System and method for processing materials using an expandable tool

Abstract

This invention relates to systems and methods for manufacturing, joining, and repairing materials using expandable materials and expandable tools. [Solution] The system for processing a workpiece includes a restraint container, a pressure-operated coupling, and an expandable medium. The restraint container includes an internal space and is configured to surround at least a portion of the workpiece to be processed. The pressure-operated coupling is configured to fix the restraint container in a closed state and to release the restraint container when the internal pressure in the restraint container's internal space reaches an operating pressure. The expandable medium is configured to be positioned and expand within the internal space between at least a portion of the restraint container and at least a portion of the workpiece, thereby applying positive pressure to the restraint container and the workpiece.

Description

Technical Field

[0001] The present disclosure generally relates to the processing of materials, and more specifically, to systems and methods for manufacturing, joining, and repairing materials using expandable materials and expandable tools.

Background Art

[0002] Many manufactured parts require one or more manufacturing processes such as joining, curing (e.g., in the case of thermosetting materials), integration (e.g., in the case of thermoplastic materials), or other processing steps, and these processes typically require control of temperature and pressure. In many cases, large industrial equipment such as autoclaves is used for these processes, and both temperature and pressure are applied under controlled conditions. However, the equipment required to obtain sufficient processing temperature and pressure is often large, complex, and expensive, and can be a bottleneck in the manufacturing process. Furthermore, large processing equipment typically does not address the needs for spot processing, repair, and remote processing. Therefore, those skilled in the art continue to make research and development efforts regarding the manufacture of materials.

Summary of the Invention

[0003] Examples of systems and methods for processing workpieces are disclosed herein. Non-limiting examples of the gist according to the present disclosure are listed below, 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, which includes an internal space and is configured to enclose at least a portion of the workpiece to be processed. The system includes a pressure-operated coupling, which is configured to fix the restraint container in a closed state and to release the restraint container when the internal pressure in the internal space of the restraint container reaches an operating pressure. The system includes an expandable medium, which is positioned in the internal space between at least a portion of the restraint container and at least a portion of the workpiece and is configured to expand to apply positive pressure to the restraint container and the workpiece.

[0005] As another example, the system of the present disclosure includes a restraint container, which is configured to enclose at least a portion of a workpiece to be processed and includes a plurality of container walls forming an internal space. The system includes a pressure-operated coupling, which is configured to fix two of the container walls and to release the two container walls when the internal pressure in the internal space reaches an operating pressure. The system includes a pressure plug, which is coupled to one of the container walls and is movable relative to that one container wall, and changes the volume of the internal space by positioning a portion of the pressure plug in the internal space. The system includes a tensioner configured to selectively apply tension between two of the container walls to control the internal pressure. The system includes a viewport formed in one of the container walls. The system includes a pressure-responsive shutter configured to cover the viewport when the internal pressure in the internal space of the restraint container reaches a processing pressure. The above system includes an expandable medium, which is positioned in the internal space between at least a portion of the container wall and at least a portion of the workpiece, and is configured to expand in such a way that it applies positive pressure to the container wall and the workpiece.

[0006] In one example, the method of the present disclosure includes: (1) housing at least a portion of the workpiece in the internal space of a restraining container; (2) applying an expandable medium between at least a portion of the restraining container and at least a portion of the workpiece in the internal space; (3) fixing the restraining container in a closed state using a pressure-operated coupling; (4) expanding the expandable medium to increase the internal pressure of the restraining container and apply positive pressure to the workpiece; and (5) automatically releasing the restraining container using the pressure-operated coupling when the internal pressure of the restraining container reaches an operating pressure.

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

[0008] [Figure 1] This is a schematic block diagram showing an example of a system for processing materials. [Figure 2] This is a flowchart illustrating an example of a method for processing materials. [Figure 3] This is a schematic diagram illustrating an example of the system, showing a workpiece placed inside a constrained container and an unexpanded expandable medium. [Figure 4] Figure 3 is a schematic diagram showing an example of the system, in which an expandable medium in an expanded state is shown. [Figure 5] A schematic diagram illustrating an example of the system. [Figure 6] A schematic diagram illustrating an example of the system. [Figure 7] A schematic diagram illustrating an example of the system. [Figure 8] A schematic diagram illustrating an example of the system. [Figure 9] A schematic diagram illustrating an example of the system. [Figure 10A] A schematic diagram illustrating an example of the system. [Figure 10B]Figure 10A is a schematic diagram showing an example of a tension-applying device for the system shown. [Figure 11] A schematic diagram illustrating an example of the system. [Figure 12] A schematic diagram illustrating an example of the system. [Figure 13] This is a schematic diagram illustrating an example of the system, demonstrating the modularity of the constrained container for accommodating workpieces by changing the volume of the internal space. [Figure 14] This is a schematic diagram showing an example of an aircraft. [Figure 15] This is a flowchart illustrating an example of aircraft manufacturing and maintenance methods. [Modes for carrying out the invention]

[0009] Referring next to Figures 1 and 3-13, this disclosure relates, for example, to a system 100 for processing a workpiece 200. Examples of the system 100 according to this disclosure are shown below. Examples of the system 100 include several 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 elements, singularities, and / or components described or illustrated in one example can be combined with other examples in various ways, without requiring the inclusion of 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.

[0010] In embodiments of System 100, high-quality processed parts can be manufactured without the use of an autoclave by utilizing a portable and modular restraint container, an expandable material, and related components. Furthermore, embodiments of System 100 facilitate the application of omnidirectional and at least substantially uniform pressure to the surface of the component being processed. Additionally, embodiments of System 100 allow the use of the expandable material for structural bonding, debulking, curing, and integration, with or without adhesives. Embodiments of System 100 enable material processing in locations where it would otherwise be impossible.

[0011] Figures 3-13 show various examples of the system 100 used to process at least a portion of the workpiece 200. Generally, a portion of the workpiece 200 refers to any part or all of the workpiece 200 that is processed using the system 100.

[0012] As shown in Figure 1, in one or more examples, the workpiece 200 includes one or more materials 210, such as a first material and a second material. In some examples, the materials 210 are identical. In some examples, the materials 210 are different. In one or more examples, the workpiece 200 may include any number of materials 210, such as base materials, material layers, components, and accessories that are joined to each other in the material processing steps. In one or more examples, one or more of the materials 210 are composite materials (e.g., composite components, composite parts, composite objects, etc.) that include one or more composite layers (also called plies). In one or more examples, one or more of the materials 210 are metallic materials (e.g., metallic components, metallic parts, metallic objects, etc.). In one or more examples, one or more of the materials 210 are ceramic materials (e.g., ceramic components, ceramic parts, ceramic objects, etc.). In one or more examples, one or more of the materials 210 are polymer materials (e.g., polymer components, polymer parts, polymer objects, etc.).

[0013] Figures 3-13 show various examples of workpieces 200 and materials 210 to be processed, cured, integrated, or joined using system 100 and / or method 1000 (Figure 2). Workpiece 200 may include any suitable number of materials 210 (e.g., material types, material layers, material parts, material components, or material parts). In various examples, workpiece 200 may include one or more composite materials, metallic materials, ceramic materials, polymer materials, thermoplastic materials, thermosetting materials, fiber-reinforced materials, and / or any other suitable materials, depending on the properties required for the joined structure.

[0014] In any of these examples, material 210 is processed using system 100 and / or according to method 1000. In one or more examples, material 210 (e.g., thermosetting material) is cured. In one or more examples, material 210 (e.g., thermoplastic material) is integrated. In one or more examples, material 210 is joined to each other by co-curing (e.g., by heating and / or pressurizing). In one or more examples, material 210 is joined to each other by co-bonding (e.g., by heating and / or pressurizing). In one or more examples, material 210 is joined to each other by secondary bonding (e.g., by heating and / or pressurizing).

[0015] The workpiece 200 can have any suitable one of a variety of different cross-sectional shapes. The material 210 includes a plurality of material layers (e.g., uncured composite materials, cured composite materials, metallic materials, ceramic materials, polymer materials, thermoplastic materials, thermosetting materials, fiber-reinforced materials, etc.), and optionally in addition to these, an adhesive layer, and these layers are joined to each other by utilizing the expansion of the expandable medium 130 to apply a positive pressure 254 to the workpiece 200. In one or more examples, the workpiece 200 includes a plurality of layers (e.g., material layers) of the material 210, and these layers are processed (e.g., cured, integrated, or joined) by utilizing the expansion of the expandable medium 130 to apply a positive pressure 254 to the workpiece 200. In one or more examples, the expandable medium 130 is arranged or positioned relative to the workpiece 200 such that a positive pressure 254 (e.g., an omnidirectional force) is applied to at least one side or surface of the workpiece 200.

[0016] As shown in FIGS. 1 and 3 - 13, in one or more examples, the system 100 includes a restraint container 110. The restraint container 110 includes an internal space 112. The restraint container 110 is configured to surround at least a portion of the workpiece 200 that is to be processed. The restraint container 110 functions as a pressurized tool chamber, and its internal space 112 may be pressurized to assist in the shaping, joining, curing, integration, or other processing of materials.

[0017] In one or more examples, the restraint container 110 functions as a portable and modular space restraint container or tool that surrounds at least a portion of the workpiece 200 being processed (e.g., manufacturing, repair, joining, etc.). The portability and modularity of the restraint container 110 enable the manufacture of workpieces and / or the processing of materials even in locations where it would otherwise be impossible. In one or more examples, the restraint container 110 is configured (e.g., sized and shaped) to accommodate and / or surround the entire workpiece 200 being processed. In one or more examples, the restraint container 110 is configured (e.g., sized and shaped) to accommodate and / or surround a portion (e.g., not the entire portion) of the workpiece 200 being processed.

