tray are sealed to each other to form a sealed chamber. When the lid is in the closed state, the deformable membrane is positioned within the sealed chamber between the tray and the lid. When the lid is in the closed state, the vacuum rig is configured to apply a vacuum to the sealed chamber.

Description

Technical Field

[0001] Priority Claim This application claims priority to U.S. Patent Application No. 63 / 702,253, filed Oct. 2, 2024, the entire content of which is incorporated herein by reference.

[0002] The present disclosure generally relates to composite material manufacturing, and more particularly to composite stringer packages, and systems and methods for constructing, consolidating, and holding composite stringer packages for composite material manufacturing.

Background Art

[0003] Aircraft generally include a fuselage, which can be considered a basic skeleton to which a skin is attached to form a smooth aerodynamic outer surface. Stringers of various shapes can be used to reinforce the fuselage and wing skins of an aircraft. To reduce the weight of an aircraft, composite materials are often used in aircraft. Modern aircraft may include both composite stringers and composite skins. Conventionally, composite stringers are attached to the composite skin by using fasteners, or by curing the composite stringer onto the composite skin, or by a combination of these two. In some conventional processes, the composite stringer is assembled with a common curing tool or mandrel for both the composite stringer and the composite skin.

[0004] Conventional composite stringer manufacturing requires the separate processing and placement of the components that form the composite stringer. This process is time-consuming and labor-intensive, and is required for each stringer. For example, the composite material plies that form the stringer are placed on a curing tool or mandrel. The composite material plies are then compressed on the curing tool or mandrel in an initial compaction step. Subsequently, bladder and / or radius fillers are placed individually on the curing tool, if necessary, to complete the stringer package. The stringer package is then compacted or otherwise compressed on the curing tool or mandrel in a subsequent compression step. Next, the composite preforms that form the composite outer panel are placed on the curing tool. The entire composite structure is then compacted or compressed again in a final compression step.

[0005] Each process involved in the production of composite stringers increases the overall manufacturing time. This manufacturing time can limit the number of aircraft that can be produced. Therefore, those skilled in the art continue their research and development efforts in the field of composite material manufacturing. [Overview of the Initiative]

[0006] A system for manufacturing composite stringer packages, a method for manufacturing composite stringer packages, a method for manufacturing composite materials, and examples of composite stringer packages are disclosed. The following is a non-exclusive list of examples of the subject matter covered by this disclosure, some of which are claimed and some are not. [Means for solving the problem]

[0007] In one example, the disclosed system includes a tray, a lid, a deformable membrane, and a vacuum rig. The tray includes a receptacle. The lid is configured to move relative to the tray between an open and a closed position. The deformable membrane is configured to be positioned on the tray. The vacuum rig is coupled to the tray. When the lid is closed, the lid and the tray are sealed to each other to form a sealed chamber. When the lid is closed, the deformable membrane is positioned within the sealed chamber between the tray and the lid. When the lid is closed, the vacuum rig is configured to apply a vacuum to the sealed chamber.

[0008] In one example, the disclosed manufacturing method includes (1) placing a deformable membrane on a tray; (2) assembling a composite stringer package; (3) positioning a lid closed to the tray to form a sealed chamber; (4) applying a vacuum to the sealed chamber when the lid is closed; and (5) compressing the composite stringer package between the deformable membrane and the lid by applying a vacuum.

[0009] In one example, the disclosed manufacturing method includes (1) placing a composite charge and a bladder in a housing to form a composite stringer package; (2) compacting the composite stringer package in the housing to form a compacted composite stringer package; (3) transporting the compacted composite stringer package in the housing; and (4) applying the compacted composite stringer package to a mandrel.

[0010] In one example, the disclosed composite stringer package comprises a composite charge positioned within a tray receptacle such that a deformable membrane lining the tray is located between the composite charge and the tray. The composite stringer package also includes a bladder positioned within the receptacle such that the composite charge is located between the deformable membrane and the bladder. The composite charge and bladder are enclosed within a sealed chamber formed by a lid and a tray. The composite charge and bladder are compressed between the deformable membrane and the lid by applying a vacuum within the sealed chamber via the deformable membrane.

[0011] Other examples of systems, methods, and composite stringer packages will become apparent from the following detailed description, accompanying drawings, and accompanying claims. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic block diagram of an example of a composite material manufacturing environment. [Figure 2] This is a flowchart illustrating an example of a method for manufacturing a composite material stringer package. [Figure 3] This is a flowchart illustrating an example of a composite material manufacturing method. [Figure 4] This is a schematic exploded perspective view of an example of a part of a system for fabricating and holding composite stringer packages. [Figure 5] This is a schematic perspective view of an example of a part of the system. [Figure 6] This is a schematic perspective view of an example of a part of the system. [Figure 7] This is a schematic perspective view of an example of a part of the system. [Figure 8] This is a schematic perspective view of an example of a breather and seal component of a system. [Figure 9] This is a schematic perspective cross-sectional view of an example of a part of the system's breather and seal. [Figure 10] This is a schematic perspective view of an example of a system vacuum rig. [Figure 11]Figure 10 is a schematic perspective cross-sectional view of an example of a vacuum rig. [Figure 12] This is a schematic perspective view of an example of a system vacuum rig. [Figure 13] Figure 12 is a schematic perspective cross-sectional view of an example of a vacuum rig. [Figure 14] This is a schematic cross-sectional view of an example system. [Figure 15] This is a schematic cross-sectional view of an example of a system and composite stringer package. [Figure 16] This is a schematic diagram of an example aircraft. [Figure 17] This is a flowchart illustrating an example of aircraft manufacturing and maintenance procedures. [Modes for carrying out the invention]

[0013] This disclosure recognizes that components of a hat-shaped composite stringer for aircraft, comprising a bladder, one or more corner fillers, one or more composite charges forming the upper part of a hat that slopes down to opposing flanges, and one or more composite charges forming the lower part from flange to flange, are currently assembled manually on mandrels, such as hardened mandrels associated with aircraft fuselage or wing sections. Ultimately, this requires that the layup and manufacturing of a part (e.g., fuselage or wing) include the time required to assemble several components of each stringer. In that case, this process must be repeated for each of the many stringers used in a part (e.g., around the fuselage).

[0014] The present disclosure also recognizes that in the layup and manufacture of components, each of the stringer components needs to be assembled manually in sequence. In many cases, such stringer fabrication can only be performed when the mandrel is accessible to the operator and / or ergonomically available. Thus, it is common to rotate the mandrel with respect to the operator based on an ergonomically convenient position for each of the stringers, which is called serial kitting. Thereafter, the fabricated stringers need to be held in place until all of the remaining stringers are fabricated manually or kitted to the mandrel. This sequential process takes a significant amount of time.

