System and method for joining materials using an expandable tool

Abstract

This relates to a system and method for joining materials using an expandable tool. [Solution] A method for joining materials includes the steps of: housing at least a portion of a first material (204) and a second material (206) in the internal space (116) of a restraining container (110); expanding an expandable medium (120) placed in the internal space (116); applying positive pressure to the restraining container (110) and at least one of the first material (204) and the second material (206) in accordance with the expansion of the expandable medium (120); and (4) joining the first material (204) and the second material (206) to each other.

Description

Technical Field

[0001] The present disclosure generally relates to joining of materials, and more specifically, to systems and methods for joining materials using an expandable tool.

Background Art

[0002] In manufacturing or assembly processes, various joining techniques are used to join materials. In many joining techniques, heat and / or pressure are applied to the materials to facilitate the joining. In many cases, the equipment required to obtain sufficient joining temperature and joining pressure is large, complex, and expensive. Also, conventional joining techniques may pose bottlenecks in the manufacturing process. Therefore, those skilled in the art continue to make research and development efforts regarding systems and methods for joining materials.

Summary of the Invention

[0003] Hereinafter, a system for joining materials, a method for joining materials, and examples of joined work are disclosed. Hereinafter, non-limiting examples of the gist according to the present disclosure are listed, and these examples include those described in the claims and those not described in the claims.

[0004] As an example, the system of the present disclosure includes a restraint container and an expandable medium. The restraint container includes a base and a cover. The restraint container has an internal space. The restraint container is configured to surround at least a part of a first material and a second material to be joined to each other. The expandable medium is configured to be disposed in the internal space between at least a part of the restraint container and at least one of the first material and the second material. The expandable medium expands, whereby the expandable medium is configured to apply a positive pressure to the restraint container and at least one of the first material and the second material.

[0005] ​As an example, the method of the present disclosure includes (1) housing at least a portion of the first material and the second material in the internal space of a restraining container; (2) inflating an expandable medium placed in the internal space; (3) applying positive pressure to the restraining container and at least one of the first material and the second material in accordance with the expansion of the expandable medium; and (4) joining the first material and the second material together.

[0006] As an example, the workpiece of this disclosure includes a first material and a second material that are joined together. At least a portion of the first material and the second material are housed in a restraining container. Within the internal space of the restraining container, an expandable medium is placed between the restraining container and at least one of the first material and the second material. The expandable medium is configured to expand to a predetermined volume when a predetermined change occurs in the properties of the expandable medium, thereby applying positive pressure to the restraining container and at least one of the first material and the second material.

[0007] Further examples of the systems, methods, and joining workpieces of this disclosure will become apparent from the following detailed description, accompanying drawings, and accompanying claims. [Brief explanation of the drawing]

[0008] [Figure 1A-1B] This is a schematic block diagram showing an example of a system for joining materials, and will be collectively referred to as Figure 1 below. [Figure 2] This is a flowchart illustrating an example of a method for joining materials. [Figure 3] This is a schematic cross-sectional view showing an example of a constraint container of a system applied to an exemplary workpiece. [Figure 4] Figure 3 is an example of the system, and is a schematic cross-sectional view showing how an expandable medium is arranged in the internal space of the restraint container. [Figure 5] Figure 4 is an example of the system, and is a schematic cross-sectional view showing the state after the expandable medium has expanded. [Figure 6] This is a schematic cross-sectional view showing an example of a constraint container for a system applied to another exemplary workpiece. [Figure 7] Figure 6 is a schematic cross-sectional view showing an example of the system, illustrating how an expandable medium is arranged in the internal space of a restraining container. [Figure 8] Figure 7 is an example of the system, and is a schematic cross-sectional view showing the state after the expandable medium has expanded. [Figure 9] This is a schematic cross-sectional view showing another example of a constraint container of the system applied to an exemplary workpiece. [Figure 10] Figure 9 is an example of the system, and is a schematic cross-sectional view showing how an expandable medium is arranged in the internal space of the restraining container. [Figure 11] Figure 10 is an example of the system, and is a schematic cross-sectional view showing the state after the expandable medium has expanded. [Figure 12] This is a schematic diagram showing some examples of work assembly including the workpiece to be joined and an expandable material. [Figure 13] This is a schematic diagram showing some examples of work assembly including the workpiece to be joined and an expandable material. [Figure 14] This is a schematic diagram showing some examples of work assembly including the workpiece to be joined and an expandable material. [Figure 15] This is a schematic diagram showing some examples of work assembly including the workpiece to be joined and an expandable material. [Figure 16] This is a flowchart illustrating an example of aircraft manufacturing and maintenance methods. [Figure 17] This is a schematic block diagram showing an example of an aircraft. [Modes for carrying out the invention]

[0009] Referring to Figures 1 to 15 as a whole, this disclosure relates, for example, to a system 100, a workpiece 200 (for example, used to form a joined structure), and a method 1000 for performing a join. In various examples, the system 100 and method 1000 can perform a join that results in a high-quality joined structure without requiring processing with an autoclave or other large and expensive equipment. The joining process realized by the system 100 and / or method 1000 enables a lower-cost, faster, and space-saving join.

[0010] In the example of System 100 and Method 1000, an expandable material and related tools are used to enable the non-autoclave manufacturing and / or repair of autoclave-quality bonded parts. According to the example of System 100 and Method 1000, it becomes easier to apply omnidirectional and at least substantially uniform pressure to the surface of the components to be bonded. Furthermore, according to the example of System 100 and Method 1000, the expandable material can be used in structural bonding and debulking, with or without the use of adhesives.

[0011] In examples of System 100 and Method 1000, expandable materials can be used in structural bonding and debulking of composites, such as secondary bonding, with or without the use of adhesives, including, for example, composite bonding under pressure (e.g., co-bonding) performed with at least one component of the bonded structure pre-cured. Also in examples of System 100 and Method 1000, epoxy adhesives or any polymer adhesive (e.g., thermosetting or thermoplastic) can be used to bond non-composite materials (e.g., metals, metal alloys, ceramics, polymer materials, hybrid materials, metal matrix composites (MMCs), ceramic matrix composites (CMCs), polymer matrix composites (PMCs, etc.)). In examples of System 100 and Method 1000, stepwise and controllable compression is performed using a detector that monitors the pressure in real time. In various examples, the detector may be a sensor or strain gauge that monitors the deformation of a pin. In various examples, the detector is a pin. In any of these examples, an alarm mode is activated in the event of pin failure (e.g., breakage).

[0012] Next, referring to Figures 1 and 3-15, examples of System 100 according to this disclosure are shown. Examples of System 100 include multiple elements, singularities, and components. Not all elements, singularities, and / or components described or illustrated in one example are essential in that example. Some or all of the elements, singularities, and / or components described or illustrated in one example can be combined with other examples in various ways, without including other elements, singularities, and / or components described in those other examples. Furthermore, such combinations do not necessarily have to be explicitly described or illustrated in the examples shown herein.

[0013] Figures 3 to 15 show various examples of the system 100 in a state where it is used to join at least a portion 210 (Figs. 3, 6, and 9) of the workpiece 200. Generally, the portion 210 of the workpiece 200 refers to any portion or the entire workpiece 200 that is joined or being joined using the system 100 and / or method 1000.

[0014] As shown in FIGS. 1 and 3 to 15, in one or more examples, the workpiece 200 includes a first material 204 and a second material 206. In one or more examples, the workpiece 200 may also include any number of other materials 202, such as substrates, material layers, components, accessories, etc. that are joined to each other.

[0015] Figures 3 to 15 show various examples of the workpiece 200 and the material 202 that are joined to each other using the system 100 and / or in accordance with the method 1000. The workpiece 200 may include any suitable number of materials 202 or material layers. In various examples, the workpiece 200 includes one or more composite materials, metallic materials, ceramic materials, polymeric materials, thermoplastic materials, thermosetting materials, fiber - reinforced materials, and / or other suitable materials depending on the desired properties of the joined structure.

[0016] The workpiece 200 may have a suitable shape among various cross - sectional shapes. As shown in FIGS. 3 to 11, in one or more examples, the workpiece 200 is a composite stiffener (e.g., hat - type stringer), and the material 202 includes a plurality of composite layers (e.g., uncured composite materials) and optionally an adhesive layer (e.g., FIGS. 6 to 8), and these layers are joined to each other by applying pressure to the workpiece 200 due to the expansion of the expandable medium 120. As shown in FIGS. 14 and 15, in one or more examples, the workpiece 200 is a composite stiffener (e.g., blade - type stringer), and the material 202 includes a plurality of composite layers (e.g., uncured composite materials and / or cured composite materials) and optionally an adhesive layer, and these layers are joined to each other by the expansion of the expandable medium 120.

[0017] In one or more examples, the workpiece 200 includes layers of a plurality of materials 202 (e.g., material layer 260), and these layers are joined to each other by applying pressure to the workpiece 200 due to the expansion of the expandable medium 120. As shown in FIGS. 12 - 15, in one or more examples, the workpiece 200 is a sandwich structure or a multi-layer panel structure joined to each other, including some (e.g., two or more) combinations of the first material layer 261 (e.g., the first material sheet or material charge), the second material layer 262 (e.g., the second material sheet or material charge), the third material layer 263 (e.g., a joining layer such as an uncured prepreg ply or adhesive film), the fourth material layer 264 (e.g., any core shown in FIGS. 12 and 13, or the base panel shown in FIG. 15), and the fifth material layer 265 (e.g., a joining layer such as an uncured prepreg ply or adhesive film).

[0018] In one or more examples, the expandable medium 120 is arranged or positioned relative to the workpiece 200 such that a positive pressure 124 (e.g., an omnidirectional force) is applied to one side of the workpiece 200. As shown in FIG. 12, in one or more examples, the first amount or the first layer 182 of the expandable medium 120 is arranged above or on the laminate of the material layers 260, whereby, during joining, the expandable medium 120 expands and a positive pressure 124 is applied to the workpiece 200, and the material layers 260 are pressed. As shown in FIG. 13, in one or more examples, the first amount or the first layer 182 of the expandable medium 120 is arranged above or on the laminate of the material layers 260, and the second amount or the second layer 184 of the expandable medium 120 is arranged below or under the laminate of the material layers 260, whereby, during joining, the expandable medium 120 expands and a positive pressure 124 is applied to the workpiece 200, and the material layers 260 are pressed.

[0019] As shown in Figures 1 and 3 to 11, in one or more examples, the system 100 includes a restraint container 110 and an expandable medium 120. The restraint container 110 houses or surrounds at least a portion of the workpiece 200. The restraint container 110 also houses the expandable medium 120. The expandable medium 120 is configured to expand, and when expanded, it applies omnidirectional force or pressure to at least a portion of the workpiece 200 housed in the restraint container 110.