[0018] As shown in FIGS. 1 and 3 - 13, in one or more examples, the restraint container 110 includes a base 114 and a cover 116. Generally, the cover 116 is coupled to the base 114 and forms or defines the internal space 112 of the container 110. In one or more examples, the cover 116 is movable relative to the base 114 and can configure the container 110 to an open state or a closed state.

[0019] As shown in FIGS. 3 - 13, in one or more examples, the workpiece 200 is on the base 114 or supported by the base 114. In one or more examples, the cover 116 is disposed relative to the base 114 and / or the workpiece 200 such that at least a portion of the workpiece 200 and the expandable medium 130 are disposed within the cover 116, restrained by the cover 116, or disposed between the cover 116 and the base 114. In one or more examples, the cover 116 enables the expandable medium 130 and the workpiece 200 to be received within the internal space 112 of the restraint container 110. In one or more examples, the cover 116 has or forms a cross - sectional profile corresponding to the cross - sectional shape of the workpiece 200. By providing the cover 116 with a cross - sectional profile corresponding to (e.g., at least generally matching or complementary to) the cross - sectional shape of the workpiece 200, it is possible to reduce the internal space 112 of the restraint container 110 and reduce the amount of the required expandable medium 130.

[0020] In one or more examples, the workpiece 200 is placed inside the restraint container 110 (e.g., on the base 114) during processing. In some examples, while the workpiece 200 is placed inside the restraint container 110, it may be necessary to adequately support at least a portion of the workpiece 200 being processed in order to apply an appropriate compressive force (e.g., positive pressure 254) to the workpiece. In one or more examples, the base 114 has a substantially incompressible surface to support one side of the workpiece 200. In other examples, the system 100 includes a forming tool 148 (Figures 3-12), depending on the type of workpiece 200 being processed. In one or more examples, the forming tool 148 is configured to be placed inside the internal space 112. In one or more examples, the forming tool 148 is incorporated into the base 114. The forming tool 148 is configured to support at least a portion of the workpiece 200. In one or more examples, the forming tool 148 (e.g., a mandrel) defines the cross-sectional shape of the workpiece 200.

[0021] As shown in Figures 1 and 3-13, in one or more examples, the system 100 includes a pressure-operated coupling 122 (e.g., one or more pressure-operated couplings 120). The pressure-operated coupling 122 is configured to fix the restraint container 110 in a closed state. The pressure-operated coupling 122 is also configured to selectively and automatically release the restraint container 110 when the internal pressure 250 of the internal space 112 of the restraint container 110 reaches an operating pressure 252.

[0022] As shown in Figures 3 and 4, in one or more examples, the cover 116 is coupled to the base 114 by a pressure-operated coupling 122, and when the internal pressure 250 reaches the operating pressure 252, for example, when the expandable medium 130 expands as shown in Figure 4, the cover 116 is released from the base 114.

[0023] As shown in Figures 3 and 4, in one or more examples, the system 100 includes fasteners 142 (e.g., one or more fasteners). In these examples, the cover 116 is further coupled to the base 114 by fasteners 142 (e.g., in a different position from the pressure-operated coupling 122). Fasteners 142 may be any suitable mechanical fastener, but are not limited to, bolts and nuts, pins, rivets, clips, clamps, hinges, latches, etc. In one or more examples, fasteners 142 allow hinged movement or pivoting between the cover 116 and the base 114 for opening and closing the container 110.

[0024] Referring again to Figures 1 and 3-13, the pressure-actuated coupling 122 is one example of a plurality of pressure-actuated couplings 120. In one or more examples, the pressure-actuated coupling 122 is an overload coupling or overload-actuated coupling configured to break (e.g., intentionally break) in response to a predetermined force generated by or corresponding to the internal pressure 250 within the restraining container 110. In one or more examples, the operating pressure 252 is an overload pressure exceeding the permissible range of the system 100 and / or the material being processed, protecting the system 100 and / or the workpiece 200 from damage caused by excessive force or pressure. In other examples, the operating pressure 252 is a predetermined processing pressure, such as a first (e.g., minimum) pressure level, to ensure good processing quality.

[0025] As shown in Figures 1 and 3-13, in one or more examples, the system 100 includes an expandable medium 130. The expandable medium 130 is configured to be positioned in the internal space 112 between at least a portion of the restraint container 110 and at least a portion of the workpiece 200. The expandable medium 130 is configured to expand, thereby applying a positive pressure 254 to the restraint container 110 and the workpiece 200.

[0026] In one or more examples, before processing, the expandable medium 130 is in an unexpanded state (e.g., Figure 3). In the unexpanded state (e.g., before expansion), the expandable medium 130 may be called an unexpanded body or unexpanded element. During the manufacturing process, the expandable medium 130 expands to an expanded state (e.g., Figures 4-13). The expanded expandable medium 130 may be called an expanded body or expanded element. In one or more examples, the expanded expandable medium 130 applies pressure to the inner surface of the restraint container 110 and the surface of the workpiece 200. In one or more examples, the expanded expandable medium 130, in part or all of the manufacturing process, applies a positive pressure 254 (due to the expansion of the expandable medium 130) to the workpiece 200, promoting compression. In one or more examples, after the workpiece 200 has been processed, the expandable medium 130 can be removed from the restraint container 110 before, simultaneously with, or after the workpiece 200 in its manufactured state is removed from the restraint container 110.

[0027] In one or more examples, the expandable medium 130 is configured to expand to an expanded volume 164 in response to a first predetermined change occurring in the attribute 168 of the expandable medium 130. When the expandable medium 130 expands, it applies or exerts a positive pressure 254 on the workpiece 200 and the restraint container 110. Generally, the expanded volume 164 is known or can be calculated based on the material composition, attribute 168, and / or the activation temperature of the expandable medium 130. In one or more examples, the expanded volume 164 of the expanded medium 130 in the expanded state is greater than the internal space 112 of the restraint container 110. In this disclosure, the internal space 112 refers to the actually usable and fillable internal space in the internal cavity of the restraint container 110. In various examples, the expansion volume 164 is substantially the same as, or slightly larger than, the internal space 112 defined by the constraining container 110, the workpiece 200, and other components placed within the constraining container 110, so that when the expandable medium 130 expands, it exerts a positive pressure 254 on the workpiece 200, unless the volume of the internal space 112 is changed (e.g., by adjusting the pressure plug 172 or controlling the variable volume element 174). In one or more examples, the amount (e.g., volume) of unexpanded expandable medium 130 introduced into the internal space 112 of the constraining container 110 is determined by tests or models that predict the pressures in the constraining space during and after expansion.

[0028] In one or more examples, the expandable medium 130 is configured to shrink to a shrink volume 166 in response to a second predetermined change occurring in the attribute 168 of the expandable medium 130. When the expandable medium 130 shrinks, it reduces or eliminates the positive pressure 254 applied to the workpiece 200 and the restraining container 110. Generally, the shrink volume 166 is known or can be calculated based on the material composition, attribute 168, and / or the activation temperature of the expandable medium 130. In various examples, the shrink volume 166 of the expandable medium 130 is smaller than the expansion volume 164. In one or more examples, the shrink volume 166 is smaller than the expansion volume 164 but larger than the volume of the expandable medium 130 before expansion (e.g., before expansion).

[0029] In one or more examples, the expandable medium 130 generates heat during expansion and / or contraction. In one or more examples, the expandable medium 130 absorbs heat during expansion and / or contraction. In these examples, the expansion or contraction caused by the activation of the expandable medium 130 can be used to control the temperature during manufacturing, for example, the temperature of the workpiece 200, the temperature of the expandable medium 130, and / or the temperature inside the restraining container 110. In one or more examples, the expandable medium 130 neither generates nor absorbs heat during expansion and / or contraction (e.g., it does not release or absorb heat).

[0030] The expandable medium 130 may include one or more of a variety of suitable types of materials or material compositions configured to expand and optionally contract when activated or in response to a change in at least one attribute 168. As shown in the figures, in one or more examples, the expandable medium 130 includes expandable pellets. In one or more examples, the expandable pellets are thermally activated at an activation temperature. In these examples, the expandable pellets are configured to expand when their temperature rises to the activation temperature. In one or more examples, the expandable pellets are chemically activated, for example, by applying an activation element 124. In one or more examples, any suitable number of expandable pellets can be placed in the internal space 112 of the restraint container 110, provided that sufficient positive pressure 254 can be applied to the workpiece 200 during expansion to perform the desired treatment. The number of expandable pellets depends on the size of the internal space 112; that is, the closer the restraint container 110 is to the contour of the workpiece 200, the fewer expandable pellets may be required. In various examples, each expandable pellet may have any suitable dimensions. In one or more examples, the length of the expandable pellet is less than about 1 centimeter. The expandable pellets may be substantially uniform in size or may contain pellets of different sizes. In one or more examples, the expandable medium 130, such as the expandable pellets, contains or takes the form of foamed pellets. In one or more examples, the foamed pellets are configured to foam when heated to at least a predetermined foaming temperature (e.g., activation temperature). In one or more examples, the foamed pellets include foamed materials such as thermoplastic materials treated with a foaming agent, gas-filled balloons, hollow microspheres, metals, other suitable components configured to expand upon heating, or a combination thereof.