[0015] The systems and methods disclosed herein enable the assembly of composite stringer components in the manufacturing process at a faster pace than currently possible. The systems and methods disclosed herein advantageously enable the fabrication or "kitting" of stringers upstream of the current process, away from the mandrel. The systems and methods disclosed herein advantageously enable the fabrication or kitting of all stringers in parallel, rather than in a conventional sequential kitting process. The systems and methods disclosed herein advantageously enable the stringer fabrication or kitting process to be carried out away from the spatial limitations imposed by the mandrel. The systems and methods disclosed herein advantageously enable the fabricated or kitted stringers to be compacted again in parallel before being placed on the mandrel. The systems and methods disclosed herein advantageously enable the stringer fabrication or kitting process to be carried out at multiple or various locations, such as away from the mandrel. The systems and methods disclosed herein advantageously enable the placement of the prepared or kitted stringers into a mandrel, thus reducing the time the mandrel is occupied. The systems and methods disclosed herein advantageously enable the holding of the prepared or kitted stringers until the time of placement into the mandrel.

[0016] As will be described in more detail herein, examples of systems and methods disclosed herein enable kitting of all components required for a composite stringer package in a composite manufacturing environment 250, including bladder, composite ply, and corner filler. Examples of systems and methods disclosed herein enable compaction or compression of the composite stringer package to form a compacted composite stringer package. Examples of systems and methods enable holding and transporting the compacted composite stringer package. Examples of systems and methods enable placing the entire compacted composite stringer package onto a curing tool in a single unit.

[0017] It will be understood that the components of system 100 and composite material stringer package 200 are schematically illustrated by the examples of FIGS. 4-15. Thus, the different components of system 100 and / or composite material stringer package 200 may be shown spaced apart for clarity.

[0018] Here, referring to FIGS. 1 and 4-15 by way of example, the present disclosure relates to a system 100 for fabricating a composite material stringer package 200, also referred to as a stringer kit system. The following is an example of system 100 according to the present disclosure. Examples of system 100 include several elements, features, and components. Not all of the elements, features, and / or components illustrated or described in an example are required in that example. Some or all of the elements, features, and / or components illustrated or described in an example can be combined with other examples in various ways without including the other elements, features, and / or components described in those other examples, although one or more such combinations are not explicitly illustrated or described by way of example herein.

[0019] As shown in FIGS. 1, 4-7, 14, and 15, in one or more examples, system 100 includes a tray 110. Tray 110 is configured to receive and / or support at least a portion of composite material stringer package 200. Tray 110 is configured to house and hold composite material stringer package 200 as needed during composite material manufacturing operations. Tray 110 forms a base structure (e.g., as shown in FIG. 4) that supports the components of composite material stringer package 200 during component placement and fabrication of composite material stringer package 200.

[0020] As shown in Figures 1, 4-6, 14, and 15, in one or more examples, the tray 110 includes a receptacle 112. The receptacle 112 is configured to receive the components of the composite stringer package 200 during fabrication or layup. Generally, the tray 110 includes a support surface on which the components of the composite stringer package 200 are placed and supported during fabrication. The support surface of the tray 110 has a geometric shape suitable for the desired geometric shape and / or shape of the stringer fabricated using the system 100. In one or more examples, the stringer is configured to have a hat-shaped cross section 202. Thus, the tray 110 is configured to support the composite stringer package 200 so that the composite stringer package 200 has a hat-shaped cross section 202. In one or more examples, the tray 110 includes a raised edge that surrounds the receptacle 112 or forms a shoulder 114 that defines the periphery of the receptacle 112. In these examples, the support surface of the tray 110 is formed by the bottom and walls of the receptacle 112 and the shoulder 114. In one or more examples, the support surface has a shape that supports the hat-shaped cross section 202 of the composite stringer package 200 manufactured using the system 100.

[0021] As shown in Figure 4, a composite stringer having a hat-shaped cross section 202 generally includes a cap, a first web extending from the cap, a first flange extending from the first web on the opposite side of the cap, a second web extending from the cap on the opposite side of the first web, and a second flange extending from the second web on the opposite side of the cap.

[0022] As shown in Figures 1, 4-7, 14, and 15, in one or more examples, the system 100 includes a lid 120. The lid 120 is configured to surround the composite stringer package 200 between the tray 110 and the lid 120. In one or more examples, the lid 120 is configured to move between an open and a closed state relative to the tray 110. In the closed state, the lid 120 closes the receptacle 112, surrounding the composite stringer package 200 between the tray 110 and the lid 120. The lid 120 can close the housing 102 so that the tray 110 and the lid 120 form a sealed internal chamber (e.g., a sealed chamber 104) that holds the composite stringer package 200, which can be pressurized by the application of vacuum to compress the composite stringer package 200. In one or more examples, the lid 120 also functions as a molding tool in which the composite stringer package 200 is compacted or compressed when a vacuum is applied.

[0023] In one or more examples, the tray 110 and lid 120 combine to form the housing 102 of the system 100. In these examples, the housing 102 forms a sealed chamber 104 that receives and surrounds the components of the composite stringer package 200 during fabrication and compaction.

[0024] As shown in Figures 1 and 15, in one or more examples, when the lid 120 is closed, the lid 120 and the tray 110 are sealed to each other to form a sealed chamber 104. The components of the composite stringer package 200 are placed inside the sealed chamber 104 for compaction or compression using the system 100. The sealed chamber 104 allows for the application of vacuum to the composite stringer package 200 placed inside the sealed chamber 104.

[0025] For the purposes of this disclosure, unless otherwise specified, items that are sealed to one another and other uses of the term “sealed” refer to items that are airtight and therefore prevent any gas from entering or leaving. For example, references to “sealed,” “sealed,” and similar terms refer to airtight seals or seals.

[0026] As shown in Figures 1, 5-7, 14, and 15, in one or more examples, the lid 120 is coupled to the tray 110. In one or more examples, the system 100 includes a hinge 194. The hinge 194 is coupled to the tray 110 and the lid 120. The hinge 194 is configured to allow the lid 120 to rotate relative to the tray 110 between an open and a closed position.

[0027] As shown in Figures 1, 7, 14, and 15, in one or more examples, the system 100 includes a latch 192. The latch 192 is configured to secure the lid 120 to the tray 110 in a closed position. In one example, the latch 192 secures or locks the lid 120 to the tray 110 in a closed position. In these examples, the latch 192 is also releaseable, allowing the lid 120 to move relative to the tray 110.

[0028] As shown in Figures 1, 4-6, 14, and 15, in one or more examples, the system 100 includes a deformable membrane 130. The deformable membrane 130 is configured to compress the composite stringer package 200 when a vacuum is applied. In one or more examples, the deformable membrane 130 is configured to be placed on a tray 110. In one or more examples, a portion of the deformable membrane 130 is configured to be received by a receptacle 112 of the tray 110. In one or more examples, the deformable membrane 130 lines the tray 110, at least the receptacle 112 of the tray 110, etc. In one or more examples, when the lid 120 is closed, the deformable membrane 130 is placed in a sealed chamber 104 between the tray 110 and the lid 120. In one or more examples, while the housing 102 is closed and a vacuum is applied within the sealed chamber 104, the deformable membrane 130 is pulled toward the molding surface (e.g., the inner surface) of the lid 120. When a vacuum is applied, the deformable membrane 130 applies a compacting or compressive force to the composite stringer package 200.