[0020] As shown in Figure 1, in one or more examples, the system 100 and method 1000 facilitate co-curing for integrally joining the workpiece 200. In these examples, the material 202 of the workpiece 200 (e.g., first material 204 and second material 206) includes an uncured composite material 212. In one or more examples, the uncured composite material 212 is a thermosetting composite material. In one or more examples, the uncured composite material 212 is a thermoplastic composite material.

[0021] In one or more examples, co-curing is achieved without the use of adhesives. For example, workpiece 200 includes a first wet prepreg cloth ply (e.g., first material 204) and a second wet prepreg cloth ply (e.g., second material 206).

[0022] In one or more examples, co-curing is achieved with an adhesive such as an adhesive film (e.g., adhesive 216). As an example, workpiece 200 includes a first wet prepreg cloth ply (e.g., first material 204), a second wet prepreg cloth ply (e.g., second material 206), and an adhesive (e.g., adhesive 216) positioned or placed between the first wet prepreg cloth ply and the second wet prepreg cloth ply.

[0023] As shown in Figure 1, in one or more co-curing examples, the uncured composite material 212 (e.g., thermosetting composite material) has a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is less than or equal to the curing temperature 220 of the thermosetting composite material. At the activation temperature 122, the expandable medium 120 is configured to expand so that the positive pressure 124 reaches or at least exceeds the curing pressure 222.

[0024] As shown in Figure 1, in one or more co-curing examples, the uncured composite material 212 (e.g., thermoplastic composite material) has an integration temperature 224 and an integration pressure 226. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is less than or equal to the integration temperature 224 of the thermoplastic composite material. At the activation temperature 122, the expandable medium 120 is configured to expand so that the positive pressure 124 is less than or equal to the curing pressure 222.

[0025] As shown in Figure 1, in one or more examples, the system 100 and method 1000 facilitate co-joining for integrally joining workpieces 200. In these examples, at least one of the materials 202 of the workpiece 200 (e.g., first material 204) includes a cured composite material 214. At least one other of the materials 202 of the workpiece 200 (e.g., second material 206) includes an uncured composite material 212. In one or more examples, the uncured composite material 212 is a thermosetting composite material. In one or more examples, the uncured composite material 212 is a thermoplastic composite material.

[0026] In one or more examples, co-bonding is achieved with an adhesive such as an adhesive film (e.g., adhesive 216). As an example, workpiece 200 includes a pre-cured laminate (e.g., first material 204), a wet prepreg crossply (e.g., second material 206), and an adhesive (e.g., adhesive 216) positioned or placed between the pre-cured laminate and the wet prepreg crossply.

[0027] As shown in Figure 1, in one or more co-bonding examples, the uncured composite material 212 (e.g., thermosetting composite material) has a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is below the curing temperature 220. At the activation temperature 122, the expandable medium 120 is configured to expand so that the positive pressure 124 is below the curing pressure 222.

[0028] As shown in Figure 1, in one or more co-bonding examples, the uncured composite material 212 (e.g., thermoplastic composite material) has an integration temperature 224 and an integration pressure 226. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122, which is below the integration temperature 224. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is below the integration pressure 226.

[0029] As shown in Figure 1, in one or more examples, the system 100 and method 1000 facilitate secondary joining for integrally joining the workpiece 200. In these examples, the material 202 of the workpiece 200 (e.g., first material 204 and second material 206) includes, but is not limited to, any suitable material or combination of materials such as metallic materials, metallic alloy materials, ceramic materials, polymer materials, hybrid materials, metal matrix composites, ceramic matrix composites, and polymer matrix composites.

[0030] In one or more examples, secondary bonding is achieved with an adhesive such as an adhesive film (e.g., adhesive 216). As an example, workpiece 200 includes a first pre-cured laminate or material layer (e.g., first material 204), a second pre-cured laminate or material layer (e.g., second material 206), and an adhesive (e.g., adhesive 216) positioned or placed between the first and second pre-cured laminates or material layers.

[0031] As shown in Figures 6 to 8, in one or more examples, the adhesive 216 is placed between the first material 204 and the second material 206. In these examples, the system 100 can use the adhesive 216 to perform adhesive secondary bonding, co-bonding, or co-curing between the first material 204 and the second material 206.

[0032] As shown in Figure 1, in one or more of the examples of co-curing, co-bonding, and / or secondary bonding, the adhesive 216 has at least one of a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is less than or equal to the curing temperature 220. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is less than or equal to the curing pressure 222. In one or more examples, the curing temperature 220 and / or curing pressure 222 of the uncured composite material 212 and the adhesive 216 are at least approximately the same. In one or more examples, the curing temperature 220 and / or curing pressure 222 of the uncured composite material 212 and the adhesive 216 are different.

[0033] In an example of secondary bonding of a first material 204 and a second material 206 using adhesive 216, the materials 202 of the workpiece 200 (e.g., the first material 204 and the second material 206) include, but are not limited to, any suitable material or combination of materials such as cured composite materials (e.g., thermosetting composite materials or thermoplastic composite materials), metallic materials, metallic alloy materials, ceramic materials, polymer materials, etc. In one or more examples, multiple materials 202 of the workpiece 200 are the same material. In one or more examples, at least one of the multiple materials 202 of the workpiece 200 is a different material.

[0034] In one or more examples, the restraint container 110 includes a base 112. In one or more examples, the restraint container 110 includes a cover 114. In one or more examples, the cover 114 is coupled to the base 112. In one or more examples, the cover 114 is configured to be coupled to the base 112. In one or more examples, the cover 114 is movable relative to the base 112. The container 110 has an internal space 116 formed by the base 112 and the cover 114.

[0035] In one or more examples, the restraining container 110 is configured to enclose at least a portion (e.g., portion 210) of the first material 204 and second material 206 of the workpiece 200 to be joined together. In one or more examples, the restraining container 110 is configured to house and / or enclose the entire workpiece 200 (e.g., its size or shape is predetermined). In one or more examples, the restraining container 110 is configured to house and / or enclose a portion of a plurality of materials 202 of the workpiece 200 to be joined together.

[0036] In one or more examples, the expandable medium 120 is configured to be placed, positioned, or placed in the internal space 116 of the restraint container 110. In one or more examples, the expandable medium 120 is placed, positioned, or placed between at least a portion of the restraint container 110 (e.g., the cover 114 and / or base 112) and at least one of the first material 204 and the second material 206. The expandable medium 120 expands, thereby being configured to apply a positive pressure 124 to the restraint container 110 and at least one of the first material 204 and the second material 206.

[0037] In one or more examples, system 100 is an adjustable tool system comprising a constraint container 110 and an expandable medium 120. The constraint container 110 is positioned relative to the workpiece 200 so that at least a portion 210 of the workpiece 200 and the expandable medium 120 are positioned within or constrained by the constraint container 110.

[0038] In one or more examples, the system 100 is configured to facilitate the application of positive pressure 124 to a portion 210 of the workpiece 200 constrained by the container 110 by expanding the expandable medium 120 during the joining process of the workpiece 200. Thus, the constraining container 110 and the expandable medium 120 are configured to apply positive pressure 124 to the workpiece 200 in a process of joining two or more materials to form or manufacture a joined structure.

[0039] In one or more examples, one or more of the materials 202 are composite materials (e.g., composite components, composite parts, composite objects, etc.) containing one or more composite layers (also called plies). In one or more examples, one or more of the materials 202 are metallic materials (e.g., metallic components, metallic parts, metallic objects, etc.). In one or more examples, one or more of the materials 202 are ceramic materials (e.g., ceramic components, ceramic parts, ceramic objects, etc.). In one or more examples, one or more of the materials 202 are polymer materials (e.g., polymer components, polymer parts, polymer objects, etc.).

[0040] In any of these examples, the materials 202 are joined to each other using system 100 and / or according to method 1000. In one or more examples, the materials 202 are bonded to each other by co-curing (e.g., using the application of heat and / or pressure). In one or more examples, the materials 202 are bonded to each other by co-bonding (e.g., using the application of heat and / or pressure). In one or more examples, the materials 202 are bonded to each other by secondary bonding (e.g., using the application of heat and / or pressure).

[0041] As shown in Figures 3 to 11, in one or more examples, the workpiece 200 is supported on or by a base 112. In one or more examples, a cover 114 is positioned relative to the base 112 and / or the workpiece 200, so that at least a portion 210 of the workpiece 200 and the expandable medium 120 are placed inside the cover 114, constrained by the cover 114, or placed between the cover and the base 112. In one or more examples, the cover 114 includes (e.g., is formed or defined) an internal space 116 and is configured to surround a portion 210 of the workpiece 200. The cover 114 allows the expandable medium 120 and the workpiece 200 to be placed inside the internal space 116 of the constraining container 110.

[0042] In one or more examples, the cover 114 has or is formed a cross-sectional profile that corresponds to the cross-sectional shape of the workpiece 200. By providing a cover 114 having a cross-sectional profile that corresponds to (for example, at least substantially coincides with or is complementary to) the cross-sectional shape of the workpiece 200, the internal space 116 of the restraining container 110 can be reduced, and the amount of expandable medium 120 required can be reduced.

[0043] In one or more examples, the base 112 is rigid. In one or more examples, the cover 114 is rigid. In one or more examples, at least one of the base 112 and the cover 114 is rigid. In one or more examples, both the base 112 and the cover 114 are rigid.

[0044] In one or more examples, the cover 114 is substantially resistant to expansion when pressure is applied to the inner surface of the cover 114 by the expandable medium 120. In this way, the pressure applied to the outer surface of the workpiece 200 (e.g., at least one of the first material 204 and the second material 206) acts in cooperation with the cover 114 to generate a pressing force on the workpiece 200.

[0045] In one or more examples, at least a portion of the cover 114, such as the wall 144 of the cover 114, is rigid (e.g., hard or inflexible) and does not expand. In these examples, at least a portion of the cover 114, such as the wall 144, can be formed from any suitable material, but is not limited to, metal materials, composite materials, cement materials, ceramic materials, and polymer materials. In these examples, the wall 144 restrains the expandable medium 120 and reacts to the positive pressure 124 generated when the expandable medium 120 expands. In these examples, the wall 144 can withstand the pressure generated in the restraining container 110 when the expandable medium 120 expands.

[0046] In one or more examples, at least a portion of the base 112 is flexible. In one or more examples, at least a portion of the cover 114 is flexible. In one or more examples, at least a portion of the base 112 is flexible and non-expandable. In one or more examples, at least a portion of the cover 114 is flexible and non-expandable. In one or more examples, at least a portion of at least one of the base 112 and the cover 114 is flexible and non-expandable or expandable. In one or more examples, at least a portion of both the base 112 and the cover 114 is flexible and non-expandable or expandable. By having at least a portion of at least one of the base 112 and the cover 114 be flexible and non-expandable, the cover 114 and / or the base 112 can be formed along (e.g., more closely) the contour shape of at least a portion of the workpiece 200 and / or the contour shape of the expandable medium 120 before it expands, and can also be easily adapted to the shape of at least a portion of the workpiece 200. As a result, the internal space 116 of the restraining container 110 can be reduced and the amount of expandable medium 120 required can be reduced. In these examples, at least a portion of the cover 114 and / or the base 112 can be formed from any suitable material that is flexible and non-expandable, for example, but not limited to, metal mesh (e.g., chainmail), ceramic mesh, polymer mesh, etc.