[0031] As shown in Figures 1 and 5-13, in one or more examples, the restraint container 110 includes a base 114 and a cover 116. The cover 116 is coupled to the base 114 by some combination of a pressure-operated coupling 122 and a fastener 142. In one or more examples, the cover 116 includes a plurality of cover sections 150. At least two of the cover sections 150 are coupled to each other by one of the pressure-operated couplings 120 (e.g., pressure-operated coupling 122), so that when the internal pressure 250 reaches an operating pressure 252, the at least two cover sections 150 are released from each other.

[0032] As shown in Figure 5, in one or more examples, one or more of the cover sections 150 are directly coupled to an adjacent cover section 150 by one of the pressure-operated couplings 120. As shown in Figure 6, in one or more examples, one or more of the cover sections 150 may also be directly coupled to the base 114 of the container 110 by a fastener 142, etc.

[0033] As shown in Figures 1, 3, and 4, in one or more examples, the restrained container 110 includes or is formed by a plurality of container walls 140. In these examples, some of the plurality of container walls 140 form a base 114, and some of the plurality of container walls 140 form a cover 116. For example, some of the plurality of container walls 140 form a cover section 150 of the cover 116, and other parts of the plurality of container walls 140 form a base 114. In these examples, at least two of the container walls 140 are coupled to each other by a pressure-operated coupling 122, so that when the internal pressure 250 reaches the operating pressure 252, the at least two container walls 140 are released from each other. Furthermore, some of the plurality of container walls 140 can be coupled to each other by fasteners 142.

[0034] As shown in Figures 1 and 5-8, in one or more examples, the cover 116 includes multiple cover layers 160. In the examples shown in Figures 5, 6, and 8, the cover 116 includes four cover layers 160 (e.g., a first cover layer 160a, a second cover layer 160b, a third cover layer 160c, and a fourth cover layer 160d). In these examples, the first cover layer 160a is the innermost layer of the cover 116, and the fourth cover layer 160d is the outermost layer of the cover 116. In the example shown in Figure 7, the cover 116 includes three cover layers 160. In these examples, the first cover layer 160a is the innermost layer of the cover 116, and the third cover layer 160c is the outermost layer of the cover 116. In one or more examples, each of the cover layers 160 is bonded to the base 114. In one or more examples, one or more of the cover layers 160 are coupled to the base 114 by one of the pressure-operated couplings 120 (e.g., a first pressure-operated coupling 120a, a second pressure-operated coupling 120b, a third pressure-operated coupling 120c, a fourth pressure-operated coupling 120d, etc., as shown in Figures 5 and 6). In one or more examples, one or more of the cover layers 160 may be coupled to the base 114 by one of the fasteners 142 (e.g., a first fastener 142a, a second fastener 142b, a third fastener 142c, a fourth fastener 142d, etc., as shown in Figure 6).

[0035] As shown in Figure 5, in one or more examples, each pressure-operated coupling 120 (e.g., first pressure-operated coupling 120a, second pressure-operated coupling 120b, third pressure-operated coupling 120c, fourth pressure-operated coupling 120d, etc.) is positioned between the associated cover layer 160 (e.g., first cover layer 160a, second cover layer 160b, third cover layer 160c, fourth cover layer 160d, etc.) and the base 114.

[0036] As shown in Figures 5 and 6, in one or more examples, each pressure-operated coupling 120 (e.g., first pressure-operated coupling 120a, second pressure-operated coupling 120b, third pressure-operated coupling 120c, fourth pressure-operated coupling 120d, etc.) is positioned between adjacent cover sections 150 (first cover section 150a and second cover section 150b) of each associated cover layer 160 (e.g., first cover layer 160a, second cover layer 160b, third cover layer 160c, fourth cover layer 160d, etc.). In these examples, each cover layer 160 is coupled to the base 114 by associated fasteners 142 (e.g., first fastener 142a, second fastener 142b, third fastener 142c, fourth fastener 142d, etc.), such as hinges or pins. In this way, when a pressure-operated coupling 120 is released (e.g., broken or ruptured), each separated section of the container 110 (e.g., cover section 150) becomes movable in some way, thereby allowing the expandable medium 130 to reach the free space (e.g., associated internal space 118) of the next outermost cover layer 160 and expand within it, thereby activating the next set of pressure-operated couplings 120 associated with that cover layer.

[0037] Each cover layer 160 and base 114 forms one of the multiple internal spaces 118 of the restraint container 110. As an example, as shown in Figure 6, the first layer of the base 114 and cover layer 160 (e.g., the first cover layer 160a) forms the first space of the internal space 118 (e.g., the first internal space 118a), the second layer of the base 114 and cover layer 160 (e.g., the second cover layer 160b) forms the second space of the internal space 118 (e.g., the second internal space 118b), the third layer of the base 114 and cover layer 160 (e.g., the third cover layer 160c) forms the third space of the internal space 118 (e.g., the third internal space 118c), and the fourth layer of the base 114 and cover layer 160 (e.g., the fourth cover layer 160d) forms the fourth space of the internal space 118 (e.g., the fourth internal space 118d). In the illustrated example, the second space within the internal space 118 is larger than the first space within the internal space 118, and the third space within the internal space 118 is larger than the second space within the internal space 118.

[0038] As shown in Figures 1 and 5-8, in one or more examples, each cover layer 160 includes or is formed by at least two of the cover sections 150 (for example, at least two of the container walls 140). In one or more examples, the cover sections 150 of each cover layer 160 are coupled to one another by one of the pressure-operated couplings 120, and when each of the multiple internal pressures 256 reaches one of the multiple operating pressures 258, the cover sections 150 of each cover layer 160 are sequentially released from one another.

[0039] In one or more examples, as shown in Figure 6, the cover sections 150 of a first layer of the cover layer 160 (e.g., first cover layer 160a) are coupled to each other by a first coupling of a pressure-operated coupling 120 (e.g., first pressure-operated coupling 120a), which is configured to be released in response to a first operating pressure of the operating pressure 258, thereby opening a second internal space 118b. The cover sections 150 of a second layer of the cover layer 160 (e.g., second cover layer 160b) are coupled to each other by a second coupling of a pressure-operated coupling 120 (e.g., second pressure-operated coupling 120b), which is configured to be released in response to a second operating pressure of the operating pressure 258, thereby opening a third internal space 118c. The cover sections 150 of the third layer of the cover layer 160 (e.g., the third cover layer 160c) are coupled to each other by the third coupling of the pressure-operated coupling 120 (e.g., the third pressure-operated coupling 120c), which is configured to be released in response to the third operating pressure of the operating pressure 258, thereby opening the fourth internal space 118d. The cover sections 150 of the fourth layer of the cover layer 160 (e.g., the fourth cover layer 160d) are coupled to each other by the fourth coupling of the pressure-operated coupling 120 (e.g., the fourth pressure-operated coupling 120d), which is configured to be released in response to the fourth operating pressure of the operating pressure 258, thereby opening the restraint container 110 and releasing the internal pressure 250 within the restraint container 110.

[0040] In one or more examples, at least one of the operating pressures 258 (e.g., each) is different from at least one other operating pressure. For example, a second operating pressure 258 is greater than a first operating pressure 258, and a third operating pressure 258 is greater than a second operating pressure 258. In such examples, the system 100 is configured to sequentially or continuously release pressure throughout the processing steps, sequentially providing larger internal space 118 to the constrained container 110. These examples have the advantage that the system 100 can control the processing pressure by entirely mechanical means without relying on complex and expensive sensors and / or programmable (e.g., feedback) controllers.

[0041] As shown in Figure 6, in one or more examples, a first coupling of the pressure-operated coupling 120 (e.g., a first pressure-operated coupling 120a) connects two of the cover sections 150 of a first layer of the cover layer 160 (e.g., a first cover layer 160a) (e.g., a first cover section 150a and a second cover section 150b), and is configured to release the two cover sections 150 when a first internal pressure 256 in a first space of the internal space 118 (e.g., a first internal space 118a formed by the base 114 and the first cover layer 160a) reaches a first operating pressure 258. Similarly, a second pressure-operated coupling of the 120 (e.g., a second pressure-operated coupling 120b) connects two of the cover sections 150 of the second layer of the cover layer 160 (e.g., a second cover layer 160b) (e.g., a first cover section 150a and a second cover section 150b), and is configured to release the two cover sections 150 when a second internal pressure of the internal pressure 256 in the first space (e.g., the second internal space 118b formed by the base 114 and the second cover layer 160b) reaches a second operating pressure of the operating pressure 258. This process is repeatable for each cover layer 160.

[0042] In these examples, the first operating pressure of the operating pressure 258 is different from the second operating pressure of the operating pressure 258. In one or more examples, the second operating pressure of the operating pressure 258 is greater than the first operating pressure of the operating pressure 258, thereby allowing a controllable increase in the pressure applied to the workpiece 200 during processing. In one or more examples, the second operating pressure of the operating pressure 258 is less than the first operating pressure of the operating pressure 258, thereby allowing a controllable decrease in the pressure applied to the workpiece 200 during processing.

[0043] The system 100 may include any number of feasible cover layers 160. Furthermore, each cover layer 160 may include any number of feasible cover sections 150 coupled to each other and / or to the base 114. In addition, each cover layer 160 may include one or more pressure-operated couplings 120 configured to be released (e.g., broken or fractured) in response to the associated operating pressure 258. Thus, the system 100 can control the processing pressure (e.g., positive pressure 254) applied to the workpiece 200 throughout the processing steps without requiring complex controllers or other processing devices.