[0029] As shown in Figures 4-6, 14 and 15, with the deformable membrane 130 positioned on the tray 110, the first portion 132 of the deformable membrane 130 is received into the receptacle 112. In one or more examples, the tray 110 includes a shoulder portion 114, which surrounds the receptacle 112. In one or more examples, with the deformable membrane 130 positioned on the tray 110, the second portion 134 of the deformable membrane 130 is positioned on the shoulder portion 114.

[0030] As shown in Figure 15, in one or more examples, when the lid 120 is closed, the lid 120 is sealed to the shoulder 114 of the tray 110 around the second portion 134 of the deformable membrane 130. In one or more examples, when the lid 120 is closed, the second portion 134 of the deformable membrane 130 is clamped between the shoulder 114 and the lid 120.

[0031] As shown in Figures 1, 4-6, 14, and 15, in one or more examples, the system 100 includes a vacuum rig 170. The vacuum rig 170 is configured to apply a vacuum (e.g., negative pressure) to a composite stringer package 200 surrounded by a tray 110 and a lid 120. In one or more examples, the vacuum rig 170 is coupled to the tray 110. In one or more examples, when the lid 120 is closed, the vacuum rig 170 is configured to apply a vacuum to a sealed chamber 104.

[0032] As shown in Figures 1, 4-6, 8, 9, 14, and 15, in one or more examples, the system 100 includes a breather 142. When the lid 120 is closed, the breather 142 is located between the lid 120 and the tray 110. When the lid 120 is closed, the breather 142 is configured to distribute vacuum into the sealed chamber 104. In one or more examples, the breather 142 is coupled to the lid 120. When the lid 120 is closed, the breather 142 is in contact with the inner surface of the lid 120 and the shoulder 114 of the tray 110.

[0033] As shown in Figures 8 and 9, in one or more examples, the breather 142 includes or takes the form of a strip of material configured to allow gas to move out of the sealed chamber 104 and to help equalize the distributed vacuum pressure throughout the sealed chamber 104 and the composite stringer package 200. In one or more examples, the breather 142 includes an arrangement of intersecting channels 196. At least one of the channels 196 terminates at an opening located on the inner circumference of the breather 142, and is in fluid communication with the sealed chamber 104 when the lid 120 is closed.

[0034] As shown in Figures 1, 4-6, 8, 9, 14, and 15, in one or more examples, the system 100 includes a seal 144. When the lid 120 is closed, the seal 144 seals the lid 120 against the tray 110. When the lid 120 is closed, the seal 144 contacts the inner surface of the lid 120 and the shoulder 114 of the tray 110. In one or more examples, the seal 144 is located or positioned around the breather 142. In one or more examples, the seal 144 is coupled to the lid 120 around and / or near the periphery of the breather 142. The seal 144 can have any suitable cross-sectional shape, such as circular, semicircular, square, rectangular, or L-shaped.

[0035] As shown in Figures 1, 4 to 7, in one or more examples, the lid 120 includes a vent 122. When the lid 120 is closed, the vent 122 is configured to be in fluid communication with the receptacle 112. When the lid 120 is closed and the composite stringer package 200 is placed inside the sealed chamber 104, the vent 122 is configured to be in fluid communication with the bladder 206 of the composite stringer package 200. The vent 122 allows the bladder 206 to remain pressurized at atmospheric pressure while a vacuum is applied to the sealed chamber 104.

[0036] As shown in Figures 1, 4, 5, 7, 10, and 11, in one or more examples, the vacuum rig 170 includes a vacuum plug 172 and a vacuum fitting 176. The vacuum plug 172 is located inside the receptacle 112. The vacuum plug 172 has a vacuum port 174. The vacuum fitting 176 is coupled to the vacuum plug 172. The vacuum fitting 176 is in fluid communication with the vacuum port 174. With the lid 120 closed and sealed in the tray 110, the vacuum port 174 is in fluid communication with the sealed chamber 104. The vacuum plug 172 and vacuum fitting 176 enable the removal of gas from the sealed chamber 104, and thus the application of vacuum to the composite stringer package 200 located inside the sealed chamber 104.

[0037] As shown in Figures 1, 4, and 5, in one or more examples, the deformable membrane 130 includes a vacuum opening 136. With the deformable membrane 130 accepted into the receptacle 112, the vacuum opening 136 is aligned with the vacuum port 174. The vacuum opening 136 allows fluid communication between the sealed chamber 104 and the vacuum fitting 176, and thus allows gas to be removed from the sealed chamber 104 through the deformable membrane 130.

[0038] As shown in Figures 1, 4, and 5, in one or more examples, the system 100 includes a vacuum fastener 146. The vacuum fastener 146 is configured to align the vacuum opening 136 with the vacuum port 174. The vacuum fastener 146 is also configured to connect the deformable membrane 130 to the tray 110. In one or more examples, with a portion of the deformable membrane 130 positioned between the vacuum fastener 146 and the vacuum plug 172, the vacuum fastener 146 is received by the vacuum port 174 of the vacuum plug 172 and locked or secured to the vacuum plug 172 within the vacuum port 174.

[0039] As shown in Figures 1, 6, 12, and 13, in one or more examples, the vacuum rig 170 includes a gauge plug 182. The gauge plug 182 is located inside a receptacle 112. In one or more examples, the gauge plug 182 is located along the receptacle 112 on the opposite side of the vacuum plug 172. In one or more examples, the gauge plug 182 includes a gauge port 184. In one or more examples, the vacuum rig 170 includes a gauge 186 coupled to the gauge plug 182. The gauge 186 is in fluid communication with the gauge port 184. The gauge 186 and the gauge plug 182 enable the measurement and monitoring of the negative pressure (e.g., vacuum level) applied to the composite stringer package 200 within the sealed chamber 104 during the consolidation or compression of the components of the composite stringer package 200.

[0040] As shown in Figures 1 and 6, in one or more examples, the deformable membrane 130 includes a gauge opening 138. With the deformable membrane 130 accepted into the receptacle 112, the gauge opening 138 is aligned with the gauge port 184. The gauge opening 138 allows fluid communication between the sealed chamber 104 and the gauge 186 through the deformable membrane 130.

[0041] As shown in Figures 1 and 6, in one or more examples, the system 100 includes a gauge fastener 148. The gauge fastener 148 is configured to align the gauge opening 138 with the gauge port 184. The gauge fastener 148 is also configured to connect the deformable membrane 130 to the tray 110. In one or more examples, with a portion of the deformable membrane 130 positioned between the gauge fastener 148 and the gauge plug 182, the gauge fastener 148 is received by the gauge port 184 of the gauge plug 182 and locked or secured to the gauge plug 182 within the gauge port 184.