[0047] In one or more examples, at least a first portion of the cover 114 is flexible and non-expandable, and at least a second portion of the cover 114 is rigid and non-expandable. In other examples, at least a first portion of the cover 114 is non-expandable (e.g., flexible and / or rigid), and at least a second portion of the cover 114 is expandable.

[0048] In one or more examples, the cover 114 is movable relative to the workpiece 200 to select, isolate, and / or target portions 210 of the workpiece 200 to be joined. Moving the cover 114 facilitates local joining of individual regions or portions of the workpiece 200. In one or more examples, the cover 114 can be completely removed from the base 112. Moving the cover 114 allows for easy loading or placement of the expandable medium 120 and the workpiece 200 into the internal space 116 of the restraint container 110.

[0049] In one or more examples, the cover 114 is set to a size and / or dimensions suitable for covering at least a portion 210 of the workpiece 200 to be joined. In these examples, the dimensions of the cover 114 (e.g., length and / or width) are smaller than at least one of the dimensions of the workpiece 200 (e.g., length and / or width).

[0050] In one or more examples, the cover 114 includes a wall 144. In one or more examples, the wall 144 forms or defines at least a portion of the internal space 116 of the restraining container 110. In one or more examples, the wall 144 has or forms a cross-sectional profile of the cover 114 that corresponds to the cross-sectional shape of the workpiece 200. In these examples, the expandable medium 120 is configured to be placed within the internal space of the cover 114 formed by the wall 144. In one or more examples, the expandable medium 120 is placed between the wall 144 and the portion 210 of the workpiece 200 to be joined.

[0051] In one or more examples, the workpiece 200 (e.g., portion 210) is placed on the base 112 during the joining process. At least portion 210 of the workpiece 200 to be joined must be adequately supported in order to apply an appropriate pressing force (e.g., positive pressure 124) to the workpiece while it is placed within the restraining container 110. In one or more examples, the base 112 has a substantially incompressible surface for supporting one side of the workpiece 200.

[0052] In one or more examples, the base 112 is substantially resistant to compression when pressure is applied to the support surface of the base 112 that is in contact with and supporting the workpiece 200. In this way, the pressure applied to the surface of the workpiece 200 acts in cooperation with the base 112 during joining to generate a compressive force on the workpiece 200.

[0053] In one or more examples, the internal space 116 of the restraint container 110 is selectively (e.g., controllably) variable. In one or more examples, at least one of the walls 144 of the cover 114 is movable, thereby allowing the internal space 116 of the restraint container 110 to be changed (e.g., reduced). The selective change or alteration of the internal space 116 allows for a reduction in the internal space 116, and correspondingly, the amount of expandable medium 120 required to fill the internal space 116 when it expands can be reduced. The selective change or alteration of the internal space 116 also allows for selective or reactive control and alteration of the internal pressure 118 of the restraint container 110 (e.g., acting on the workpiece 200 within the internal space 116).

[0054] In one or more examples, the cover 114 includes any suitable elements or singularities to facilitate the introduction of the expandable medium 120 into the internal space 116 and / or the removal of the expandable medium from the internal space. In one or more examples, the cover 114 includes a removable or openable panel (e.g., a door) which, when positioned relative to the workpiece 200, allows access to the internal space 116 and the introduction of the expandable medium 120.

[0055] As shown in Figures 1 and 9 to 11, in one or more examples, the system 100 includes a pressure detector 130. The pressure detector 130 is configured to detect the internal pressure 118 of the internal space 116 of the confinement container 110. In one or more examples, the pressure detector 130 facilitates monitoring of the internal pressure 118 of the internal space 116 of the confinement container 110. In one or more examples, the pressure detector 130 also functions as a fail-safe to limit the internal pressure 118 of the confinement container 110.

[0056] As shown in Figures 1 and 9 to 11, in one or more examples, the pressure detector 130 includes or takes the form of a sensor 132 and is configured to detect or identify the internal pressure 118 of the restraint container 110, and consequently the positive pressure 124 or omnidirectional force applied to the workpiece 200 by the expandable medium 120 during and after the expansion of the expandable medium 120. In these examples, the sensor 132 may include, but is not limited to, any suitable type or number of sensors such as pressure sensors, load sensors, strain gauges, other sensor devices, and combinations thereof.

[0057] As shown in Figure 1, in one or more examples, the system 100 includes a controller 150. In one or more examples, the controller 150 receives input signals or data from a sensor 132, thereby monitoring the internal pressure 118 in the restraint container 110, and then increasing or decreasing the internal pressure as necessary to achieve and / or maintain a desired magnitude of positive pressure 124 applied to the workpiece 200 by the expansion of the expandable medium 120.

[0058] In one or more examples, the controller 150 includes or takes the form of a closed-loop controller, or uses closed-loop control of the internal pressure 118 present in the restraint container 110 and / or the pressure applied to the workpiece 200 during the joining operation. In one or more examples, the controller 150 uses real-time pressure measurements from the sensor 132 to control or adjust the internal pressure 118 present in the restraint container 110 and / or the pressure applied to the workpiece 200.

[0059] In one or more examples, the internal pressure 118 is controlled by increasing or decreasing the internal space 116 of the restraint container 110, for example, by selectively changing the position of one or more of the walls 144 of the restraint container 110. In one or more examples, the internal pressure 118 is controlled by selectively expanding or contracting the expandable medium 120 within the internal space 116. In one or more examples, the internal pressure 118 is controlled by selectively expanding or contracting expandable elements 176 further arranged within the internal space 116.

[0060] In one or more examples, the expansion and / or contraction of the expandable medium 120 is selectively controllable. For example, the expandable medium 120 is configured to expand or contract selectively or controllably as a method for controlling the pressure generated in the restraining container 110 and / or applied to the workpiece 200 during bonding. In various examples, the expansion and / or contraction of the expandable medium 120 can be controlled by any of various methods, for example, by heating or cooling the expandable medium 120.

[0061] In one or more examples, the pressure detector 130 includes, or takes the form of, a fail-safe mechanism configured to prevent overpressure in the internal space 116 of the restraint container 110 and / or regulate the pressure. For example, the pressure detector 130 includes at least one pin 134 (e.g., a shear pin) used to bond the cover 114 to the base 112 or to bond multiple segments or portions of the cover 114 to each other. In one or more examples, the pin 134 is configured to break at a predetermined pressure higher than the pressure required or needed for the bonding process, thereby releasing the cover 114 and releasing the pressure inside the restraint container 110.

[0062] In one or more examples, the pressure detector 130 includes a combination of a pin 134 and a sensor 132. In these examples, the sensor 132 may be a strain gauge connected to the pin 134 and may be configured to detect deformation of the pin 134 caused by the internal pressure 118 in the restraint container 110, and / or strain or load applied to the pin 134. In these examples, the pressure detector 130 can provide real-time pressure detection and fail-safe functionality. In one or more examples, if the detected pressure (e.g., magnitude) is higher than the alarm pressure or threshold pressure, the system 100 is configured to automatically shut down and perform other safety measures such as forced air cooling, release of internal pressure, and opening of the restraint container 110. In one or more examples, the pin 134 is a sacrificial pin with a known breaking strength corresponding to the maximum allowable internal pressure of the alarm level. In these examples, if the pin 134 breaks, the system 100 enters alarm mode. In other examples, the system 100 includes multiple safety control layers.

[0063] As shown in Figures 1 and 3 to 5, in one or more examples, the system 100 includes a heater 140. The heater 140 is heat-transferably coupled to an expandable medium 120. The heater 140 is configured to heat the expandable medium 120 to an activation temperature 122, at which point the expandable medium 120 expands in its internal space 116, applying a positive pressure 124 to the workpiece 200.

[0064] In one or more examples, the heater 140 is an internal heater and is configured to be located in the internal space 116 of the restraint container 110 together with the expandable medium 120. In one or more examples, the heater 140 is an external heater and is configured to be located outside the restraint container 110. In one or more examples, the heater 140 is incorporated into the restraint container 110 and / or the expandable medium 120 using a smart susceptor heating element or the like.

[0065] The heater 140 may take any suitable form or include any suitable heating device. In various examples in which the expandable medium 120 is thermally activated and expands, the constraining container 110, such as the cover 114, may be heated from the outside. Alternatively, or in addition to this, the system 100 may include one or more exothermic substances configured to heat the expandable medium 120 to a predetermined temperature in which it expands.

[0066] In one or more examples, at least a portion of the restraining container 110, for example, at least a portion of the cover 114, is heat-reflective. For example, at least one of the walls 144 of the cover 114 is heat-reflective. In one or more examples, at least a portion of the inner surface of the cover 114 and / or the base 112 contains or is coated with a heat-reflective material. The heat-reflective properties can improve the heating of the expandable medium 120 during the bonding process and activate the expansion of the expandable medium 120.

[0067] As shown in Figure 1, in one or more examples, the system 100 includes a retainer 146. The retainer 146 is configured to hold the restraint container 110 in a closed state. For example, the retainer 146 is configured to hold the cover 114 to the base 112 or to fasten the base 112 and cover 114 together during the joining process after the workpiece 200 and the expandable medium 120 have been placed into the internal space 116 of the restraint container 110. The retainer 146 includes any suitable mechanism capable of fastening the cover 114 to the base 112. In one or more examples, the retainer 146 includes at least one clamp configured to fasten or secure the cover 114 to the base 112 in place. The clamp may include, but is not limited to, any suitable type of clamping and fastening device, such as a mechanical clamp, magnetic clamp, pneumatic clamp, spring clamp, latch, pin, fastener, or weight. The retainer 146 may include any number of clamps.

[0068] In one or more examples, the retainer 146 and the pressure detector 130 are integrated into a single component. For example, a pin 134 is used to secure the restraint container 110 in a closed position (e.g., to hold the base 112 and cover 114 together). Optionally, the sensor 132 can also be used to detect the internal pressure 118.

[0069] As shown in Figure 1, in one or more examples, the system includes at least one intermediate layer 164. In these examples, the intermediate layer 164 is placed in the internal space 116 of the constraining container 110 together with the expandable medium 120 and the workpiece 200. In one or more examples, the intermediate layer 164 is placed between the constraining container 110 and the expandable medium 120. In one or more examples, the intermediate layer 164 is placed between the expandable medium 120 and the workpiece 200. In one or more examples, the intermediate layer 164 is placed within the expandable medium 120.