[0044] As shown in Figures 3-13, in one or more examples, at least a portion of the restraint container 110 (e.g., the cover 116 and / or the base 114) is rigid. In one or more examples, at least a portion of the restraint container 110 (e.g., the cover 116 and / or the base 114) is flexible. In one or more examples, at least a portion of the restraint container 110 (e.g., the cover 116 and / or the base 114) is flexible and non-expandable. In one or more examples, at least a portion of the restraint container 110 (e.g., the cover 116 and / or the base 114) is flexible and expandable. In one or more examples, at least a portion of the restraint container 110 is substantially resistant to expansion when pressure is applied to the inner surface of the restraint container 110 by at least an expandable medium 130. In this way, the pressure applied to the outer surface of the workpiece 200 acts in cooperation with the restraint container 110 to generate a compressive force (e.g., positive pressure 254) on the workpiece 200 for processing.

[0045] As shown in Figures 3-6, 8, 9, 11, and 13, in one or more examples, at least a portion of the cover 116, such as at least one cover section 150, is rigid. In this specification, “rigid” means substantially rigid, hard, non-flexible and non-expandable, and resistant to bending and deformation. In these examples, at least a portion of the base 114 and / or cover 116 (e.g., at least some of the container walls 140) is formed from any suitable material, including, but not limited to, metallic materials, composite materials, cement materials, ceramic materials, polymer materials, etc. In these examples, the constrained container 110 constrains the expandable medium 130 and reacts to the positive pressure 254 generated by the expandable medium 130 during expansion. In these examples, the constrained container 110 can withstand the pressure generated in the internal space 112 when the expandable medium 130 expands.

[0046] As shown in Figures 7, 8, 10A, and 12, in one or more examples, at least a portion of the cover 116, such as at least one cover section 150, is flexible. In this specification, "flexible" means being able to bend or deform without causing breakage or permanent deformation. In these examples, the flexible portion of the restraint container 110 may be inflatable or inflatable. By making at least a portion of at least one of the base 114 and / or cover 116 (e.g., at least some of the container walls 140) flexible, the restraint container 110 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 inflatable medium 130 before it expands, and can easily conform to the shape of at least a portion of the workpiece 200. As a result, the internal space 112 of the restraint container 110 is reduced, and consequently, the amount of inflatable medium 130 required can be reduced, thereby increasing the portability of the system 100. By making at least a portion of the restraint container 110 flexible and non-expandable, conformability to the shape can be improved, and the internal processing pressure can be controlled more precisely. By making at least a portion of the restraint container 110 flexible and expandable, conformability to the shape can be improved, and a certain degree of tolerance to the internal processing pressure can be provided. In one or more examples, at least a portion of the restraint container 110 can be formed from any suitable flexible and non-expandable material, which includes, but is not limited to, metal mesh (e.g., chainmail), ceramic mesh, polymer mesh, etc. In one or more examples, at least a portion of the restraint container 110 can be formed from any suitable flexible and expandable material, which includes, but is not limited to, natural rubber or synthetic rubber, silicone, etc.

[0047] As shown in Figures 7 and 8, in one or more examples, either the cover layer 160 or the cover section 150 is flexible and can have any suitable shape before the expansion of the expandable medium 130. For example, the cover layer 160 or the cover section 150 can conform to the shape of the workpiece 200 and / or the unexpanded (i.e., unexpanded) expandable medium 130 in the internal space 112. Note that the shapes of the flexible cover layer 160 shown in Figures 7 and 8 are merely illustrative.

[0048] As shown in Figure 1, in one or more examples, the pressure-operated coupling 122 includes a shear coupling 126. In these examples, the shear coupling 126 includes any suitable mechanical device used to connect multiple parts of the restraining container 110 (e.g., cover 116 and base 114, multiple cover sections 150, or multiple container walls 140), the mechanical device which transmits force between the connected elements and provides protection from excessive force by allowing limited relative motion or breakage under certain conditions. In these examples, the shear coupling 126 includes a shear element (e.g., a pin or disk) designed to break or "shear" when the internal pressure 250 exceeds a predetermined limit (e.g., operating pressure 252). In one or more examples, the shear coupling 126 functions as a safety mechanism to prevent damage to the system 100 and / or workpiece 200 by disconnecting the connection in the event of overload. In one or more examples, the shear coupling 126 functions as a pressure control mechanism that releases pressure by disconnecting the connection at a predetermined point during processing. In one or more examples, the shear coupling 126 includes or takes the form of a shear pin.

[0049] As shown in Figure 1, in one or more examples, the pressure-operated coupling 122 includes a linear tension coupling 128. In these examples, the linear tension coupling 128 includes any suitable mechanical device used to connect a portion of the restraining container 110 (e.g., cover 116 and base 114, multiple cover sections 150, or multiple container walls 140), the mechanical device which transmits force between the connected elements and provides protection from excessive force by allowing breakage under certain conditions. In these examples, the linear tension coupling 128 includes an elongated coupling element designed to break when the internal pressure 250 exceeds a predetermined limit (e.g., operating pressure 252). In one or more examples, the linear tension coupling 128 functions as a safety mechanism to prevent damage to the system 100 and / or workpiece 200 by disconnecting the connection in the event of overload. In one or more examples, the linear tension coupling 128 functions as a pressure control mechanism to release pressure by disconnecting the connection at a predetermined point during processing. In one or more examples, the linear tension coupling 128 includes, or can take the form of, a line of weakening in the restraint container 110, a zipper coupling (e.g., having engaging teeth that interlock to transmit force), a snap coupling (e.g., a spring clip or latch that snaps into place when connected, or a grooved or raised surface that engages for secure attachment), a hook-and-loop fastener-like couple, and the like.

[0050] As shown in Figures 1, 10A, and 10B, in one or more examples, the system 100 includes a tensioner 190. The tensioner 190 is configured to selectively apply tension between two sections in the restraining container 110, for example, between two cover sections 150, between two container walls 140, or between the cover 116 and the base 114, thereby enabling control of the internal pressure 250 or providing some tolerance (e.g., expansion) before the pressure-actuated coupling 122 ruptures.

[0051] As shown in Figure 10A, in one or more examples, the tensioner 190 is incorporated into the cover 116 of the restraint container 110. In these examples, the tensioner 190 is coupled at a first end to one cover section 150 (e.g., first cover section 150a) and at a second end on the opposite side to another cover section 150 (e.g., second cover section 150b). The tensioner 190 may be various types of mechanical devices configured to apply, maintain, and / or adjust tension between multiple cover sections 150 of the cover 116, or between the cover 116 and the base 114. In one or more examples, the tensioner 190 is adjustable.

[0052] As shown in Figure 10B, in various examples, the tensioner 190 includes or takes the form of a spring tensioner. However, other tensioning mechanisms can also be used. In one or more examples, the tensioner 190 includes at least one spring 192. In one or more examples, the tensioner 190 includes a guide plate 194, and at least one of the springs 192 is coupled to the guide plate 194 by a bracket 196. In these examples, each spring 192 is also coupled to one of the cover sections 150. In one or more examples, the load on the spring 192 can be adjusted or changed using a bolt fastener having a threaded shank coupled to the bracket 196, and the load or tension of the spring can be increased or decreased by opening and closing the bracket 196 by rotating the bolt. In one or more examples, the tensioner 190 is configured to allow expansion and contraction due to the relative movement of the cover 116 when the expandable material 130 expands. As an example, the guide plate 194 has overlapping portions of material that allow for contraction and expansion.

[0053] As shown in Figure 10B, in one or more examples, the tensioner 190 is further configured to indicate an internal pressure 250. In these examples, the force (e.g., tension) applied to the tensioner 190 by the cover section 150 in response to the increase in internal pressure 250 due to the expansion of the expandable medium 130 is directly proportional to the displacement (e.g., extension or compression) of the spring 192. Thus, the displacement of the spring 192 is used to measure the force acting on the cover section 150 when the expandable medium 130 expands. In one or more examples, the tensioner 190 is positioned on a guide plate 194 and includes a scale 198 that visually indicates the internal pressure 250.

[0054] As shown in Figure 10A, in one or more examples, the tensioner 190 is coupled to at least one of the cover sections 150 by at least one of the pressure-operated couplings 120. In these examples, the pressure-operated coupling 120 is configured to be released (e.g., broken or fractured) when the internal pressure 250 reaches the operating pressure 252.

[0055] As shown in Figures 1 and 9, in one or more examples, the system 100 includes pressure plugs 172. In one or more examples, the system 100 includes any number of pressure plugs 172 (for example, Figure 9 shows four pressure plugs 172). The pressure plugs 172 are coupled to a confinement container 110, and a portion of the pressure plugs 172 is located within the internal space 112. The pressure plugs 172 are movable relative to the confinement container 110 to change the volume of the internal space 112. By selectively changing or altering the volume of the internal space 112 using the pressure plugs 172, it is possible to selectively or responsively change and control the internal pressure 250 within the confinement container 110 (for example, acting on the workpiece 200 within the internal space 112).

[0056] In one or more examples, at least one pressure plug 172 is coupled to one of the cover sections 150. The pressure plug 172 is movable relative to the cover section 150 and can move in and out of the internal space 112. Therefore, inserting the pressure plug 172 into the internal space 112 reduces the open space that can be filled by the expansion of the expandable medium 130, thereby increasing the internal pressure 250 and, consequently, the positive pressure 254 applied to the workpiece 200. Conversely, withdrawing the pressure plug 172 from the internal space 112 increases the open space that can be filled by the expansion of the expandable medium 130, thereby decreasing the internal pressure 250 and, consequently, the positive pressure 254 applied to the workpiece 200. Therefore, the positive pressure 254 applied to the workpiece 200 during processing can be adjusted by inserting or withdrawing the pressure plug 172.