[0042] In other examples (not explicitly shown), system 100 (e.g., vacuum rig 170) may include a second vacuum plug and a second vacuum fitting. The second vacuum plug is located within the receptacle 112, such as at the end of tray 110 opposite to the end where the vacuum plug 172 is located. The second vacuum plug includes a second vacuum port. The second vacuum fitting is coupled to the second vacuum plug. The second vacuum fitting is in fluid communication with the second vacuum port. With the lid 120 closed and the tray 110 sealed, the second vacuum port is in fluid communication with the sealed chamber 104. The second vacuum plug and second vacuum fitting allow gas to be removed from the sealed chamber 104 from both ends of tray 110, and thus allow vacuum to be applied to the composite stringer package 200 located within the sealed chamber 104. In these examples, the deformable membrane 130 includes a second vacuum opening. With the deformable membrane 130 received in the receptacle 112, the second vacuum opening is aligned with the second vacuum port. The second vacuum opening allows fluid communication between the sealed chamber 104 and the second vacuum fitting, and thus allows gas to be removed from the sealed chamber 104 through the deformable membrane 130. In these examples, the vacuum fastener 146 is configured to align the vacuum opening 136 with the vacuum port 174. The second vacuum fastener is also configured to connect the deformable membrane 130 to the tray 110. In one or more examples, with a portion of the deformable membrane 130 positioned between the second vacuum fastener and the second vacuum plug, the second vacuum fastener is received into the second vacuum port of the second vacuum plug and locked or secured to the second vacuum plug within the second vacuum port.

[0043] In one or more examples, the vacuum plug 172 is located within the receptacle 112 at one end of the tray 110 (e.g., the first end). The gauge plug 182 (or second vacuum plug) is located within the receptacle 112 at the other end of the tray 110 opposite to the vacuum plug 172 (e.g., the second end). In one or more examples, the vacuum plug 172 is located near the first end of the composite stringer package 200 or the first end of the deformable membrane 130. The gauge plug 182 (or second vacuum plug) is located near the second end of the composite stringer package 200 or the second end of the deformable membrane 130.

[0044] As shown in Figure 1, in one or more examples, the lid 120 is made from a rigid material 150. In one or more examples, the rigid material 150 of the lid 120 is made from a composite material 152. In one or more examples, the rigid material 150 of the lid 120 is made from a metallic material 154. In one or more examples, the rigid material 150 of the lid 120 is made from a polymer material 156. In one or more examples, the rigid material 150 of the lid 120 is made from a polycarbonate material 158.

[0045] As shown in Figure 1, in one or more examples, the tray 110 is made from a rigid material 150. In one or more examples, the rigid material 150 of the tray 110 is made from a composite material 152. In one or more examples, the rigid material 150 of the tray 110 is made from a metallic material 154. In one or more examples, the rigid material 150 of the tray 110 is made from a polymer material 156. In one or more examples, the rigid material 150 of the tray 110 is made from a polycarbonate material 158.

[0046] As shown in Figure 1, in one or more examples, the deformable membrane 130 is made from a flexible material 160. In one or more examples, the rubber material 162 of the deformable membrane 130 is made from a rubber material 162. In one or more examples, the flexible material 160 of the deformable membrane 130 is made from a polymer material 164. In one or more examples, the flexible material 160 of the deformable membrane 130 is made from a silicone material 166. In one or more examples, the deformable membrane 130 is made from a material suitable for contact with the unfired composite material of the components forming the composite stringer package 200. In one or more examples, the deformable membrane 130 includes or is formed from synthetic rubber sheets, silicone rubber sheets, fluoroelastomer (e.g., Viton®) rubber sheets, such as those commercially available from Mosites Rubber Company, Inc. in Texas, USA.

[0047] Referring here to Figure 2, as an example, this disclosure also relates to a method 1000 for producing a composite stringer package 200, also referred to herein as the stringer kitting method. The following are examples of method 1000 according to this disclosure. In one or more examples, method 1000 is carried out using system 100 (Figure 1). Examples of method 1000 include several elements, steps, actions or processes. Not all elements, steps, actions or processes described or illustrated in an example are required in that example. Some or all elements, steps, actions or processes described or illustrated in an example can be combined in various ways with other examples without requiring the inclusion of other elements, steps, actions or processes described in other examples, but one or more such combinations are not expressly described or illustrated herein by example.

[0048] In one or more examples, method 1000 includes step 1002 of placing the deformable membrane 130 on the tray 110. In one or more examples, the deformable membrane 130 is placed on the tray 110 such that the deformable membrane 130 lines the tray 110 and is positioned between the tray 110 and the components of the composite stringer package 200.

[0049] In one or more examples, method 1000 includes step 1004 for assembling a composite stringer package 200, which includes a hat-shaped section 202. In one or more examples, step 1004 for assembling the composite stringer package 200 includes step 1006 for placing the composite charge 204 in the receptacle 112 of the tray 110 such that the deformable membrane 130 is located between the tray 110 and the composite charge 204. In one or more examples, step 1004 for assembling the composite stringer package 200 includes step 1008 for placing the bladder 206 in the receptacle 112 of the tray 110 such that the composite charge 204 is located between the tray 110 and the bladder 206. In one or more examples, step 1004 of assembling the composite stringer package 200 includes placing at least one corner filler (e.g., a first corner filler 212 and / or a second corner filler 214) in the receptacle 112 of the tray 110 along each side of the bladder 206.

[0050] In one or more examples, the composite charge 204 has a hat-shaped section 202. In some examples, the bladder 206 is positioned on or above the composite charge 204. In other examples, the composite charge 204 is positioned around (e.g., molded or encased) at least a portion of the bladder 206 to further support the hat-shaped section 202. The first corner filler 212 is positioned in contact with the composite charge 204 and the bladder 206. The second corner filler 214 is positioned in contact with the composite charge 204 and the bladder 206. In one or more examples, the first corner filler 212 and / or the second corner filler 214 extend along the entire length of the composite stringer package 200 and are aligned spaced apart from each other.

[0051] In one or more examples, method 1000 includes the steps of: positioning the lid 120 in a closed state relative to the tray 110 to form a sealed chamber 104; and sealing the lid 120 to the tray 110 in a closed state using a seal 144 located between the lid 120 and the tray 110.

[0052] In one or more examples, method 1000 includes step 1014 of fluidly coupling a vacuum source 178 to a sealed chamber 104 using a vacuum rig 170. If the lid 120 is closed and the vacuum source 178 is coupled to the vacuum rig 170, method 1000 includes step 1016 of applying a vacuum to the sealed chamber 104. In one or more examples, method 1000 includes step 1018 of distributing the vacuum to the sealed chamber 104 using a breather 142 located between the lid 120 and the tray 110.