[0070] In one or more examples, the intermediate layer 164 includes or takes the form of a bladder. In one or more examples, the bladder is filled with a fluid (e.g., gas or liquid) and is configured to equalize the positive pressure applied to the workpiece 200, thereby allowing the positive pressure 124 to be applied more uniformly. The bladder is selected to be heat-resistant and easily removable after the workpiece 200 has been joined.

[0071] As shown in Figure 1, in one or more examples, the expandable medium 120 is configured to expand to an expansion volume 128 when a predetermined change occurs in the attributes 126 of the expandable medium 120, thereby applying or acting a positive pressure 124 on the workpiece 200 and the restraint container 110. Generally, the expansion volume 128 is known or can be calculated based on the material composition, attributes 126, and / or activation temperature 122 of the expandable medium 120.

[0072] In one or more examples, the expanded volume 128 of the expanded expandable medium 120 is greater than the internal space 116 of the confinement container 110. In this disclosure, the internal space 116 refers to the actually usable and fillable internal volume in the internal cavity of the confinement container 110. In various examples, the expanded volume 128 is substantially the same as or slightly larger than the internal space 116, so that when the expandable medium 120 expands, it exerts a positive pressure 124 on the workpiece 200 unless the internal space 116 is altered (e.g., by movement of the wall 144 or control of the expandable element 176). In one or more examples, the amount (e.g., volume) of the unexpanded expandable medium 120 to be introduced into the internal space 116 of the confinement container 110 is determined by a test or model that predicts the pressures during and after expansion in the confinement volume.

[0073] The expandable medium 120 may comprise one or more of various suitable types of materials or material compositions configured to expand upon activation or in response to a change in at least one attribute 126. As shown in Figure 1, in one or more examples, the expandable medium 120 comprises expandable pellets 162. In one or more examples, the expandable pellets 162 are thermally activated at an activation temperature 122. In these examples, the expandable pellets 162 are configured to expand when their temperature rises to the activation temperature 122.

[0074] In one or more examples, any suitable number of expandable pellets 162 can be placed within the internal space 116 of the restraining container 110, provided that they can apply sufficient positive pressure 124 to the workpiece 200 during expansion for bonding. The number of expandable pellets 162 is determined by the size of the internal space 116. That is, if the restraining container 110 conforms more closely to the contour of the workpiece 200, fewer expandable pellets 162 may be required.

[0075] In various examples, each of the expandable pellets 162 may have any suitable dimensions. In one or more examples, the length of the expandable pellets 162 is less than about 1 centimeter. The expandable pellets 162 may be substantially uniform in size, or they may contain pellets of different sizes.

[0076] In one or more examples, the activation temperature 122 of the expandable pellet 162 is lower than, at least equal to, or higher than the curing temperature 220 of the workpiece 200. In one or more examples, the activation temperature 122 of the expandable pellet 162 is lower than, at least equal to, or higher than the curing temperature 220 of the uncured composite material 212 and / or adhesive 216. In one or more examples, the activation temperature 122 of the expandable pellet 162 is lower than, at least equal to, or higher than the integration temperature 224 of the uncured composite material 212.

[0077] As shown in Figure 1, in one or more examples, the expandable medium 120, such as an expandable pellet 162, includes or takes the form of a foaming pellet 166. In one or more examples, the foaming pellet 166 is configured to foam when heated to at least a predetermined foaming temperature (e.g., activation temperature 122). In one or more examples, the foaming pellet 166 includes a foaming material such as a thermoplastic material treated with a foaming agent, a gas-filled balloon, a hollow microsphere, a metal, other suitable components configured to expand when heated, or a combination thereof.

[0078] As shown in Figure 1, in one or more examples, the expandable medium 120 includes an encapsulation element 168. In one or more examples, the expandable medium 120 is placed within the encapsulation element 168. In one or more examples, the expandable pellets 162 are placed within the encapsulation element 168. In one or more examples, the encapsulation element 168 surrounds the expandable medium 120 (e.g., the expandable pellets 162), thereby facilitating the handling of the expandable medium 120 and facilitating the removal of the expandable medium 120 after bonding is complete.

[0079] The encapsulation element 168 can take any suitable form, such as an encapsulation film, a sealing material layer, a bag, or a pouch. In one or more examples, the encapsulation element 168 is not expandable. In one or more examples, the encapsulation element 168 is expandable. In one or more examples, the encapsulation element 168 is made of a nylon or polyester fabric (e.g., fire hose material).

[0080] In one or more examples, prior to the bonding process, the expandable medium 120 is in an unexpanded state (e.g., Figures 4, 7, and 10). The unexpanded expandable medium 120 may be referred to as an unexpanded body or unexpanded element. During the bonding process, the expandable medium 120 expands to an expanded state (e.g., Figures 5, 8, and 11). The expanded expandable medium 120 may be referred to as an expanded body or expanded element.

[0081] In one or more examples, the expanded expandable medium 120 in its expanded state applies pressure to the inner surface of the restraining container 110 (e.g., the cover 114 and / or base 112) and the surface of a portion 210 of the workpiece 200 (e.g., the unjoined material or unjoined component of the workpiece). In one or more examples, the expanded expandable medium 120 applies a positive pressure 124 (resulting from the expansion of the expandable medium 120) to the workpiece 200 to facilitate compression during part or all of the joining process. In one or more examples, after the workpiece 200 has been joined, the expandable medium 120 can be removed from the restraining container 110, and this removal may occur before, simultaneously with, or after the joined workpiece 200 is removed from the restraining container 110.

[0082] In this disclosure, the terms “expandable,” “expandable,” “expanding,” and similar terms refer to the ability to expand itself, or the possibility or ability to increase in size and / or volume. Expandable materials or individual elements can increase in size or volume symmetrically or asymmetrically. If an expandable material is symmetrically expandable, it can expand substantially equally along each axis. If an expandable material exhibits asymmetric expansion, it can expand more along the first axis, or along both the first and second axes, than along the other axes. In various examples, the expandable medium 120 is configured to expand when a predetermined change occurs in the expandable medium 120. The predetermined change is typically a change in the physical or chemical properties of the expandable medium 120 related to its expansion, or a combination thereof, and / or a change in other appropriate properties. Unless otherwise specified, expansion of the expandable medium 120 refers to an increase in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. For example, the expandable medium 120 may be configured to expand when its temperature rises from a low temperature, such as ambient temperature, to a predetermined high temperature (e.g., activation temperature 122). Therefore, if joining the workpiece 200 involves raising the temperature of the workpiece 200, the expandable medium 120 expands in the internal space 116 during the joining process. The expandable medium 120 (e.g., during or after expansion) applies pressure to the inside of the restraining container 110 and to the workpiece 200 during the joining process.

[0083] In one or more examples, the expandable medium 120 is selected to apply sufficient pressure to effectively compress the material 202 of the workpiece 200 and achieve proper bonding when the expandable medium 120 expands in the internal space 116 of the restraining container 110. For some materials 202, bonding can be achieved sufficiently with a pressure of less than 1 atmosphere, while for other materials 202, bonding can be achieved more effectively with a pressure of 1 atmosphere or more. In one or more examples, the expandable medium 120 is selected to generate sufficient pressure to apply pressures that would conventionally require an autoclave (e.g., 1 to 5 atmospheres).

[0084] In one or more examples, the bonding process can be simplified and facilitated by adding the expandable medium 120 as a plurality of expandable pellets 162 (also called expandable beads). In these examples, the expandable pellets 162 are configured to expand in volume when heated to at least a predetermined temperature (e.g., activation temperature 122).

[0085] In one or more examples, the expandable medium 120 comprises one or more different types, varieties, or compositions of expandable material (e.g., different types or compositions of expandable pellets 162). In these examples, each of the different types of expandable material is configured to expand (e.g., to a predetermined volume) when heated to a predetermined temperature. In one or more examples, the compositions of the different types of expandable medium 120 (e.g., different types of expandable pellets 162) can be designed to establish a desired relationship as a function of time between the expansion volume of each type and the temperature of each type.

[0086] In one or more examples, the degree of expansion of an expandable medium 120 (e.g., expandable pellets 162) of a given type or composition can be measured and recorded, as can the force produced by the expansion. Thus, by changing the composition, a desired degree of expansion and expansion force can be obtained. In this way, the amount of expandable medium 120 to employ (e.g., the number of expandable pellets 162) and / or the composition of the expandable medium 120 (e.g., expandable pellets 162) can be selected so that the expansion of multiple expandable mediums 120 within a known volume (e.g., internal space 116) imparts a desired pressure to the workpiece 200 at one or more stages of the bonding process.

[0087] As shown in Figure 1, in one or more examples, the system 100 includes additional elements configured to change or adjust the pressure applied by the expandable medium 120. Such elements include, but are not limited to, one or more volume-constant elements 172 (e.g., substantially incompressible elements) and / or one or more contractible elements 174 (e.g., fluid-filled bags) that can increase in volume before or during joining, or decrease in volume after joining.

[0088] As shown in Figure 1, in one or more examples, the system 100 includes at least one inflatable element 176. In one or more examples, the inflatable element 176 is placed in the internal space 116 of the confinement container 110 together with the inflatable medium 120 and the workpiece 200. In one or more examples, the inflatable element 176 is an element that changes the volume of the system 100 and is configured to selectively expand and / or contract to selectively reduce or expand the internal space 116 of the confinement container 110, which is filled by the inflatable medium 120 when expanded. In one or more examples, the inflatable element 176 includes or takes the form of a bag or balloon containing some type of inflatable material (e.g., inflatable medium 120). In one or more examples, a chemical substance (e.g., baking soda powder) can be introduced into the balloon. When the chemical substance is heated to generate a gas, the balloon expands to reduce the fillable volume in the confinement container 110 (internal space 116) and / or impart positive pressure to the confinement space. In other examples, the expandable element 176 is an example of various types of expandable media 120.

[0089] As shown in Figures 1 and 15, in one or more examples, the system 100 includes at least one intensifier 178. In one or more examples, the intensifier 178 is placed in the internal space 116 of the restraint container 110 together with the expandable medium 120 and the workpiece 200. In one or more examples, the intensifier 178 is another type or example of the expandable medium 120, or another type of expandable material. In one or more examples, the intensifier 178 is selectively expandable to increase or enhance the pressure applied to the workpiece 200 at one or more locations. For example, the intensifier 178 is placed near a predetermined location or area of ​​the workpiece 200 (e.g., the location or area, or its vicinity), such as a cavity or contour between several different parts of the workpiece 200, so that enhanced pressure is applied to the radius of the contour during joining.

[0090] Referring next to Figure 2, an example of Method 1000 according to the Disclosure is shown. In one or more examples, Method 1000 is performed using System 100 (Figure 1). An example of Method 1000 includes multiple elements, steps, actions, or processes. Not all elements, steps, actions, or processes described or illustrated in one example are necessarily required in that example. Some or all elements, steps, actions, or processes described or illustrated in one example can be combined with other examples in various ways, without requiring the inclusion of other elements, steps, actions, or processes described in those other examples. Furthermore, such combinations do not necessarily have to be explicitly described or illustrated in the examples shown herein.