[0057] As shown in Figure 9, in one or more examples, each of the pressure plugs 172 is coupled to a different cover section 150, allowing control of the internal space 112 and the positive pressure 254 in each portion at a specific or targeted location. In the illustrated example, the pressure plugs 172 are positioned on the sides and top of the workpiece 200, allowing the positive pressure 254 applied to these areas of the workpiece 200 to be increased or decreased as needed during processing. As an example, the pressure plugs 172 are positioned near (e.g., at or close to) a predetermined location or area of ​​the workpiece 200, such as a cavity or contour between several different parts of the workpiece 200, thereby applying increased pressure to the rounded portion of the contour during manufacturing (e.g., during curing, integration, and / or joining).

[0058] The pressure plug 172 can take any of several suitable forms. In one example, the pressure plug 172 is inserted into a threaded hole in the restraining container 110 and includes a threaded shaft that screws into the threaded hole. In another example, the pressure plug 172 takes the form of a plunger mechanism.

[0059] As shown in Figures 1, 9, 10A, 11, and 12, in one or more examples, the system 100 includes an inspection hatch 180. The inspection hatch 180 is configured to visually indicate when the internal pressure 250 has reached a desired or predetermined processing pressure 260 that is lower than the operating pressure 252. In one or more examples, the inspection hatch 180 includes a viewport 182 and a pressure-responsive shutter 184. The viewport 182 is formed in the restraint container 110. In one or more examples, the viewport 182 is formed in the cover 116, for example, in one of the cover sections 150 (e.g., Figures 9, 11, and 12). In one or more examples, the viewport 182 is formed in the guide plate 194 of the tensioner 190 (Figure 10A). The pressure-responsive shutter 184 is configured to cover the viewport 182 when the internal pressure 250 in the internal space 112 of the restraint container 110 reaches the processing pressure 260. Therefore, when the internal pressure 250 reaches the processing pressure 260, the pressure-response shutter 184 covers the viewport 182, thereby visually indicating that the processing pressure 260 has been achieved.

[0060] As shown in Figures 1, 9, 10A, 11, and 12, in one or more examples, the pressure-responsive shutter 184 includes a panel 186 and a pressure-release fastener 188. The panel 186 is coupled to a constrained container 110. As an example, the panel 186 is coupled to a cover 116, for example, one of the cover sections 150 or a guide plate 194 of a tensioner 190. The panel 186 can move relative to the constrained container 110 (e.g., by pivoting or hinged movement) to cover the viewport 182. The pressure-release fastener 188 is configured to hold or bias the panel 186 away from the viewport 182. The pressure-release fastener 188 is also configured to release the panel 186 when the internal pressure 250 in the internal space 112 of the constrained container 110 reaches a processing pressure 260. For example, when the expandable medium 130 expands, it applies a positive pressure 254 to the panel 186. When the positive pressure 254 reaches a processing pressure 260, the pressure release fastener 188 is released (e.g., unfastened or broken), which allows the panel 186 to move (e.g., oscillate or pivot) to a position that covers the viewport 182.

[0061] In one or more examples, the movable parts of the pressure-responsive shutter 184 are shielded from the expandable medium 130 so as not to interfere with or obstruct the movement of the parts relative to the viewport 182. In one or more examples, the inspection hatch 180 includes rails for the panel 186 to slide relative to the viewport 182 when the panel 186 is released by the pressure-release fastener 188.

[0062] As shown in Figures 1, 11 and 12, in one or more examples, the expandable medium 130 includes a first expandable material 132 and a second expandable material 136. In one or more examples, the first expandable material 132 is configured to expand to a first expansion volume 134, and the second expandable material 136 is configured to expand to a second expansion volume 138. In these examples, the first expansion volume 134 and the second expansion volume 138 are different. In one or more examples, the first expandable material 132 is configured to expand in response to a first condition, and the second expandable material 136 is configured to expand in response to a second condition. Therefore, it is possible to apply a first magnitude positive pressure 254 or a first example processing pressure 260 using the expansion of the first expandable material 132, and then to apply a second magnitude positive pressure 254 or a second example processing pressure 260 using the expansion of the first expansion volume 134.

[0063] As shown in Figure 13, in one or more examples, the combination of pressure-operated couplings 122 and fasteners 142 between each of the cover sections 150 and the base 114 (for example, between multiple different container walls 140) allows the constrained container 110 to be configured in any of the various sizes and / or shapes to accommodate various types of workpieces 200.

[0064] As shown in Figure 1, in one or more examples, the system 100 includes a wrapping element 144. The wrapping element 144 is configured to wrap at least a portion (e.g., a certain amount) of the expandable medium 130. The wrapping element 144 is positioned in the internal space 112 between the restraining container 110 and at least a portion of the workpiece 200. In one or more examples, at least a portion of the expandable medium 130 is placed inside the wrapping element 144. In one or more examples, expandable pellets are placed or contained inside the wrapping element 144. In one or more examples, the wrapping element 144 wraps the expandable medium 130 (e.g., expandable pellets), thereby facilitating the handling of the expandable medium 130 as well as facilitating its removal after processing is complete. The wrapping element 144 can take any suitable form, such as a sealing film, a sealing material layer, a bag, or a pouch. In one or more examples, the wrapping element 144 is non-expandable. In one or more examples, the wrapping element 144 is expandable. In one or more examples, the wrapping element 144 is made of a nylon or polyester fabric (e.g., fire hose material).

[0065] As shown in Figure 1, in one or more examples, the system 100 includes an activating element 124. The activating element 124 is configured to initiate at least one of the expansion and / or contraction of the expandable medium 130 in the internal space 112. The type or composition of the activating element 124, or the mechanism used by the activating element 124, may vary depending on the type or composition of the expandable medium 130. In one or more examples, the activating element 124 is a chemical substance, water, a heater, etc.

[0066] As shown in Figure 1, in one or more examples, the system 100 includes at least one volumetric element 174. The volumetric element 174 is configured to expand and / or contract in an internal space 112, and can selectively control or change the volume of the internal space 112 in the constrained container 110, or selectively increase and / or decrease the positive pressure 254 (e.g., processing pressure 260) in the constrained container. The volumetric element 174 may have any feasible cross-sectional shape, such as circular, elliptical, or polygonal. The volumetric element 174 is extendable along at least one axis. In one or more examples, the volumetric element 174 is an intermediate layer located in the internal space 112. In one or more examples, the volumetric element 174 includes or takes the form of a bag-like body or other expandable element. In one or more examples, the volume-variable element 174 is filled with a fluid (e.g., gas or liquid) and is configured to equalize the positive pressure 254 applied to the workpiece 200, thereby ensuring a more uniform application of the positive pressure 254. The volume-variable element 174 may be selected to be heat-resistant and easily removable after the workpiece 200 has been manufactured. In one or more examples, the volume-variable element 174 is an expandable element or other volume-changing component in the system 100 and is configured to selectively expand and / or contract in order to selectively increase or decrease the volume of the internal space 112 that can be filled by the expandable medium 130 when the expandable medium 130 expands. In one or more examples, the volume-variable element 174 includes or takes the form of a sealed bag or balloon having some type of expandable material (e.g., expandable medium 130). In one or more examples, the volume-variable element 174 may be filled with a chemical substance (e.g., baking soda powder). When this chemical is heated to generate a gas, the volume-variable element 174 expands, reducing the fillable volume (internal space 112) of the confinement container 110 and / or adding an additional positive pressure 254 in the confinement space. In other examples, the volume-variable element 174 is one example of various types of expandable media 130 (e.g., a wrapping element 144).In one or more examples, the volume-variable element 174 takes the form of a pressure-increasing material or functions as one and is placed in the internal space 112 together with the expandable medium 130 and the workpiece 200. In one or more examples, the volume-variable element 174 is another type or example of the expandable medium 130, or a different type of expandable material. In one or more examples, the volume-variable element 174 is selectively expandable to increase or amplify the pressure applied to one or more locations on the workpiece 200. For example, the volume-variable element 174 is placed near a predetermined location or area of ​​the workpiece 200, such as a cavity or contour between several different parts of the workpiece 200, thereby applying increased pressure to the curved portion of the contour during manufacturing (e.g., during curing, integration, and / or joining).

[0067] As shown in Figure 1, in one or more examples, the system 100 includes at least one volume-constant element 176. The volume-constant element 176 is configured to maintain a constant size and volume so as to fill a portion of the internal space 112. The volume-constant element 176 may have any feasible cross-sectional shape, such as circular, elliptical, or polygonal. The volume-constant element 176 is extendable along at least one axis.

[0068] In one or more examples, the system 100 includes one or more other processing components, such as a coal plate or bagging material, which are placed in the internal space 112 between the expandable medium 130 and at least a portion of the workpiece 200. In one or more examples, the coal plate contributes to the integration and improvement of the surface condition of the workpiece 200. In one or more examples, the bagging material includes or takes the form of a vacuum bagging material, a vacuum laminate bagging material, or other sheet material, which uses atmospheric pressure during the manufacturing process to fix and hold components of the workpiece 200 in place below the bagging material.