[0053] In one or more examples, method 1000 includes step 1020 of forming a sealed chamber 104 with the lid 120 closed and sealed to the tray 110. The composite stringer package 200 (e.g., assembled components of the composite stringer package 200) is enclosed within the sealed chamber 104.

[0054] In one or more examples, a vacuum is applied to a chamber formed by the tray 110 and the lid 120 to form a sealed chamber 104. In these examples, by applying a vacuum before or during the formation of the sealed chamber 104, the vacuum can provide a force that allows the seal 144 to "catch" and form an airtight chamber when the lid 120 is closed (e.g., when moved to the closed position). In these examples, the atmospheric pressure inside the sealed chamber 104 is reduced using vacuum, and then the atmospheric pressure outside the sealed chamber 104 results in compression. Thus, without a vacuum, the inside and outside of the sealed chamber 104 would be balanced.

[0055] In one or more examples, system 100 includes a vacuum source 178. The vacuum source 178 is coupled to a vacuum fitting 176. The vacuum source 178 generates a vacuum and brings it into the housing 102 and the sealed chamber 104. As an example, the vacuum source 178 includes a vacuum pump coupled to the vacuum fitting 176 via a suitable vacuum line, etc. When the housing 102 is closed, the vacuum source 178 is selectively controlled to apply a vacuum into the sealed chamber 104. In one or more examples, method 1000 includes step 1022 of measuring the vacuum pressure in the sealed chamber 104 using a vacuum rig 170.

[0056] In one or more examples, method 1000 includes step 1024 of venting the bladder 206 to the atmosphere through a vent 122 of the lid 120. By venting the bladder 206, it is possible to keep the bladder 206 pressurized during the compression of the composite stringer package 200.

[0057] In one or more examples, method 1000 includes step 1026 of compressing the composite stringer package 200 between the deformable membrane 130 and the lid 120. The compression step 1026 is achieved by or in accordance with the application of a vacuum.

[0058] In one or more examples, Method 1000 includes step 1028 of holding a composite stringer package 200 in a sealed chamber 104. In these examples, the composite stringer package 200 is held in a sealed chamber 104 formed by a tray 110 and a lid 120, and a vacuum is applied to the sealed chamber 104. In this embodiment, the composite stringer package 200 can be fabricated (for example, as shown by Method 2000) and compacted, and kept ready for application during larger composite manufacturing operations.

[0059] Referring here to Figure 3, as an example, this disclosure further covers Method 2000 for the manufacture of composite materials, also referred to herein as a composite material manufacturing method. The following are examples of Method 2000 according to this disclosure. In one or more examples, Method 2000 is carried out using System 100 (Figure 1). Examples of Method 1000 include several elements, steps, operations or processes. Not all elements, steps, operations or processes described or illustrated in an example are required in that example. Some or all elements, steps, operations or processes described or illustrated in an example can be combined with other examples in various ways without requiring the inclusion of other elements, steps, operations or processes described in other examples, but one or more such combinations are not expressly described or illustrated herein by example.

[0060] In one or more examples, Method 2000 includes step 2002 of placing a composite charge 204, a bladder 206, and optionally, at least one of a first corner filler 212 and / or a second corner filler 214, within the housing 102. Method 2000 includes step 2004 of forming a composite stringer package 200 by arranging the components. In these examples, the housing 102 includes or is formed by a tray 110 and a lid 120.

[0061] In one or more examples, Method 2000 includes the step of fluidly coupling a vacuum source 178 to a sealed chamber 104. In one or more examples, the vacuum source 178 is fluidly coupled to the sealed chamber 104 using a vacuum rig 170. Method 2000 includes the step 2006 of applying a vacuum to the sealed chamber 104 in order to compress the composite stringer package 200. In one or more examples, a vacuum is applied to the sealed chamber 104 using a vacuum rig 170. In one or more examples, Method 2000 includes the step of measuring the vacuum pressure inside the sealed chamber 104. In one or more examples, the vacuum pressure is measured using a vacuum rig 170. In one or more examples, the Method includes the step of venting the bladder 206 of the composite stringer package 200 to the atmosphere through a vent 122 of the lid 120. The bladder 206 is vented to the atmosphere while a vacuum is applied.

[0062] In one or more examples, Method 2000 includes step 2008 of forming a sealed chamber 104 within a housing 102 that encloses a composite stringer package 200. In these examples, the sealed chamber 104 is formed by moving a lid 120 to a closed position, thereby sealing the lid 120 and the tray 110 together.

[0063] In one or more examples, a vacuum is applied to a chamber formed by the tray 110 and the lid 120 to form a sealed chamber 104. In these examples, by applying a vacuum before or during the formation of the sealed chamber 104, the vacuum can provide a force that allows the seal 144 to "catch" and form an airtight chamber when the lid 120 is closed (for example, when it is moved to the closed position).

[0064] In one or more examples, Method 2000 includes a step 2010 of consolidating or compressing the composite stringer package 200. In one or more examples, the components of the composite stringer package 200 are consolidated or otherwise compressed within a sealed chamber 104 and between the deformable membrane 130 and the lid 120. The consolidation step 2010 is achieved by or in accordance with the application of a vacuum. Method 2000 includes a step 2012 of forming a consolidated composite stringer package 210. The consolidated composite stringer package 210 is formed in accordance with the consolidation of the components of the composite stringer package 200 within the sealed chamber 104 by applying a vacuum.

[0065] In one or more examples, Method 2000 includes a step 2014 of holding a compacted composite stringer package 210 in a housing 102. In these examples, the compacted composite stringer package 210 is held in a sealed chamber 104 formed by the housing 102 (e.g., a tray 110 and a lid 120), and a vacuum is applied to the sealed chamber 104. In this embodiment, the composite stringer package 200 may be kept ready for application during subsequent composite manufacturing operations.

[0066] In one or more examples, Method 2000 includes step 2016 of transporting the compacted composite stringer package 210 from the housing 102 to the mandrel 220. Method 2000 includes step 2018 of removing the compacted composite stringer package 210 from the housing 102. Method 2000 includes step 2020 of placing the compacted composite stringer package 210 on the mandrel 220. Method 2000 includes step 2022 of placing the composite preform 222 on the mandrel 220 above the compacted composite stringer package 210. Method 2000 includes step 2024 of co-curing the composite preform 222 and the compacted composite stringer package 210 on the mandrel 220.

[0067] Referring here to Figures 1, 4-7, 14, and 15, the Disclosure further covers, as an example, a composite stringer package 200 and / or a compacted composite stringer package 210 (Figure 15). The following is an example of a composite stringer package 200 according to the Disclosure. The example of a composite stringer package 200 includes several elements, features, and components. In one or more examples, the composite stringer package 200 is manufactured using system 100 (Figure 1) and / or according to method 1000 (Figure 2). Not all elements, features, and / or components described or illustrated in an example are required in that example. Some or all elements, features, and / or components described or illustrated in an example can be combined with other examples in various ways without requiring the inclusion of other elements, features, and / or components described in other examples, but one or more such combinations are not expressly described or illustrated by example herein.