[0091] In one or more examples, method 1000 includes step 1002 of housing at least a portion 210 of a workpiece 200, such as at least a portion of a first material 204 and a second material 206, in the internal space 116 of a restraining container 110. In one or more examples, the materials 202 of individual portions of the workpiece 200 are joined. In these examples, the base 112 and cover 114 of the restraining container 110 are positioned to surround the portions 210 of the workpiece 200 to be joined. In one or more examples, the material 202 of the entire workpiece 200 is joined. In these examples, the entire workpiece 200 is placed (e.g., dropped) into the internal space 116 of the restraining container 110.

[0092] In one or more examples, method 1000 includes step 1004 of housing the expandable medium 120 in the internal space 116 of a restraining container 110. In one or more examples, the workpiece 200 and the expandable medium 120 are housed together in the restraining container 110. In one or more examples, a predetermined amount of unexpanded expandable medium 120 is housed or placed in a restraining container 110 that is positioned around the workpiece 200 (e.g., surrounding at least a portion of it). As shown in Figures 9 to 12, in one or more examples, the expandable medium 120 is generally positioned on one side of the workpiece 200 so that the workpiece 200 is pressed or compressed between the expandable medium 120 and other substructures or support structures (e.g., base 112) during joining. As shown in Figures 12 to 15, in one or more examples, the expandable medium 120 is generally positioned on multiple sides (e.g., both sides) of the workpiece 200 so that the workpiece 200 is pressed or compressed between a first portion of the expandable medium 120 and a second portion of the expandable medium 120 on the opposite side during joining.

[0093] In one or more examples, method 1000 includes a step 1006 of increasing the temperature. In one or more examples, the temperature of the expandable medium 120 is increased to an activation temperature 122. In one or more examples, the temperature of the workpiece 200 is increased to a suitable processing temperature to facilitate the bonding of the material 202.

[0094] In one or more examples, method 1000 includes step 1008 of expanding an expandable medium 120 located in an internal space 116. In one or more examples, the expandable medium 120 is expanded in response to changing an attribute 126 of the expandable medium 120. In one or more examples, the expandable medium 120 is expanded in response to raising the temperature of the expandable medium 120 to an activation temperature 122.

[0095] In one or more examples, method 1000 includes step 1010 of applying a positive pressure 124 to a restraining container 110 and a workpiece 200 (e.g., at least one of a first material 204 and a second material 206). Here, the positive pressure 124 is applied to the workpiece 200 in accordance with the expansion of the expandable medium 120. The expanded expandable medium 120 fills the internal space 116 and applies the positive pressure 124 to the workpiece 200.

[0096] In one or more examples, the expansion of the expandable medium 120 causes omnidirectional forces to act on at least one surface or portion of the workpiece 200. As shown in Figures 3 to 12, in one or more examples, the expansion of the expandable medium 120 causes a bonding force (e.g., positive pressure 124) to act on one side of the workpiece 200, thereby pressing or compressing the workpiece 200 between the expandable medium 120 and the base 112. As shown in Figures 13 to 15, in one or more examples, the expansion of the expandable medium 120 causes bonding forces (e.g., positive pressure 124) to act on multiple sides (e.g., both sides) of the workpiece 200, thereby pressing or compressing the workpiece 200 between a first portion of the expandable medium 120 and a second portion of the expandable medium 120 on the opposite side during bonding.

[0097] In one or more examples, method 1000 includes a step 1012 of joining materials 202, such as at least a first material 204 and a second material 206. In one or more examples, according to method 1000, the joining step 1012 includes a step 1014 of co-curing the materials 202 (e.g., the first material 204 and the second material 206). In one or more examples, according to method 1000, the joining step 1012 includes a step 1016 of co-joining the materials 202 (e.g., the first material 204 and the second material 206). In one or more examples, according to method 1000, the joining step 1012 includes a step 1018 of secondary joining the materials 202 (e.g., the first material 204 and the second material 206).

[0098] In one or more examples, according to Method 1000, the first material 204 and the second material 206 include an uncured composite material 212. The uncured composite material 212 includes either a curing temperature 220 (e.g., for thermosetting composite materials) or an integration temperature 224 (e.g., for thermoplastic composite materials). In these examples, bonding is achieved by co-curing with or without adhesive.

[0099] In one or more examples, according to method 1000, the first material 204 includes a cured composite material 214. The second material 206 includes an uncured composite material 212. The uncured composite material 212 includes either a curing temperature 220 (e.g., for a thermosetting composite material) or an integration temperature 224 (e.g., for a thermoplastic composite material). In these examples, bonding is achieved by co-bonding.

[0100] In one or more examples, according to method 1000, the first material 204 and the second material 206 include any of various material compositions other than the uncured composite material 212 and the adhesive 216. In these examples, bonding is achieved by secondary bonding.

[0101] In one or more examples, the curing temperature 220 of the uncured composite material 212 (e.g., thermosetting composite material) is 122 or higher than the activation temperature. In one or more examples, the curing pressure 222 of the uncured composite material 212 (e.g., the pressure required for sufficient curing and / or bonding of the uncured composite material) is 124 or lower than the positive pressure.

[0102] In one or more examples, the integration temperature 224 of the uncured composite material 212 (e.g., thermoplastic composite material) is above the activation temperature 122. In one or more examples, the integration pressure 226 of the uncured composite material 212 (e.g., the pressure required for sufficient integration and bonding of the uncured composite material) is below a positive pressure of 124.

[0103] In one or more examples, according to method 1000, the adhesive 216 is placed between a plurality of materials 202 (e.g., a first material 204 and a second material 206). The adhesive 216 has a curing temperature 220. The curing temperature 220 of the adhesive 216 is above the activation temperature 122. In one or more examples, the curing pressure 222 of the adhesive 216 (e.g., the pressure required for sufficient bonding of the adhesive materials) is below a positive pressure of 124.

[0104] In one or more examples, method 1000 includes step 1020 of detecting the internal pressure 118 of the internal space 116. In these examples, the internal pressure 118 is detected using a pressure detector 130. In one or more examples, the internal pressure 118 is monitored (e.g., in real time) by a sensor 132. In one or more examples, pressure failsafe is implemented by a pin 134.

[0105] Referring again to Figure 1, an example of workpiece 200 according to this disclosure is shown. In one or more examples, a joined structure is formed by joining the workpiece 200 using system 100 and / or method 1000 (Figure 2). An example of workpiece 200 includes multiple elements, steps, actions, or processes. Not all elements, steps, actions, or processes described or illustrated in one example are necessarily required in that example. Some or all elements, steps, actions, or processes described or illustrated in one example can be combined with other examples in various ways, without including other elements, steps, actions, or processes described in those other examples. Furthermore, such combinations do not necessarily have to be explicitly described or illustrated in the examples shown herein.

[0106] In one or more examples, the workpiece 200 is a joined workpiece or forms a joined structure. The workpiece 200 includes a plurality of materials 202 that are joined together, such as at least a first material 204 and a second material 206. At least portions of the first material 204 and the second material 206 are housed in a restraint container 110. An expandable medium 120 is placed in the internal space 116 of the restraint container 110, between the restraint container 110 and at least one of the first material 204 and the second material 206. The expandable medium 120 is configured to expand to a predetermined volume when a predetermined change occurs in its attribute 126, thereby applying a positive pressure 124 to the restraint container 110 and at least one of the first material 204 and the second material 206.

[0107] In one or more examples of workpiece 200, the first material 204 and the second material 206 include an uncured composite material 212 (e.g., a thermosetting composite material) having a curing temperature 220 and a curing pressure 222. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is equal to or less than the curing temperature 220, thereby applying a positive pressure 124 equal to or greater than the curing pressure 222.

[0108] In one or more examples of workpiece 200, the first material 204 and the second material 206 include an uncured composite material 212 (e.g., a thermoplastic composite material) having an integration temperature 224 and an integration pressure 226. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is equal to or less than the integration temperature 224, thereby applying a positive pressure 124 which is equal to or greater than the integration pressure 226.

[0109] In one or more examples of workpiece 200, the first material 204 includes a cured composite material 214. In one or more examples, the second material 206 includes an uncured composite material 212 (e.g., a thermosetting composite material) having a curing temperature 220 and a curing pressure 222. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is equal to or less than the curing temperature 220, and to apply a positive pressure 124 which is equal to or greater than the curing pressure 222. In one or more examples, the second material 206 includes an uncured composite material 212 (e.g., a thermoplastic composite material) having an integration temperature 224 and an integration pressure 226. In these examples, the expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature 122 which is equal to or less than the integration temperature 224, and to apply a positive pressure 124 which is equal to or greater than the integration pressure 226.

[0110] In one or more examples, the workpiece 200 includes an adhesive 216. The adhesive 216 is placed between at least two of the materials 202 of the workpiece 200, for example, between a first material 204 and a second material 206. The adhesive 216 has at least one of a curing temperature 220 and a curing pressure 222. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature 122 which is equal to or less than the curing temperature 220. At the activation temperature 122, the expandable medium 120 is configured to expand such that the positive pressure 124 is equal to or less than the curing pressure 222.

[0111] As shown in Figures 1, 4, 7, 10, and 12-15, in one or more examples, the work assembly 250 includes a workpiece 200 and a system 100. The workpiece 200 is placed within a restraint container 110. The restraint container 110 is configured to enclose a portion 210 of the workpiece 200. In one example, the portion 210 of the workpiece 200 is covered or surrounded by the restraint container 110. The restraint container 110 is configured to facilitate the application of pressure to the surface of the workpiece 200 by the expansion of an expandable medium 120. In one or more examples, the workpiece 200 is placed on a base 112 or, if necessary, supported by reinforcing members from a position opposite to the direction of the cover 114 and positive pressure 124.

[0112] As shown in Figures 4, 7, 10, and 12-15, in one or more examples, the expandable medium 120 is added to the internal space 116. The amount of expandable medium 120 used is suitable for the expandable medium 120 to come into contact with the inner surface of the workpiece 200 and the restraining container 110 during and / or after expansion, generating and imparting positive pressure 124 to one or more surfaces of the workpiece 200.

[0113] The expandable medium 120 can take any suitable form. In one or more examples, the expandable medium 120 is added to the restraint container 110 in the form of pellets, beads, granules, powder, or foam. Alternatively, or in addition to this, the expandable medium 120 may be added to the restraint container 110 in the form of multiple solid or semi-solid parts that are separated from each other, such as multiple layers of the expandable medium 120 that can be hung over a portion 210 of the workpiece 200. The layers of the expandable medium 120 can be arranged by adding individual encapsulation elements 168 (e.g., bags or pouches) filled with pellets, beads, or small pieces of the expandable medium 120. In Figures 3 to 15, the expandable medium 120 is shown in the form of multiple expandable pellets 162, but this is a representative example and does not limit the structure or composition of the expandable medium 120.