[0069] As shown in Figure 1, in one or more examples, the system 100 includes a heater 162. The heater 162 is thermally coupled to the expandable medium 130. In one or more examples, the heater 162 is configured to heat the expandable medium 130 to an activation temperature, at which point the expandable medium 130 expands in the internal space 112, applying a positive pressure 254 to the workpiece 200. In one or more examples, the heater 162 is configured to heat the workpiece 200 to a desired processing temperature (e.g., curing, integration, or bonding). In one or more examples, the heater 162 is an internal heater and is configured to be located within the internal space 112 together with the expandable medium 130. In one or more examples, the heater 162 is an external heater and is configured to be located outside the restraint container 110. In one or more examples, the heater 162 is incorporated into the restraint container 110 and / or the expandable medium 130 using, for example, a smart susceptor heating element. The heater 162 may take any suitable form or include any suitable heating device. In various examples in which the expandable medium 130 is activated by heat and expands, the restraining container 110 may be heated externally. Alternatively, or in addition to this, the system 100 may include one or more exothermic substances configured to heat the expandable medium 130 to a predetermined temperature in which the expandable medium 130 expands.

[0070] In one or more examples, at least a portion of the restraint container 110 is heat-reflective. In one or more examples, at least one of the container walls 140 forming the cover 116 (e.g., cover section 150) and / or base 114 is heat-reflective. In one or more examples, at least a portion of the inner surface of the restraint container 110 contains or is coated with a heat-reflective material. The heat reflectivity improves the heating efficiency of the expandable medium 130 and promotes the expansion of the expandable medium 130 in the manufacturing process.

[0071] As shown in Figures 1 and 3-11, in one or more examples, the system 100 includes various combinations of elements, including one or more of the following: a restraining container 110, a pressure-actuated coupling 122, a pressure plug 172, a tensioner 190, a viewport 182, a pressure-responsive shutter 184, and an expandable medium 130. The restraining container 110 is configured to enclose at least a portion of the workpiece 200 to be processed and includes a plurality of container walls 140 that form an internal space 112. The pressure-actuated coupling 122 is configured to fix two of the container walls 140 together and is configured to release the two container walls 140 when the internal pressure 250 of the internal space 112 reaches an operating pressure 252. The pressure plug 172 is coupled to one of the container walls 140 and is movable relative to that container wall 140, and a portion of the pressure plug 172 is positioned in the internal space 112, thereby changing the volume of the internal space 112. The tensioner 190 is configured to selectively apply tension between two container walls 140 to control the internal pressure 250. A viewport 182 is formed in one of the multiple container walls 140. A pressure-responsive shutter 184 is configured to cover the viewport 182 when the internal pressure 250 in the internal space 112 of the constrained container 110 reaches a processing pressure 260. An expandable medium 130 is positioned in the internal space 112 between at least a portion of the container walls 140 and at least a portion of the workpiece 200 and is configured to expand, thereby applying a positive pressure 254 to the container walls 140 and the workpiece 200.

[0072] Referring now to Figure 2, as an example, the disclosure also relates to a method 1000 for processing workpiece 200, which is also referred to herein as a processing method. The following are examples of method 1000 according to the disclosure. In one or more examples, method 1000 is carried out using system 100 (Figures 1 and 3-13). Examples of method 1000 include 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.

[0073] In one or more examples, method 1000 includes step 1002 of surrounding the workpiece 200. At least a portion of the workpiece 200 is placed in the internal space 112 and housed in the restraint container 110.

[0074] In one or more examples, method 1000 includes step 1004 of introducing an expandable medium 130. The expandable medium 130 is introduced (e.g., placed) in the internal space 112 between at least a portion of the constraining container 110 and at least a portion of the workpiece 200.

[0075] In one or more examples, method 1000 includes a step 1006 of closing the restraint container 110. The restraint container 110 is secured in the closed position using a pressure-operated coupling 122 (e.g., one or more of the pressure-operated couplings 120). In one or more examples, the restraint container 110 is also secured in the closed position by one or more of the fasteners 142. In one or more examples, the closing step 1006 includes a step of assembling the restraint container 110 using the container wall 140 to form, for example, a base 114 and a cover 116 (e.g., a cover section 150). In these examples, the restraint container 110 is assembled using any combination of pressure-operated couplings 122 and fasteners 142.

[0076] In one or more examples, Method 1000 includes step 1008 of inflating an expandable medium 130. The expandable medium 130 expands to increase the internal pressure 250 of the restraining container 110 and to process the workpiece 200 by applying a positive pressure 254 to it. Thus, Method 1000 includes step 1010 of applying a positive pressure 254 to at least a portion of the workpiece 200 and step 1012 of processing the workpiece 200 in response to the application of the positive pressure 254.

[0077] In one or more examples, method 1000 includes a step 1014 for automatically releasing the restraint container 110. The restraint container 110 is automatically released using a pressure-operated coupling 122 when the internal pressure 250 of the restraint container 110 reaches an operating pressure 252. In one or more examples, the restraint container 110 is released by the pressure-operated coupling 122 at a predetermined point in time or pressure during processing. For example, the cover layer 160 is released sequentially as the pressure gradually increases during the processing step. In other examples, the restraint container 110 is released by the pressure-operated coupling 122 in response to overload pressure or as a safety protocol.

[0078] In one or more examples, method 1000 includes a step 1016 for controlling the internal pressure 250 of the restraint container 110. In one or more examples, the step 1016 for controlling the internal pressure 250 includes, or is achieved by, a step for controlling the internal space 112 of the restraint container 110. For example, the internal space 112 and / or internal pressure 250 can be controlled using one of a pressure plug 172, a tensioner 190, an expandable medium 130 of various materials or activation conditions, and / or a volume-variable element 174, or a combination thereof.

[0079] In one or more examples, method 1000 includes a step 1018 indicating the internal pressure 250 of the restraint container 110. In one or more examples, the step 1018 indicating the internal pressure 250 of the restraint container 110 includes, or is achieved by, a step indicating that the internal pressure 250 of the restraint container 110 has reached the processing pressure 260. For example, the internal pressure 250 of the restraint container 110 can be indicated using either the scale 198 of the tensioner 190 and / or the inspection hatch 180, or a combination thereof.

[0080] In examples of System 100 and Method 1000, expandable materials are used for structural joining and debulking, such as curing, integration, and / or secondary joining of composite materials, with or without adhesives, and include, for example, joining of composite materials under pressure (e.g., co-joining), in which at least one component of the joined structure is pre-cured. Furthermore, in examples of System 100 and Method 1000, non-composite materials (e.g., metals, metal alloys, ceramics, polymers, hybrid materials, metal matrix composites (MMCs), ceramic matrix composites (CMCs), polymer matrix composites (PMCs), etc.) can be joined by using epoxy adhesives or any polymer adhesives (e.g., thermosetting resins or thermoplastic resins).

[0081] In one or more examples, processing step 1012 includes a step of curing or integrating the workpiece 200. In one or more examples, processing step 1012 includes a step of joining the workpiece 200. In one or more examples, the joining step includes or takes the form of co-curing of the workpiece 200. In one or more examples, the joining step includes or takes the form of co-joining of the workpiece 200. In one or more examples, the joining step includes or takes the form of secondary joining of the workpiece 200.

[0082] In one or more examples, System 100 and Method 1000 facilitate co-curing for integrally joining workpieces 200. In these examples, the material 210 of workpiece 200 includes an uncured composite material. In one or more examples, the uncured composite material is a thermosetting composite material. In one or more examples, the uncured composite material is a thermoplastic composite material. In one or more examples, co-curing is achieved without the use of an adhesive. As an example, workpiece 200 includes a first wet prepreg cloth ply (e.g., first material) and a second wet prepreg cloth ply (e.g., second material). In one or more examples, co-curing is achieved within an adhesive such as an adhesive film. As an example, the workpiece 200 includes a first wet prepreg cloth ply (e.g., a first material), a second wet prepreg cloth ply (e.g., a second material), and an adhesive (e.g., a third material) positioned or placed between the first wet prepreg cloth ply and the second wet prepreg cloth ply. In one or more co-curing examples, the uncured composite material (e.g., a thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 130 is configured to expand when the temperature of the expandable medium 130 rises to an activation temperature that is equal to or lower than the curing temperature of the thermosetting composite material. The expandable medium is configured to expand at the activation temperature such that the positive pressure 254 reaches or at least exceeds the curing pressure. In one or more co-curing examples, the uncured composite material (e.g., a thermoplastic composite material) has an integration temperature and an integration pressure. The expandable medium 130 is configured to expand when the temperature of the expandable medium 130 rises to an activation temperature that is equal to or lower than the integration temperature of the thermoplastic composite material. The expandable medium 130 is configured to expand at the activation temperature such that the positive pressure 254 is less than or equal to the curing pressure.

[0083] In one or more examples, System 100 and Method 1000 facilitate co-bonding for integrally joining workpieces 200. In these examples, at least one of the materials 210 of the workpiece 200 (e.g., first material) includes a cured composite material. At least another of the materials 210 of the workpiece 200 (e.g., second material) includes an uncured composite material. In one or more examples, the uncured composite material is a thermosetting composite material. In one or more examples, the uncured composite material is a thermoplastic composite material. In one or more examples, co-bonding is achieved with an adhesive such as an adhesive film. As an example, workpiece 200 includes a pre-cured laminate (e.g., first material), a wet prepreg crossply (e.g., second material), and an adhesive (e.g., third material) positioned or placed between the pre-cured laminate and the wet prepreg crossply. In one or more examples of co-bonding, the uncured composite material (e.g., thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 130 is configured to expand when its temperature rises to an activation temperature below the curing temperature. The expandable medium 130 is configured to expand at this activation temperature so that the positive pressure 254 is below the curing pressure. In one or more examples of co-bonding, the uncured composite material (e.g., thermoplastic composite material) has an integration temperature and an integration pressure. The expandable medium 130 is configured to expand when its temperature rises to an activation temperature below the integration temperature. The expandable medium is configured to expand at the activation temperature so that the positive pressure 254 is below the integration pressure.