[0068] In one or more examples, the composite stringer package 200 includes a composite charge 204. The composite charge 204 is positioned within the receptacle 112 of the tray 110 such that a deformable membrane 130 lining the tray 110 is located between the composite charge 204 and the tray 110. The composite stringer package 200 includes a bladder 206. The bladder 206 is positioned within the receptacle 112 such that the composite charge 204 is located between the deformable membrane 130 and the bladder 206. In one or more examples of the composite stringer package 200, the composite charge 204 and the bladder 206 are enclosed within a sealed chamber 104 formed by a lid 120 and the tray 110. In one or more examples of the composite stringer package 200, the composite charge 204 and bladder 206 are compressed between the deformable membrane 130 and the lid 120 by creating a vacuum inside the sealed chamber 104 via the deformable membrane 130.

[0069] Examples of the system 100, method 1000, method 2000, and composite stringer package 200 described herein may be related to, or used in connection with, an aircraft 1200 (Figure 16) and an aerospace manufacturing and maintenance method 1100 (Figure 17). For example, the aircraft 1200 and / or the manufacturing and maintenance method 1100 may utilize the system 100 and / or a compacted composite stringer package 210 formed according to method 1000 and / or method 2000.

[0070] Figure 15 shows an example of an aircraft 1200. The aircraft 1200 can be any aerospace vehicle or platform. In one or more examples, the aircraft 1200 includes a fuselage 1202 having an interior 1206. The aircraft 1200 includes several onboard systems 1204 (e.g., high-level systems). An example of the onboard systems 1204 of the aircraft 1200 includes a propulsion system 1208, a hydraulic system 1212, an electrical system 1210, and an environmental system 1214. In other examples, the onboard systems 1204 also include one or more control systems coupled to the fuselage 1202 of the aircraft 1200. In yet another example, the onboard systems 1204 also include one or more other systems 1216, such as, but not limited to, a communications system, an avionics system, a software distribution system, a network communications system, a passenger information / entertainment system, a guidance system, a radar system, and a weapons system. The aircraft 1200 may have any number of composite components or structures, including composite stringers 1222, manufactured and / or compacted using system 100 and / or according to method 1000 and / or method 2000. For example, the fuselage 1218 and / or wings 1220 of the aircraft 1200 may include composite stringers 1222.

[0071] Referring to Figure 17, prior to the start of production of aircraft 1200, the manufacturing and maintenance procedures 1100 include the specifications and design 1102 of aircraft 1200 and material procurement 1104. During the production of aircraft 1200, the manufacturing of aircraft 1200's components and subassemblies 1106 and system integration 1108 are carried out. Subsequently, aircraft 1200 is brought into service 1112 after certification and transport 1110. Periodic maintenance and inspection 1114 include the modification, reconfiguration, and refurbishment of one or more systems of aircraft 1200.

[0072] Each process of the manufacturing and maintenance inspection method 1100 shown in Figure 17 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, the system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; the third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and the operator may be an airline, leasing company, military organization, flight operations organization, etc.

[0073] Examples of the system 100, method 1000, method 2000, and composite stringer package 200 shown and described herein may be employed in any one or more stages of the manufacturing and maintenance inspection method 1100 shown in the flowchart in Figure 17. In one example, a composite stringer 1222 for an aircraft 1200 may be manufactured and / or compacted using the system 100 and / or according to method 1000 during the manufacturing of components and subassemblies 1106 and / or as part of the system integration 1108. Furthermore, the composite stringer 1222 for the aircraft 1200 may be manufactured and / or compacted using the system 100 and / or according to method 1000 during the commissioning of the aircraft 1200 1112. Furthermore, composite stringers 1222 for aircraft 1200 may be manufactured and / or compacted using system 100 and / or according to method 1000 during system integration 1108 and certification and transport 1110. Similarly, composite stringers 1222 for aircraft 1200 may be manufactured and / or compacted using system 100 and / or according to method 1000 during the commissioning 1112 and maintenance and inspection 1114 of aircraft 1200.

[0074] For further details, refer to the accompanying drawings illustrating specific examples described herein. Other examples having different structures and functions will not deviate from the scope of this disclosure. Similar reference numerals may refer to the same feature, element, or component in different drawings. Throughout this disclosure, several items may be referred to individually as that item, several items may be referred to collectively as that item, and similar reference numerals may be used. Furthermore, as used herein, a feature, element, component, or step preceding the words "one (a)" or "one (an)" should be understood as not excluding multiple features, elements, components, or steps unless explicitly stated otherwise.

[0075] Exemplary and non-exclusive examples of the subject matter of this disclosure are provided above, although they are not necessarily claimed. References to “examples” in this specification mean that one or more features, structures, elements, components, properties and / or operating steps described in relation to an example are included in at least one aspect, embodiment and / or implementation of the subject matter of this disclosure. Thus, throughout this disclosure, the phrases “one example,” “another example,” “one or more examples,” and similar wording may, but not necessarily, refer to the same example. Furthermore, the subject matter characterizing any one example may, but not necessarily, include the subject matter characterizing any other example. Also, the subject matter characterizing any one example may, but not necessarily, be combined with the subject matter characterizing any other example.

[0076] As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured to perform” a specified function is capable of actually performing the specified function without modification, rather than merely having the potential to perform the specified function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware “configured to perform” a specified function is specifically selected, created, implemented, used, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” means an existing characteristic of the system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as “configured to perform” a particular function may also be described as “adapted to” and / or “operating to” perform that function.

[0077] Unless otherwise specified, terms such as “first,” “second,” and “third” are used herein solely as labels and are not intended to impose any order, arrangement, or hierarchical requirements on the items they refer to. Furthermore, a reference to, for example, the “second” item does not require or exclude the presence of, for example, the “first” item or items with lower numbers, and / or, for example, the “third” item or items with higher numbers.

[0078] As used herein, the phrase “at least one of” means, when used with a list of items, that any combination of one or more of the listed items may be used, or that only one of each item in the list may be required. For example, “at least one of item A, item B, and item C” may include, but not limited to, item A, or item A and item B. This example may also include item A, item B, and item C, or item B and item C. In other examples, “at least one of” may be, for example, two of item A, one of item B, and ten of item C, or four of item B and seven of item C, or any other suitable combination. As used herein, the terms “and / or” and the “ / ” symbol include any combination of one or more of the enumerated items relating to them.

[0079] For the purposes of this disclosure, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, connected in communication, or otherwise related to each other (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various examples, elements may be related directly or indirectly. For example, element A may be directly related to element B. In another example, element A may be indirectly related to element B, for example, through another element C. It will be understood that not all relationships between various disclosed elements are necessarily represented. Therefore, other couplings may exist that are not illustrated.