[0114] In various examples, the expandable medium 120 is added to the internal space 116 of the restraint container 110 in an unexpanded state. As shown in Figures 4, 5, 7, 8, 10, and 11, before and / or during the joining process, the expandable medium 120 expands (e.g., increases in volume) to at least partially fill the internal space 116, thereby applying positive pressure directly or indirectly to at least some of the inner surfaces of the restraint container 110 and the surface (e.g., the outer surface) of the workpiece 200. The pressure of the expanding expandable medium 120 promotes the pressing and integration of the portion 210 of the workpiece 200 to be joined.

[0115] In various examples, the expandable medium 120 is configured to expand (for example, to a predetermined volume and / or pressure) when a predetermined change occurs in the attributes 126 of the expandable medium 120 (for example, in an unexpanded state). In one or more examples, the expandable medium 120 is placed (for example, inserted or added) in the internal space 116 of the constraining container 110 in an unexpanded state. While the expandable medium 120 is placed in the internal space 116 (in an unexpanded state), a predetermined change occurs in the attributes 126 of the unexpanded expandable medium 120. The expandable medium 120 expands in accordance with the predetermined change that has occurred. The attributes 126 of the expandable medium 120 may be physical and / or chemical attributes.

[0116] In one or more examples, the expandable medium 120 is configured to expand in volume when it interacts with water. For example, the expandable medium 120 is or contains a desiccant, which may increase in volume when it absorbs water. For example, anhydrous calcium sulfate (anhydrous gypsum) increases in volume by approximately 61% when it absorbs water to produce gypsum. In these examples, water can be added directly to the expandable medium 120, for example, by adding water or steam inside the confinement container 110. Alternatively, or in addition to this, water or steam can also be generated inside the confinement container 110, for example, by a suitable chemical reaction.

[0117] In one or more examples, a predetermined change in the attribute 126 of the expandable medium 120 includes a temperature change of the expandable medium 120 and / or a temperature change of one or more parts of the expandable medium 120. Therefore, causing a predetermined change in the attribute 126 of the expandable medium 120 may include raising the temperature of the unexpanded expandable element from a low temperature such as ambient temperature (e.g., room temperature) to at least the initial temperature or a predetermined temperature higher than the ambient temperature (e.g., the predetermined temperature is a temperature that is any degree higher than the ambient temperature and is suitable for causing a predetermined expansion of the expandable element). Subsequently, the expandable element undergoes thermal expansion due to the temperature rise.

[0118] In one or more examples, the expandable medium 120 is a heat-activated expandable element. In these examples, the heat-activated expandable element is configured to expand when the temperature of the expandable medium 120 rises to at least a predetermined temperature. Alternatively, or in addition to this, the expandable medium 120 is expanded by heating it to at least a predetermined temperature, which generates a predetermined pressure on the workpiece 200. Typically, the predetermined pressure is sufficient to properly cure the composite material.

[0119] In one or more examples, the predetermined change occurring in the attribute 126 of the expandable medium 120 is a combination of two or more properties of the expandable medium 120, such as a ratio or product of quantitative values ​​related to the properties of the expandable medium 120, such as two materials with different coefficients of thermal expansion.

[0120] In various examples, the joining process of the workpiece 200 includes causing a predetermined change in attribute 126 of the expandable medium 120. In one or more examples, the expansion of the expandable medium 120 occurs automatically during the joining process. For example, attribute 126 is the temperature of the expandable medium 120, and the heat applied to the workpiece assembly 250 during the joining process causes a predetermined change in the temperature of the expandable medium 120. That is, the heat applied to the workpiece assembly 250 during the joining process causes the temperature of the expandable medium 120 to rise to at least a predetermined temperature related to a desired volume and / or desired volume increase. One or more properties of the expandable medium 120 can be designed so that the temperature change occurring in the expandable medium 120 during joining of the workpiece 200 causes the expandable medium 120 to expand to a predetermined desired amount as a result of thermal expansion. Alternatively, or in addition to this, additional steps may be required to expand the expandable medium 120, in addition to the steps required for curing the workpiece 200. For example, expanding the expandable medium 120 may include applying an electric field, injecting a liquid, gas, and / or other suitable material, and / or causing other suitable changes in the expandable medium 120.

[0121] In various examples, the expandable medium 120 includes any material that is thermally expandable and capable of expanding when it reaches a predetermined temperature. In certain examples, a group of plastic polymers that soften upon heating are called thermoplastic materials. Solid thermoplastic materials soften and become viscous liquids when heated above their glass transition temperature but below their melting point. In this state, the thermoplastic material can be reshaped, and more specifically, it can be expanded.

[0122] Various types of thermoplastic materials are known, including acrylic polymers, acrylonitrile butadiene styrene (ABS) polymers, nylon polymers, polylactic acid (PLA) polymers, polybenzimidazole polymers, polycarbonate polymers, polyethersulfone (PES) polymers, polyetherimide (PEI) polymers, polyethylene (PE) polymers, polyphenylene oxide (PPO) polymers, polyphenylene sulfide (PPS) polymers, polyvinyl chloride (PVC) polymers, polyvinylidene fluoride (PVDF) polymers, and polytetrafluoroethylene (PTFE) polymers. In particular, an expandable medium 120 containing acrylonitrile butadiene styrene (ABS) polymer may exhibit suitable physical properties when used in combination with the examples described herein.

[0123] In one or more examples, the expandable medium 120 (e.g., expandable pellets 162) may further include a blowing agent. The blowing agent is selected such that, when heated to at least a predetermined temperature, it forms multiple pores, cavities, or voids within the material of the expandable medium 120, thereby increasing the volume of the expandable medium 120. As an example, a suitable blowing agent may be an inert gas that permeates the expandable medium 120 under pressure. Such a blowing agent can be configured to expand in multiple locations within the expandable medium 120 when the temperature of the expandable medium 120 rises from the ambient temperature or initial temperature to a predetermined higher temperature, and the expanded gas forms pores, cavities, or voids within the pellets. When using a blowing agent, it can be applied to the expandable medium 120 before heating.

[0124] In an example where the expandable medium 120 contains a blowing agent, the blowing agent may be any suitable substance capable of obtaining the desired degree of expansion. The blowing agent may include physical blowing agents such as chlorofluorocarbons, hydrochlorofluorocarbons, hydrocarbons, or liquid carbon dioxide. Alternatively, or in addition to these, the blowing agent may include a chemical blowing agent selected to react with one or more components of the expandable medium 120. Examples of such chemical blowing agents include isocyanates and water for polyurethanes, azodicarbonamide for vinyls, hydrazine and other nitrogen-based materials for thermoplastic foams and elastomer foams, and sodium bicarbonate for thermoplastic foams.

[0125] In examples where the expandable medium 120 contains a foaming agent, the foaming agent may include a foaming agent. In these examples, the foaming agent may be selected to generate gas, and the foaming agent may be a material that promotes foam formation, such as a surfactant. Suitable foaming agents include sodium laureth sulfate, sodium lauryl ether sulfate (SLES), sodium lauryl sulfate (also known as sodium dodecyl sulfate or SDS), and ammonium lauryl sulfate (ALS).

[0126] In the joining process of the workpiece 200, the expandable medium 120 (e.g., expandable pellets 162) is expanded from an unexpanded state (Figures 5 and 7) to an expanded state (Figures 6 and 8). In one or more examples, the expandable pellets 162 are configured to expand in response to the heat applied to the workpiece assembly 250 during joining. The expandable pellets 162 expand to fill the internal space 116 of the cover 114, and the expanded expandable pellets 162 apply positive pressure to the workpiece 200, causing the workpiece 200 to harden.

[0127] In one or more examples, the expandable medium 120 (e.g., expandable pellets 162) is configured (e.g., formulated) to be at least partially deformable after expansion, during expansion, and / or before expansion. This degree of deformability allows the expandable medium 120 to fill, for example, small gaps that may naturally occur between multiple pellets, between pellets and the inner surface of the cover 114, and / or between pellets and the workpiece 200. By filling these gaps, the expandable medium 120 can substantially smooth the surface of the workpiece 200.

[0128] In various examples, after a portion 202 of the workpiece 200 has hardened, the cover 114 can be opened, released, or removed as needed, allowing the expandable medium 120 to be removed. While the expandable medium 120 is usually easily removed after the workpiece 200 has hardened, in some cases, it tends to remain expanded and tightly packed after the workpiece 200 has hardened and cooled, hindering removal. In such cases, the expandable medium 120 can be configured in one or more additional ways to facilitate separation from the workpiece 200, base 112, and / or cover 114. As an example, the expandable pellet 162 can be configured to change shape and / or size as needed, thereby making it easier to remove the pellet. For example, the expandable pellet 162 can be configured to shrink when cooled, so that after the workpiece 200 has hardened and cooled, the expandable pellet 162 shrinks in the internal space 116, facilitating removal.

[0129] In one or more examples, the expandable medium 120 is modified to minimize sintering (self-adhesion) during heating and expansion. Alternatively, or in addition to this, the expandable medium 120 can be configured to minimize the possibility of adhesion to surfaces by, for example, coating the expandable pellets 162 with a suitable agent intended to prevent adhesion and / or promote separation.

[0130] In one or more examples, suitable agents to be added to the expandable medium 120 include lubricants. For example, by adding a lubricant to the expandable pellets 162, adhesion between the expandable pellets 162 can be reduced before and / or after volume expansion. A suitable lubricant does not interfere with the curing and / or joining of the workpiece 200 and prevents the expandable pellets 162 from substantially adhering to each other or to components of the restraint container 110 or the workpiece assembly 250. A suitable lubricant may include a liquid, a powder, or a combination thereof. When added as a powder, a suitable lubricant may include nanopowder. Alternatively, or in addition to this, a suitable lubricant may include silicon-based materials, fluorinated polymers, or other substantially inert substances. For example, a suitable lubricant may include polytetrafluoroethylene (PTFE) powder, PTFE nanopowder, silicone, perfluoropolyether (PFPE), perfluoroalkyl ether (PFAE), perfluoropolyalkyl ether (PFPAE), and / or similar substances. Such lubricants can be applied to the expandable pellets 162 before they are placed in the restraint container 110. Alternatively, or in addition to this, a suitable lubricant can be applied to the expandable pellets 162 while they are in the restraint container 110. Coating at least a portion of the expandable pellets 162 with a suitable lubricant may include mixing the lubricant with these pellets and / or pouring the lubricant onto these pellets. Alternatively, or in addition to this, at least a portion of a plurality of expandable pellets 162 may be coated with the desired lubricant, and then these pellets may be mixed with a plurality of uncoated pellets.