[0084] In one or more examples, the system 100 and method 1000 facilitate secondary joining for integrally joining workpieces 200. In these examples, the material 210 of the workpiece 200 (e.g., first material and second material) includes any suitable material or combination of materials, such as, but not limited to, metallic materials, metallic alloy materials, ceramic materials, polymer materials, hybrid materials, metal matrix composites, ceramic matrix composites, polymer matrix composites, etc. In one or more examples, secondary joining is achieved with an adhesive, such as an adhesive film. As an example, the workpiece 200 includes a first pre-cured laminate or material layer (e.g., first material), a second pre-cured laminate or material layer (e.g., second material), and an adhesive (e.g., third material) positioned or placed between the first and second pre-cured laminates or material layers. In one or more examples, the adhesive is placed between the first material and the second material. In these examples, system 100 can use an adhesive to perform secondary bonding, co-bonding, or co-curing of the first and second materials with the adhesive. In one or more of the co-curing, co-bonding, and / or secondary bonding examples, the adhesive has at least one of a curing temperature and a curing pressure. The expandable medium 130 is configured to expand when the temperature of the expandable medium 130 rises to an activation temperature that is below the curing temperature. The expandable medium 130 is configured to expand at the activation temperature such that the positive pressure 254 is below the curing pressure. In one or more examples, the curing temperature and / or curing pressure of the uncured composite material and the adhesive are at least approximately the same. In one or more examples, the curing temperature and / or curing pressure of the uncured composite material and the adhesive are different.

[0085] In this disclosure, the terms “expandable,” “expanding,” “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 expands 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 130 is configured to expand when a predetermined change occurs in the expandable medium 130. The predetermined change is typically a change in the physical or chemical properties of the expandable medium 130 related to its expansion, or a combination thereof, and / or a change in other appropriate properties. Unless otherwise specified, expansion of the expandable medium 130 refers to an increase in the volume of the expandable medium 130, the surface area of ​​the expandable medium 130, and / or the spatial extent of the expandable medium 130 in one or more dimensions. For example, the expandable medium 130 may be configured to expand when its temperature rises from a low temperature, such as the ambient temperature, to a predetermined high temperature (e.g., an activation temperature). Therefore, if the manufacturing of the workpiece 200 involves raising the temperature of the workpiece 200, the expandable medium 130 expands in the internal space 112 during the manufacturing process. The expandable medium 130 (e.g., during or after expansion) applies pressure to the inside of the restraint container 110 and to the workpiece 200 during the joining process.

[0086] In this disclosure, the terms “shrinkable,” “shrinkable,” “shrinking,” and similar terms refer to the ability to shrink, or the possibility or ability to reduce size and / or volume. Shrinkable materials or individual elements can reduce size or volume symmetrically or asymmetrically. If a shrinkable material is symmetrically shrinkable, it shrinks substantially equally along each axis. If a shrinkable material exhibits asymmetric shrinkage, it can shrink more along the first axis, or along both the first and second axes, than along the other axes. In various examples, the expandable medium 130 is configured to shrink when a predetermined change occurs in the expandable medium 130. The predetermined change is typically a change in the physical or chemical properties of the expandable medium 130 related to the shrinkage of the expandable medium 130, or a combination thereof, and / or a change in other appropriate properties. Unless otherwise stated, contraction of the expandable medium 130 refers to a decrease in the volume of the expandable medium 130, the surface area of ​​the expandable medium 130, and / or the spatial extent of the expandable medium 130 in one or more dimensions. As an example, the expandable medium 130 may be configured to contract when its temperature decreases from a high temperature to a predetermined low temperature.

[0087] In one or more examples, the expandable medium 130 is selected such that, when the expandable medium 130 expands in the internal space 112, it applies sufficient pressure to effectively compress the material 210 of the workpiece 200 and perform proper curing or bonding. For some materials 210, bonding can be achieved sufficiently with a pressure of less than 1 atmosphere, while for other materials 210, bonding can be achieved more effectively with a pressure of 1 atmosphere or more. In one or more examples, the expandable medium 130 is selected such that it generates sufficient pressure to apply (e.g., 1 to 5 atmospheres) that would conventionally require an autoclave.

[0088] In one or more examples, the expandable medium 130 includes one or more different types, varieties, or compositions of expandable materials (e.g., expandable pellets of different types or compositions), such as a first expandable material 132 and a second expandable material 136. In these examples, each of the different types of expandable materials is configured to expand and / or contract (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 130 (e.g., different types of expandable pellets) 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. In one or more examples, the degree of expansion of a given type or composition of expandable medium 130 (e.g., expandable pellets) 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 and / or composition of the expandable medium 130 to be employed can be selected such that expansion and / or contraction within a known enclosed space (e.g., internal space 112) imparts a desired pressure to the workpiece 200 at one or more stages of the manufacturing process.

[0089] The expandable medium 130 can take any suitable form. In one or more examples, the expandable medium 130 is added to the restraint container 110 in the form of pellets, beads, granules, powder, or foam, for example. Alternatively, or in addition to the above, the expandable medium 130 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 130 that can be hung over a portion of the workpiece 200. The layers of the expandable medium 130 can be arranged by adding individual wrapping elements (e.g., bags or pouches) filled with pellets, beads, or small pieces of the expandable medium 130. In Figures 3 to 13, the expandable medium 130 is shown in the form of multiple expandable pellets, but this is a representative example and does not limit the structure or composition of the expandable medium 130. In various examples, the expandable medium 130 is added to the internal space 112 in an unexpanded state. As shown in the figure, before and / or during the manufacturing process, the expandable medium 130 expands (e.g., increases in volume) to at least partially fill the internal space 112, thereby applying positive pressure directly or indirectly to at least some surfaces of the constraining container 110 and at least some surfaces (e.g., the outer surface) of the workpiece 200. The pressure of the expanding expandable medium 130 promotes the compression and integration of parts of the workpiece 200 being processed. In various examples, the expandable medium 130 is configured to expand (e.g., to a predetermined volume and / or pressure) when a predetermined change occurs in the attributes 168 of the expandable medium 130 (e.g., in an unexpanded state). In one or more examples, the expandable medium 130 is applied (e.g., inserted or added) to the internal space 112 of the constraining container 110 in an unexpanded state. While the expandable medium 130 is placed in the internal space 112 (in an unexpanded state), a predetermined change occurs in the attributes 168 of the unexpanded expandable medium 130. The expandable medium 130 expands in accordance with the predetermined change that has occurred. The attributes 168 of the expandable medium 130 may be physical and / or chemical attributes. In one or more examples, the expandable medium 130 is configured to expand in volume when it interacts with water. For example, the expandable medium 130 is or contains a desiccant, which may increase in volume when it absorbs water.For example, when anhydrous calcium sulfate (anhydrous gypsum) absorbs water to produce gypsum, its volume increases by approximately 61%. In these examples, water can be added directly to the expandable medium 130, 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 within the confinement container 110, for example, by an appropriate chemical reaction. In one or more examples, a predetermined change in the attribute 168 of the expandable medium 130 includes a temperature change of the expandable medium 130 and / or a temperature change of one or more parts of the expandable medium 130. Therefore, causing a predetermined change in the attribute 168 of the expandable medium 130 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 increase. In one or more examples, the expandable medium 130 is a thermally activated expandable element. In these examples, the thermally activated expandable element is configured to expand when the temperature of the expandable medium 130 rises to at least a predetermined temperature. Alternatively, or in addition to this, the expandable medium 130 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. In one or more examples, the predetermined change in attribute 168 of the expandable medium 130 is represented by a combination of two or more properties of the expandable medium 130, such as a ratio or product of quantitative values ​​related to the properties of the expandable medium 130, or two materials with different coefficients of thermal expansion. In various examples, the manufacturing process of the workpiece 200 includes causing a predetermined change in attribute 168 of the expandable medium 130. In one or more examples, the expansion of the expandable medium 130 occurs automatically in the manufacturing process. For example, attribute 168 is the temperature of the expandable medium 130, and a predetermined change in the temperature of the expandable medium 130 occurs due to the heat applied during the manufacturing process.In other words, the heat applied to the workpiece 200 during the bonding process causes the temperature of the expandable medium 130 to rise to at least a predetermined temperature related to the desired volume and / or desired volume increase. One or more properties of the expandable medium 130 can be designed so that, due to the temperature change occurring in the expandable medium 130 during the manufacture of the workpiece 200, the expandable medium 130 expands to a predetermined desired amount as a result of thermal expansion. Alternatively, or in addition to this, expanding the expandable medium 130 may require additional steps beyond the steps required for curing the workpiece 200. For example, expanding the expandable medium 130 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 130. In various examples, the expandable medium 130 includes any material that is thermally expandable and capable of expanding when a predetermined temperature is reached. 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, thermoplastic materials can be reshaped, and more specifically, expanded. 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 130 containing acrylonitrile butadiene styrene (ABS) polymer may exhibit suitable physical properties when used in combination with the examples described herein. In one or more examples, the expandable medium 130 (e.g., expandable pellets) may further contain a foaming 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 130, thereby increasing the volume of the expandable medium 130. For example, a suitable blowing agent may be an inert gas that permeates the expandable medium 130 under pressure. Such a blowing agent can be configured to expand in multiple locations within the expandable medium 130 when its temperature rises from the ambient temperature or initial temperature to a predetermined higher temperature, and the expanded gas forms pores, cavities, or voids within the pellet. When using a blowing agent, it can be applied to the expandable medium 130 before heating. In an example where the expandable medium 130 contains a blowing agent, the blowing agent may be any suitable substance capable of achieving 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 the above, the blowing agent may include a chemical blowing agent selected to react with one or more components of the expandable medium 130. 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. In examples where the expandable medium 130 includes a blowing agent, the blowing agent may include a foaming agent. In these examples, the blowing 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). In the manufacturing process of the workpiece 200, the expandable medium 130 is expanded from an unexpanded state to an expanded state. In one or more examples, the expandable medium 130 is configured to expand in response to heat applied during curing or bonding. The expandable medium 130 expands to fill the internal space 112 of the restraining container 110, and the expanded expandable medium 130 applies positive pressure to the workpiece 200.In one or more examples, the expandable medium 130 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 130 to fill small gaps that may naturally occur, for example, between multiple pellets, between pellets and the inner surface of the restraint container 110, and / or between pellets and the workpiece 200. By filling these gaps, the expandable medium 130 can substantially smooth the surface of the workpiece 200. In various examples, after a portion of the workpiece 200 has been manufactured, the restraint container 110 can be opened or released as needed to remove the expandable medium 130. While the expandable medium 130 is usually easily removed after the workpiece 200 has been manufactured, in some cases, it tends to remain expanded and densely packed after processing and cooling of the workpiece 200, hindering removal. In such cases, the expandable medium 130 may be provided with one or more additional configurations to facilitate separation from the workpiece 200 and the restraining container 110. For example, the expandable medium 130 may be configured to change shape and / or size as needed, thereby making it easier to remove. For example, the expandable medium 130 may be configured to shrink when cooled, thereby shrinking in the internal space 112 after processing and cooling of the workpiece 200, making it easier to remove. In one or more examples, the expandable medium 130 is modified to minimize sintering (self-adhesion) during heating and expansion. Alternatively, or in addition to this, the expandable medium 130 may be configured to minimize the possibility of adhesion to surfaces by coating the expandable pellets with a suitable agent configured to prevent adhesion and / or promote separation. In one or more examples, suitable agents to be added to the expandable medium 130 include lubricants. For example, adding a lubricant to the expandable pellets can reduce adhesion between the expandable pellets before and / or after volume expansion.A suitable lubricant does not interfere with the curing and / or bonding of the workpiece 200 and prevents the expandable pellets from substantially adhering to each other or to the restraining container 110 or to the components of the workpiece 200. 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 the above, a suitable lubricant may include silicon-based materials, fluorinated polymers, or other substantially inert substances. For example, suitable lubricants include polytetrafluoroethylene (PTFE) powder, PTFE nanopowder, silicone, and perfluoropolyether (PFPE). The lubricant may include perfluoroalkyl ethers (PFAEs), perfluoropolyalkyl ethers (PFPAEs), and / or similar substances. Such lubricants may be applied to the expandable pellets before they are placed in the restraint container 110. Alternatively, or in addition to this, a suitable lubricant may be applied to the expandable pellets while they are in the restraint container 110. Coating at least a portion of the expandable pellets 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 group of expandable pellets may be coated with the desired lubricant, and then these pellets may be mixed with a group of uncoated pellets. In one or more examples, crystalline and / or semi-crystalline properties along the outer surface of the expandable pellets may help prevent the pellets from sintering together. In one or more examples, at least a portion of the expandable pellets are configured to have a crystalline region along the outer surface of the pellets by pretreatment or the like, and the addition of the expandable medium 130 includes adding a plurality of expandable pellets having highly crystalline surface regions in order to reduce adhesion between pellets before and / or after the volume expansion of the expandable pellets. In one or more examples, expandable pellets can be those that exhibit high crystallinity on the outer surface of the pellets (for example, those in which the proportion of volume having a crystalline structure is high in the region near the outer surface of each pellet). Crystallinity of expandable pellets can be achieved by adjusting one or more elements, 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 blowing agent in the pellets, and the composition and / or concentration of the blowing agent. The outer surface of the expandable pellets may be crystalline before foaming, during foaming, and / or after foaming.