[0080] As used herein, the term “approximately” refers to or represents conditions that are close to but not exactly as described, and that still perform the desired function or achieve the desired result. For example, “approximately” refers to conditions that are within a certain acceptable tolerance or precision, such as conditions that are within 10% of the described conditions. However, the term “approximately” does not exclude conditions that are strictly described. As used herein, the term “substantially” refers to conditions that are essentially described, and that perform the desired function or achieve the desired result.

[0081] Figures 1 and 4-16 above may represent functional elements, features, or components and do not necessarily imply a specific structure. Therefore, modifications, additions, and / or omissions may be made to the illustrated structures. Furthermore, those skilled in the art will understand that not all elements, features, and / or components described and illustrated in Figures 1 and 4-16 are necessarily included in all examples, and not all elements, features, and / or components described herein are necessarily shown in each exemplary example. Therefore, some of the elements, features, and / or components described and illustrated in Figures 1 and 4-16 may be combined in various ways, and such combinations, one or more of which are not explicitly shown herein, may be combined without requiring the inclusion of other features described and illustrated in Figures 1 and 4-16, other drawings, and / or accompanying disclosures. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise specified, the schematic diagrams of the examples shown in Figures 1 and 4-16 above do not imply structural limitations with respect to the exemplary examples. Rather, while one exemplary structure is shown, it should be understood that the structure may be modified where appropriate. Therefore, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, similar, or at least substantially similar, elements, features, and / or components are labeled with the same numbers in Figures 1 and 4-16, respectively, and such elements, features, and / or components may not be described in detail herein with reference to Figures 1 and 4-16, respectively. Similarly, not all elements, features, and / or components may be labeled in Figures 1 and 4-16, but for consistency, their associated reference numbers may be used herein.

[0082] In Figures 2, 3, and 17 above, blocks may represent operations, steps, and / or parts thereof, and the lines connecting the various blocks do not imply a specific order or dependency of operations or parts thereof. It will be understood that not all dependencies between various disclosed operations are necessarily represented. Figures 2, 3, and 17, and accompanying disclosures illustrating the operations of the disclosed methods described herein, should not be construed as necessarily determining the sequence in which the operations are performed. Rather, one exemplary sequence is shown, but it should be understood that the sequence of operations may be modified where appropriate. Thus, modifications, additions, and / or omissions can be made to the illustrated operations, and certain operations may be performed in different orders or simultaneously. In addition, those skilled in the art will understand that not all described operations necessarily need to be performed.

[0083] Furthermore, throughout this Specification, references to features, benefits, or similar terms used herein do not imply that all features and benefits that may be realized in the examples disclosed herein should be or are found in any single example. Rather, terms referring to features and benefits should be understood to mean that a particular feature, benefit, or characteristic described in relation to an example is included in at least one example. Accordingly, descriptions of features, benefits, and similar terms used throughout this Disclosure may, but not necessarily, refer to the same example.

[0084] The features, advantages, and characteristics described in one example may be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein may be practiced without one or more of the particular features or advantages of a particular example. In other examples, additional features and advantages may be recognized in a particular example that are not present in all examples. Furthermore, while various examples of System 100, Method 1000, Method 2000, and Composite Stringer Package 200 are shown and described herein, those skilled in the art may recall modifications upon reading this specification. This application includes such modifications and is limited only by the claims. [Explanation of Symbols]

[0085] 100 Systems 102 Housing 104 Sealed Chamber 110 trays 112 Receptacles 114 Shoulder 120 Lid 122 Ventilation opening 130 Deformable film 132 The first part of the deformable film 134 The second part of the deformable membrane 136 Vacuum opening 138 gauge opening 142 Breezer 144 stickers 146 Vacuum fasteners 148 Gauge fasteners 150 rigid material 152 Composite materials 154 Metal materials 156 Polymer Materials 158 Polycarbonate materials 160 Flexible materials 162 Rubber materials 164 Polymer Materials 166 Silicone Materials 170 Vacuum Rig 172 Vacuum plug 174 Vacuum Ports 176 Vacuum fittings 178 Vacuum source 182 gauge plug 184 Gauge Port 186 gauge 192 Latch 194 Hinge 196 channels 200 Composite Material Stringer Package 202 Hat-shaped cross-section 204 Composite material charge 206 Brada 210 Compacted Composite Stringer Package 212 First corner filler 214 Second corner filler 220 Mandrels 222 Composite material preforms 250 Composite manufacturing environment

Claims

1. A system (100) for manufacturing a composite material stringer package (200), A tray (110) equipped with a receptacle (112), A lid (120) moves between an open state and a closed state relative to the tray (110), A deformable membrane (130) configured to be placed on the tray (110), A vacuum rig (170) coupled to the tray (110), Equipped with, When the lid (120) is in the closed state, The lid (120) and the tray (110) are sealed to each other to form a sealed chamber (104). The deformable membrane (130) is placed in the sealed chamber (104) between the tray (110) and the lid (120). A system (100) in which the vacuum rig (170) applies a vacuum to the sealed chamber (104).

2. The system (100) according to claim 1, wherein when the deformable membrane (130) is placed on the tray (110), a first portion (132) of the deformable membrane (130) is received in the receptacle (112).

3. The tray (110) further includes shoulder portions (114) surrounding the receptacle (112), When the deformable membrane (130) is placed on the tray (110), the second portion (134) of the deformable membrane (130) is placed on the shoulder portion (114). The system (100) according to claim 2.

4. The system (100) according to claim 3, wherein when the lid (120) is in the closed state, the lid (120) is sealed to the shoulder portion (114) of the tray (110) around the second portion (134) of the deformable membrane (130).

5. The system (100) according to claim 3, wherein when the lid (120) is in the closed state, the second portion (134) of the deformable membrane (130) is clamped between the shoulder portion (114) and the lid (120).

6. The system (100) according to claim 1, further comprising a breather (142) coupled to the lid (120), wherein when the lid (120) is in the closed state, the breather (142) is positioned between the lid (120) and the tray (110) and distributes vacuum to the sealed chamber (104).

7. The system (100) according to claim 6, further comprising a seal (144) coupled to the lid (120) around the breather (142), wherein the seal (144) seals the lid (120) to the tray (110) when the lid (120) is in the closed state.

8. The lid (120) is equipped with a ventilation opening (122), When the lid (120) is in the closed state, the vent (122) is configured to be in fluid communication with the receptacle (112). The system (100) according to claim 1.

9. The vacuum rig (170) A vacuum plug (172) is disposed within the receptacle (112) and is equipped with a vacuum port (174), A vacuum connector (176) is coupled to the vacuum plug (172) and is in fluid communication with the vacuum port (174), Equipped with, When the lid (120) is in the closed state and sealed to the tray (110), the vacuum port (172) is in fluid communication with the sealed chamber (104). The system (100) according to claim 1.