[0131] In one or more examples, crystalline and / or semi-crystalline properties along the outer surface of the expandable pellets 162 may help prevent the pellets from sintering together. In one or more examples, at least a portion of the expandable pellets 162 are configured to have crystalline regions along the outer surface of the pellets by pretreatment, etc., and the addition of the expandable medium 120 includes adding a plurality of expandable pellets 162 having highly crystalline surface regions to reduce adhesion between pellets before and / or after volume expansion of the expandable pellets 162. In one or more examples, the expandable pellets 162 can be used when the outer surface of the pellets exhibits high crystallinity (for example, when the proportion of volume having a crystalline structure in the region near the outer surface of each pellet is high). Crystallinity of the expandable pellets 162 can be achieved by adjusting one or more factors, including the material composition of the pellets, the manufacturing temperature at which the pellets are heated during manufacturing, the time for which the pellet temperature is maintained at the manufacturing temperature during manufacturing, the electric and / or magnetic fields applied during manufacturing, the distribution of the foaming agent in the pellets, and the composition and / or concentration of the foaming agent. The outer surface of the expandable pellet 162 may be crystalline before, during, and / or after foaming.

[0132] As illustrated and described herein, examples of System 100 and Method 1000 offer various advantages and benefits compared to conventional joining techniques. Examples of System 100 and Method 1000 enable the joining of composite materials under pressure, co-joining with at least one side pre-cured, and secondary joining of non-composite materials (metals, ceramics, hybrids, MMCs, CMCs, etc.) using epoxy adhesives or other polymer adhesives (thermosetting or thermoplastic). Examples of System 100 and Method 1000 allow for gradual and controllable compression without the use of catastrophic high pressures. This eliminates the need for high-pressure gas tanks and / or storage units. It also enables controlled failure modes or fail-safe designs. Examples of System 100 and Method 1000 enable convenient portable or modular tool applications, including heating elements and compression devices that can be incorporated into the same tool. This eliminates the need for additional heating devices. Examples of System 100 and Method 1000 facilitate the formation of a target thermal environment in which a foam can be used as an insulating layer when it is necessary to isolate heat from a specific area of ​​the workpiece 200. This enables adaptive thermal management and / or single-sided heating configurations (e.g., from prepreg to pre-curing). Examples of System 100 and Method 1000 enable joining of the workpiece 200 using in-situ tooling (especially in the case of co-joining and secondary joining). Examples of System 100 and Method 1000 enable the use of various expandable materials, which are not limited to foam materials but may include, for example, bags with a high coefficient of thermal expansion (CTE) or other flexible materials. Examples of System 100 and Method 1000 enable the application of pressure in all directions (compared to hot pressing, etc.). Examples of System 100 and Method 1000 enable the control of heat transfer by various heating configurations. Examples of system 100 and method 1000 enable stress annealing that can alleviate localized stress concentrations using continuous pressure from an expandable medium 120.Examples of System 100 and Method 1000 enable control of pressure distribution for structural joining, for example, by using pressure compartments partitioned within a single constraining container (e.g., multiple different design shapes and / or multiple different inflatable materials) to equalize or localize pressure. Examples of System 100 and Method 1000 can be sustainable by using reusable inflatable materials, reducing the installation footprint of the equipment, and reducing reliance on energy sources and waste disposal. Examples of System 100 and Method 1000 enable the extrusion of adhesive and / or air, thereby reducing the porosity of the joining line. Examples of System 100 and Method 1000 enable higher-than-usual pressures (>100 psi) in applications of thermoplastic composite materials. Examples of System 100 and Method 1000 enable the continuous application of high pressure to extremely smooth surfaces (e.g., metals and composite materials). Examples of System 100 and Method 1000 enable the application of pre-compressive forces before final joining or final curing. Examples of System 100 and Method 1000 enable hybrid bonding. Examples of System 100 and Method 1000 allow the use of an expandable material that can be mixed into the adhesive, which functions as a bond line controller, such as glass beads, to achieve uniform bonding and intentionally control differences between bonded surfaces.

[0133] Referring here to Figures 14 and 15, the examples of System 100, Method 1000, and Workpiece 200 described herein relate to, or can be used in, a manufacturing and maintenance method 1100 in the aerospace field, as shown in the flowchart of Figure 16, and an aircraft 1200 schematically shown in Figure 17. For example, an aircraft 1200 and / or a manufacturing and maintenance method 1100 may use System 100 and / or a joint structure (e.g., Workpiece 200) manufactured according to Method 1000.

[0134] Referring to Figure 17, an example of an aircraft 1200 is shown. The aircraft 1200 may 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 a number of onboard systems 1204 (e.g., high-level systems). Examples of onboard systems 1204 of the aircraft 1200 include 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 connected to the fuselage 1202 of the aircraft 1200. In yet another example, the onboard systems 1204 include one or more other systems, such as, but are 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, a weapons system, and so on. The aircraft 1200 may include any number of components, including workpieces 200 that are manufactured, produced, joined, and / or installed using system 100 and / or in accordance with method 1000.

[0135] Referring to Figure 16, before the start of production of aircraft 1200, the manufacturing and maintenance methods 1100 include the specification and design of aircraft 1200 1102 and material procurement 1104. During the production of aircraft 1200, the manufacturing of aircraft 1200's components and small assemblies 1106 and system integration 1108 are carried out. Subsequently, aircraft 1200 goes through the certification and delivery process 1110 and enters service 1112. Routine maintenance and upkeep 1114 includes improvements, reconfigurations, and modifications of one or more systems of aircraft 1200.

[0136] Each step of the manufacturing and maintenance method 1100 shown in Figure 14 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). The system integrator may include, but is not limited to, several aircraft manufacturers and major system subcontractors. The third party may include, but is not limited to, several sellers, subcontractors, and suppliers. The operator may be an airline, leasing company, military organization, service organization, etc.

[0137] Examples of the system 100, method 1000, and workpiece 200 illustrated and described herein can be employed at any one or more stages of the manufacturing and maintenance method 1100 shown in the flowchart of Figure 16. For example, a component of the aircraft 1200 including the workpiece 200 may be manufactured, fabricated, joined, and / or installed using the system 100 and / or according to method 1000 as part of the manufacturing of parts and assemblies 1106 and / or system integration 1108. Furthermore, a component of the aircraft 1200 including the workpiece 200 may be manufactured, fabricated, joined, and / or installed using the system 100 and / or according to method 1000 during the commissioning of the aircraft 1200 1112. Also, a component of the aircraft 1200 including the workpiece 200 may be manufactured, fabricated, joined, and / or installed using the system 100 and / or according to method 1000 in system integration 1108 and certification and delivery 1110. Similarly, components of the aircraft 1200, including the workpiece 200, may be fabricated, manufactured, joined, and / or installed using the system 100 and / or in accordance with method 1000 during the aircraft 1200's service 1112 and during maintenance and servicing 1114.

[0138] The detailed description above refers to the accompanying drawings, which illustrate specific embodiments described in this disclosure. Therefore, other embodiments having different structures and operations do not deviate from the scope of this disclosure. Note that in different drawings, similar reference numerals may indicate the same feature, element, or component. Throughout this disclosure, any one of several elements may be referred to individually as an element, and several elements may be referred to collectively as an element and indicated by the same reference numeral. Furthermore, in this specification, features, elements, components, or steps described in the singular form should be understood not to exclude multiple features, elements, components, or steps unless otherwise specified.

[0139] The above provides illustrative and non-exclusive examples of the gist of this disclosure, which may include both those described in the claims and those not described. In this specification, “Example” means that one or more functions, structures, elements, components, features, and / or operating steps described in relation to that example are included in at least one aspect, embodiment, and / or embodiment of the gist of this disclosure. Therefore, “one example,” “another example,” “one or more examples,” and similar terms in this disclosure may, but not necessarily, refer to the same example. Furthermore, features characterizing one example may, but not necessarily, include features characterizing another example. Furthermore, features characterizing one example may, but not necessarily, be combined with features characterizing another example.

[0140] In this specification, a system, apparatus, device, structure, article, element, component, or hardware “configured” to perform a particular function means that it can perform that particular function without any modification, and not that it could perform that particular function with any modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware “configured” to perform a particular function means that it has been specifically selected, manufactured, implemented, used, programmed, and / or designed for the purpose of performing that particular function. As used herein, the term “configured” refers to a feature that the system, apparatus, structure, article, element, component, or hardware already possesses, which enables the system, apparatus, structure, article, element, component, or hardware to perform that particular function without any modification. In this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as “configured” to perform a particular function may also be described, in addition to or instead of this description, as “adapted” and / or “operable” to perform that function.

[0141] Unless otherwise specified, terms such as "first," "second," and "third" are used merely as indicators and do not impose any requirements regarding order, position, or hierarchy on the elements they refer to. Furthermore, referring to, for example, the "second" element does not require or exclude the presence of, for example, the "first" element or any smaller ordinal elements, and / or the "third" element or any larger ordinal elements.

[0142] In this specification, when the expression "at least one" is used with respect to an enumeration of elements, it means that one or more of the enumerated elements may be used in various combinations, or that only one of the enumerated elements may be required. For example, "at least one of elements A, B, and C" may include, but is not limited to, element A, or element A and element B. In this example, it may also include element A, element B, and element C, or element B and element C. In other examples, "at least one" may, for example, be two elements A, one element B, and ten elements C, or four elements B and seven elements C, or any other appropriate combination. In this specification, the expression "and / or," and the symbol " / ," include any and all combinations of one or more of the elements enumerated in connection therewith.

[0143] In this specification, “joined,” “connected,” and similar terms mean that two or more elements are related to each other by joining, linking, fixing, attaching, connecting, communicating, or otherwise (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, multiple elements may be related directly or indirectly. For example, element A may be directly related to element B. Alternatively, element A may be indirectly related to element B, for example, through another element C. Not all possible connections between elements disclosed are necessarily shown. Therefore, connections other than those illustrated may exist.

[0144] In this specification, the term "approximately" means a state that is not exactly identical to the described state, but is close to it and capable of performing the desired function or achieving the desired result. For example, "approximately" means a state that is within a given acceptable tolerance or precision range, for example, a state that is within 10% of the described state. However, the term "approximately" does not exclude a state that is exactly identical to the described state. In this specification, the term "substantially" means a state that is essentially the same as the described state and capable of performing the desired function or achieving the desired result.