10. The deformable membrane (120) is provided with a vacuum opening (136), When the deformable membrane (120) is received by the receptacle (112), the vacuum opening (136) is aligned with the vacuum port (174). The system (100) according to claim 9.

11. The system (100) according to claim 9, further comprising a vacuum fastener (146) configured to align the vacuum opening (136) with the vacuum port (174) and to connect the deformable membrane (120) to the tray (110).

12. The system (100) according to claim 9, further comprising a gauge plug (182) located in the receptacle (112) opposite to the vacuum plug (172).

13. The gauge plug (182) is equipped with a gauge port (184), The vacuum rig (170) further comprises a gauge (186) coupled to the gauge plug (182) and in fluid communication with the gauge port (184), The system (100) according to claim 12.

14. The deformable membrane (120) is provided with a gauge opening (138), When the deformable membrane (120) is received within the receptacle (112), the gauge opening (138) is aligned with the gauge port (184). The system (100) according to claim 13.

15. The system (100) according to claim 14, further comprising a gauge fastener (148) that aligns the gauge opening (138) with the gauge port (184) and connects the deformable membrane (120) to the tray (110).

16. The system (100) according to claim 1, further comprising a latch (192) for fixing the lid (120) to the tray (110) in the closed state.

17. The system (100) according to claim 1, further comprising a hinge (194) coupled to the tray (110) and the lid (120), which allows the lid (120) to rotate relative to the tray (110) between the open state and the closed state.

18. The system (100) according to claim 1, wherein the lid (120) is made of a rigid material (150).

19. The system (100) according to claim 1, wherein the lid (120) is made of a composite material (152).

20. The system (100) according to claim 1, wherein the lid (120) is made of a metal material (154).

21. The system (100) according to claim 1, wherein the lid (120) is made of a polymer material (156).

22. The system (100) according to claim 1, wherein the lid (120) is made of a polycarbonate material (158).

23. The system (100) according to claim 1, wherein the tray (110) is made of a rigid material (150).

24. The system (100) according to claim 1, wherein the tray (110) is made of a composite material (152).

25. The system (100) according to claim 1, wherein the tray (110) is made of a metal material (154).

26. The system (100) according to claim 1, wherein the tray (110) is made of a polymer material (156).

27. The system (100) according to claim 1, wherein the deformable membrane (130) is made from a flexible material (160).

28. The system (100) according to claim 1, wherein the deformable membrane (130) is made from a rubber material (162).

29. The system (100) according to claim 1, wherein the deformable membrane (130) is made from a polymer material (164).

30. The system (100) according to claim 1, wherein the deformable membrane (130) is made from a silicone material (166).

31. A method (1000) for producing a composite material stringer package (200), The steps include placing a deformable membrane (130) on a tray (110), The steps include assembling the composite material stringer package (200) having a hat-shaped cross section (202), The steps include: positioning the lid (120) in a closed position relative to the tray (110) in order to form a sealed chamber (104); The steps include applying a vacuum to the sealed chamber (104) when the lid (120) is in a closed state, The steps include compressing the composite stringer package (200) between the deformable membrane (130) and the lid (120) by applying the vacuum, A method including (1000).

32. The step of assembling the composite material stringer package (200) is: The steps include: placing the composite material charge (204) in the receptacle (112) of the tray (110) such that the deformable membrane (130) is positioned between the tray (110) and the composite material charge (204); The steps include: positioning the bladder (206) within the receptacle (112) of the tray (110) such that the composite material charge (204) is located between the tray (110) and the bladder (206); The method according to claim 31 (1000), including the following.

33. The method according to claim 31 (1000), further comprising the step of distributing the vacuum into the sealed chamber (104) using a breather (142) located between the lid (120) and the tray (110).

34. The method according to claim 31 (1000), further comprising the step of sealing the lid (120) to the tray (110) in the closed state using a seal (144) located between the lid (120) and the tray (110).

35. The method according to claim 31 (1000), further comprising the step of venting the bladder (206) of the composite stringer package (200) to the atmosphere through the vent (122) of the lid (120).

36. The method according to claim 31 (1000), wherein applying a vacuum to the sealed chamber (104) includes the step of fluidly coupling a vacuum source (178) to the sealed chamber (104) using a vacuum rig (170).

37. The method according to claim 36 (1000), further comprising the step of measuring the vacuum pressure in the sealed chamber (104) using the vacuum rig (170).

38. The method according to claim 31 (1000), further comprising the step of holding the composite material stringer package (200) inside the sealed chamber (104).

39. A method for manufacturing composite materials (2000), The steps include arranging a composite material charge (204) and a bladder (206) within a housing (102) to form a composite material stringer package (200), The steps include: compacting the composite material stringer package (200) within the housing (102) into a compacted composite material stringer package (210); The steps include transporting the compacted composite material stringer package (210) within the housing (102), The steps include applying the compacted composite stringer package (210) to a mandrel (220), A method including (2000).

40. The step of compacting the composite material stringer package (200) is The steps include forming a sealed chamber (104) surrounding the composite material stringer package (200) within the housing (102), The steps include: fluidly coupling a vacuum source (178) to the sealed chamber (104) using a vacuum rig (170); The steps include applying a vacuum to the sealed chamber (104) in order to compress the composite material stringer package (200), The method according to claim 39 (2000), including the following.

41. The method according to claim 40 (2000), further comprising the step of measuring the vacuum pressure in the sealed chamber (104) using the vacuum rig (170).

42. The method according to claim 39 (2000), further comprising the step of venting the bladder (206) to the atmosphere through a vent (122) in the housing (102).

43. The method according to claim 39 (2000), further comprising the step of removing the compacted composite stringer package (210) from the housing (102).

44. The method according to claim 39 (2000), further comprising the step of applying a composite material preform (222) to the mandrel (220) and the compacted composite material stringer package (210).

45. The method according to claim 44 (2000), further comprising the step of co-curing the composite material preform (222) and the compacted composite material stringer package (210) on the mandrel (220).

46. The method according to claim 39 (2000), further comprising the step of holding the compacted composite stringer package (210) within the housing (102).

47. A composite material charge (204) is positioned within the receptacle (112) of the tray (110) such that a deformable membrane (130) lining the tray (110) is located between the composite material charge (204) and the tray (110), A bladder, wherein the composite material charge (204) is located between the deformable membrane (130) and the bladder (206) and the bladder (206) is disposed within the receptacle (112), A composite stringer package (200) comprising, The composite material charge (204) and the bladder (206) are surrounded within a sealed chamber (104) formed by the lid (120) and the tray (110). A composite stringer package (200) in which the composite charge (204) and the bladder (206) are compressed between the deformable membrane (130) and the lid (120) to form a compacted composite stringer package (210) by applying a vacuum into the sealed chamber (104) via the deformable membrane (130).

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