[0145] Figures 1, 3-15, and 17, referenced in the above description, represent functional elements, features, or components and do not necessarily suggest a specific structure. Therefore, modifications, additions, and / or omissions are possible with respect to the illustrated structures. Furthermore, as those skilled in the art will see, not all elements, features, and / or components shown and described in Figures 1, 3-15, and 17 are necessarily included in all embodiments, nor are all described elements, features, and / or components shown in each illustrated example. Therefore, some of the elements, features, and / or components shown and described in Figures 1, 3-15, and 17 can be combined in various ways without including other features shown in Figures 1, 3-15, 17, or other drawings and / or accompanying disclosures, and such combinations do not need to be explicitly stated in this disclosure. Similarly, additional features, not limited to the described embodiments, can be combined with some or all of the features illustrated and described herein. Unless otherwise stated, the schematic diagrams of the embodiments shown in Figures 1, 3-15, and 17 are not intended to suggest any structural limitations on the exemplary embodiments. Rather, they show one exemplary structure, which can be modified as appropriate. Therefore, it is possible to modify, add to, and / or omit the illustrated structure. Furthermore, in Figures 1, 3-15, and 17, elements, features, and / or components that serve similar purposes, or at least substantially similar purposes, are given the same reference numerals, and such elements, features, and / or components may not be described in detail with reference to Figures 1, 3-15, and 17. Similarly, in Figures 1, 3-15, and 17, not all elements, features, and / or components are given reference numerals, but the reference numerals associated with these elements may be used in the specification for consistency.

[0146] In Figures 2 and 16 referenced above, blocks may represent processes, steps, and / or parts thereof, and the lines connecting the various blocks do not suggest a specific order or dependency of the processes or parts thereof. Not all dependencies between the various processes disclosed are necessarily shown. Figures 2 and 16, and the accompanying disclosures describing the processes in the methods described herein, do not necessarily determine the order in which these processes are performed. Rather, they show an exemplary order, but the order of these processes can be changed as appropriate. Therefore, the exemplary processes can be modified, added to, and / or omitted, and some processes can be performed in different orders or simultaneously. In addition, as will be apparent to those skilled in the art, it is not necessary to perform all of the described processes.

[0147] Furthermore, the features, advantages, or similar expressions described herein do not imply that all features and advantages achievable in the embodiments of this disclosure should be included in, or are included in, any single example. Rather, the descriptions of features and advantages mean that certain features, advantages, or characteristics described in relation to a single example are included in at least one example. Accordingly, the features, advantages, and similar expressions described herein may or may not refer to the same example.

[0148] Features, advantages, and characteristics of any given embodiment can be combined in appropriate manner in one or more other embodiments. Those skilled in the art will understand that the embodiments described herein can be implemented without having one or more specific features or advantages of any particular embodiment. Additional features and advantages may be recognized in some embodiments, but these may not be present in all embodiments. Furthermore, while various embodiments of System 100, Method 1000, and Workpiece 200 have been illustrated and described, those skilled in the art will be able to make various modifications by reading this specification. Such modifications are included and are limited only by the claims.

[0149] This disclosure further includes the following note:

[0150] Note 1. A system (100) for joining materials (202), A restraint container (110) having an internal space (116) and including a base (112) and a cover (114), the restraint container (110) is configured to enclose at least a portion of a first material (204) and a second material (206) that are joined together, A system (100) comprising, in the internal space (116), an expandable medium (120) disposed between at least a portion of the restraint container (110) and at least one of the first material (204) and the second material (206), wherein the expandable medium (120) expands, thereby causing the expandable medium to apply positive pressure (124) to the restraint container (110) and at least one of the first material (204) and the second material (206).

[0151] Note 2. The system (100) as described in Appendix 1, wherein at least one of the base (112) and the cover (114) is rigid.

[0152] Note 3. The system (100) according to Appendix 1, wherein at least a portion of at least one of the base (112) and the cover (114) is flexible.

[0153] Note 4. The first material (204) and the second material (206) each include an uncured composite material (212) having a curing temperature (220). The system (100) described in Appendix 1, wherein the expandable medium (120) is configured to expand when the temperature of the expandable medium (120) rises to an activation temperature (122) that is below the curing temperature (220).

[0154] Note 5. The first material (204) includes a cured composite material (214), The second material (206) comprises an uncured composite material (212) having a curing temperature (220), The system (100) described in Appendix 1, wherein the expandable medium (120) is configured to expand when the temperature of the expandable medium (120) rises to an activation temperature (122) that is below the curing temperature (220).

[0155] Note 6. An adhesive (216) is placed between the first material (204) and the second material (206). The adhesive (216) has at least one of a curing temperature (220) and a curing pressure (222), The expandable medium (120) is configured to expand when its temperature rises to an activation temperature (122) which is below the curing temperature (220). The positive pressure (124) is less than or equal to the hardening pressure (222), as described in Appendix 1 (100).

[0156] Note 7. The system (100) according to Appendix 1 further includes a pressure detector (130) configured to detect the internal pressure of the internal space (116).

[0157] Note 8. The system (100) according to Appendix 1, further comprising a heater (140) that is heat-transferable to the expandable medium (120).

[0158] Note 9. A method (1000) for joining materials (202), The internal space (116) of the restraining container (110) contains at least a portion of the first material (204) and the second material (206), To expand the expandable medium (120) placed in the internal space (116), In accordance with the expansion of the expandable medium (120), a positive pressure (124) is applied to the restraining container and at least one of the first material (204) and the second material (206), A method (1000) comprising joining the first material (204) and the second material (206) to each other.

[0159] Note 10. The joining method (1000) according to Appendix 9 further comprises co-curing the first material (204) and the second material (206).

[0160] Note 11. The method further includes raising the temperature of the expandable medium (120) to the activation temperature (122), The method according to Appendix 10 (1000), wherein the first material (204) and the second material (206) include an uncured composite material (212) having a curing temperature (220) above the activation temperature (122).

[0161] Note 12. The joining method (1000) described in Appendix 9, comprising co-joining the first material (204) and the second material (206).

[0162] Note 13. The method further includes raising the temperature of the expandable medium (120) to the activation temperature (122), The first material (204) includes a cured composite material (214), The method according to Appendix 12 (1000), wherein the second material (206) includes an uncured composite material (212) having a curing temperature (220) above the activation temperature (122).

[0163] Note 14. The joining method (1000) described in Appendix 9, which includes secondary joining of the first material (204) and the second material (206).

[0164] Note 15. The method further includes raising the temperature of the expandable medium (120) to the activation temperature (122), An adhesive (216) is placed between the first material (204) and the second material (206). The adhesive (216) has at least one of the following: a curing temperature (220) above the activation temperature (122) and a curing pressure (222) above the positive pressure (124), according to the method (1000) described in Appendix 14.

[0165] Note 16. The method according to Appendix 9 (1000), further comprising detecting the internal pressure (118) of the internal space (116).

[0166] Note 17. It includes a first material (204) and a second material (206) that are joined together, At least a portion of the first material (204) and the second material (206) is housed in a restraining container (110), In the internal space (116) of the restraint container (110), an expandable medium (120) is placed between the restraint container (110) and at least one of the first material (204) and the second material (206). The expandable medium (120) is configured to expand to a predetermined volume when a predetermined change occurs in the attributes (126) of the expandable medium (120), thereby applying positive pressure (124) to the restraining container (110) and at least one of the first material (204) and the second material (206) of the workpiece (200).

[0167] Note 18. The first material (204) and the second material (206) each include an uncured composite material (212) having a curing temperature (220). The workpiece (200) described in Appendix 17 is configured such that the expandable medium (120) expands when its temperature rises to an activation temperature (122) which is below the curing temperature (220).

[0168] Note 19. The first material (204) includes a cured composite material (214), The second material (206) comprises an uncured composite material (212) having a curing temperature (220), The workpiece (200) described in Appendix 17 is configured such that the expandable medium (120) expands when its temperature rises to an activation temperature (122) which is below the curing temperature (220).

[0169] Note 20. The material further includes an adhesive (216) disposed between the first material (204) and the second material (206), The adhesive (216) has at least one of a curing temperature (220) and a curing pressure (222), The expandable medium (120) is configured to expand when its temperature rises to an activation temperature (122) which is below the curing temperature (220). The positive pressure (124) is less than or equal to the hardening pressure (222), as described in Appendix 17, for the workpiece (200).

Claims

1. A system for joining materials, A restraining container having an internal space and including a base and a cover, the restraining container is configured to enclose at least a portion of a first material and a second material that are joined together, A system comprising, in the internal space, an expandable medium disposed between at least a portion of the restraint container and at least one of the first material and the second material, wherein the expandable medium expands, thereby applying positive pressure to the restraint container and at least one of the first material and the second material.

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

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

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

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

6. An adhesive is placed between the first material and the second material. The adhesive has at least one of a curing temperature and a curing pressure. The expandable medium is configured to expand when its temperature rises to an activation temperature below the curing temperature. The system according to claim 1, wherein the positive pressure is less than or equal to the hardening pressure.

7. The system according to claim 1, further comprising a pressure detector configured to detect the internal pressure of the internal space.

8. The system according to claim 1, further comprising a heater that is heat-transferably coupled to the expandable medium.

9. A method for joining materials, The internal space of the restraining container contains at least a portion of the first material and the second material, To expand the expandable medium placed in the internal space, In accordance with the expansion of the expandable medium, positive pressure is applied to the restraining container and to at least one of the first material and the second material. A method comprising joining the first material and the second material to each other.

10. The method according to claim 9, further comprising co-curing the first material and the second material.

11. The method further includes raising the temperature of the expandable medium to an activation temperature. The method according to claim 10, wherein the first material and the second material include an uncured composite material having a curing temperature at or above the activation temperature.

12. The method according to claim 9, wherein the joining includes co-joining the first material and the second material.

13. The method further includes raising the temperature of the expandable medium to an activation temperature. The first material includes a cured composite material, The method according to claim 12, wherein the second material includes an uncured composite material having a curing temperature above the activation temperature.

14. The method according to claim 9, wherein the joining includes secondary joining of the first material and the second material.

15. The method further includes raising the temperature of the expandable medium to an activation temperature. An adhesive is placed between the first material and the second material. The method according to claim 14, wherein the adhesive has at least one of the following: a curing temperature equal to or greater than the activation temperature and a curing pressure equal to or greater than the positive pressure.

16. The method according to claim 9, further comprising detecting the internal pressure of the internal space.

17. It includes a first material and a second material that are joined together, At least a portion of the first material and the second material is housed in a restraint container. In the internal space of the restraint container, an expandable medium is placed between the restraint container and at least one of the first material and the second material. The expandable medium is configured to expand to a predetermined volume when a predetermined change occurs in its attributes, thereby applying positive pressure to the restraining container and at least one of the first and second materials in a workpiece.

18. The first material and the second material include an uncured composite material having a curing temperature. The workpiece according to claim 17, wherein the expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature below the curing temperature.

19. The first material includes a cured composite material, The second material includes an uncured composite material having a curing temperature, The workpiece according to claim 17, wherein the expandable medium is configured to expand when the temperature of the expandable medium rises to an activation temperature below the curing temperature.

20. The material further includes an adhesive placed between the first material and the second material. The adhesive has at least one of a curing temperature and a curing pressure. The expandable medium is configured to expand when its temperature rises to an activation temperature below the curing temperature. The workpiece according to claim 17, wherein the positive pressure is less than or equal to the hardening pressure.

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