[0090] In one or more examples, the system 100 includes additional elements configured to change or adjust the pressure applied by the expandable medium 130, such elements including, but not limited to, one or more volume-constant elements 176 (e.g., substantially incompressible elements) and / or one or more volume-variable elements 174 (e.g., expandable and contractible elements) that can increase in volume before or during manufacturing, or decrease in volume after manufacturing.

[0091] Next, referring to Figures 14 and 15, embodiments of the system 100 and method 1000 described herein relate to, or can be used in connection with, the aircraft 1200 schematically shown in Figure 14 and the manufacturing and maintenance method 1100 in the aerospace field shown in the flowchart of Figure 15. For example, the aircraft 1200 and / or the manufacturing and maintenance method 1100 may include, or utilize, components, parts, or workpieces manufactured or restored using the system 100 and / or according to the method 1000.

[0092] Referring to Figure 14, which shows an example of an aircraft 1200, the aircraft 1200 can be any aerospace vehicle or platform. In one or more examples, the aircraft 1200 includes a fuselage 1202 having an interior 1206. The aircraft 1200 includes several onboard systems 1204 (e.g., high-level systems). Examples of the 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 also include one or more other systems 1216, examples of which include, 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 the like. The aircraft 1200 may include any number of components or parts manufactured or restored using system 100 and / or in accordance with method 1000.

[0093] Referring to Figure 15, prior to the start of production of aircraft 1200, the manufacturing and maintenance method 1100 includes the specification and design of aircraft 1200 1102 and material procurement 1104. During the manufacturing of aircraft 1200, the manufacturing of aircraft 1200's parts and subassemblies 1106 and system integration 1108 are carried out. Subsequently, aircraft 1200 undergoes certification and delivery 1110 and enters service 1112. Periodic maintenance and upkeep 1114 includes improvements, reconfigurations, and modifications of one or more systems of aircraft 1200.

[0094] Each step of the manufacturing and maintenance method 1100 shown in Figure 15 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.

[0095] Examples of systems 100 and methods 1000 illustrated and described herein can be employed at any one or more stages of the manufacturing and maintenance methods 1100 shown in the flowchart of Figure 15. In one example, components of aircraft 1200 may be manufactured using system 100 and / or according to method 1000 as part of the manufacturing of parts and subassemblies 1106 and / or system integration 1108. Furthermore, components of aircraft 1200 may be manufactured using system 100 and / or according to method 1000 during the commissioning of aircraft 1200 1112. Also, components of aircraft 1200 may be manufactured using system 100 and / or according to method 1000 in system integration 1108 and certification and delivery 1110. Similarly, components of aircraft 1200 may be manufactured using system 100 and / or according to method 1000 during the commissioning of aircraft 1200 1112 and in maintenance and servicing 1114.

[0096] The detailed descriptions above refer to the accompanying drawings illustrating specific embodiments described herein. Other embodiments having different structures and operations do not deviate from the scope of this disclosure. The same reference numerals may refer to the same feature, element, or component in different drawings. Throughout this disclosure, any one of several elements may be referred to individually as an element, or several elements may be referred to collectively as an element and indicated by the same reference numeral. Furthermore, in this specification, a feature, element, component, or step described in the singular form does not preclude multiple features, elements, components, or steps unless otherwise specified.

[0097] The above provides illustrative and non-limiting 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 features, structures, elements, components, properties, 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 may not, refer to the same example. Furthermore, the gist characterizing one example may, but may not, include the gist characterizing any other example. Furthermore, the gist characterizing one example may, but may not, be combined with the gist characterizing any other example.

[0098] 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.

[0099] 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.

[0100] In this specification, when the expression “at least one” is used in reference 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 element A, or elements A and B, but is not limited to this. In this example, it may also include elements A, B, and C, or elements B and 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, but is not limited to this. In this specification, the terms “and / or” and the symbol “ / ” include any and all combinations of one or more of the elements enumerated in connection therewith.

[0101] In this disclosure, “joined,” “joined,” and similar terms refer to two or more elements being joined, connected, fixed, attached, connected, communicated, or otherwise related to each other (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various examples, multiple elements may be related directly or indirectly. For example, element A may be directly related to element B, or element A may be indirectly related to element B through another element C. Not all possible relationships between the various elements disclosed are necessarily shown. Therefore, other types of connections may exist that are not illustrated.

[0102] 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.

[0103] Figures 1 and 3-14, referenced in the above description, represent functional elements, features, or components and do not necessarily imply 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 and 3-14 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 and 3-14 can be combined in various ways without including other features shown and described in Figures 1 and 3-14 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 and 3-14 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 structures. Furthermore, in Figures 1 and 3-14, 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 and 3-14. Similarly, not all elements, features, and / or components in Figures 1 and 3-14 are given reference numerals, but the reference numerals associated with these elements may be used in the description for consistency.

[0104] In Figures 2 and 15 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 15, 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.

[0105] 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.

[0106] 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 and Method 1000 have been illustrated and described, those skilled in the art will be able to make various modifications by reading this specification. This application includes such modifications and is limited only by the claims.

Claims

1. A constraint container that includes an internal space and is configured to enclose at least a portion of the workpiece to be processed, A pressure-operated coupling is configured to fix the restraint container in a closed state, and to release the restraint container when the internal pressure in the internal space of the restraint container reaches an operating pressure, A system comprising: an expandable medium disposed between at least a portion of the restraint container and at least a portion of the workpiece in the internal space, and configured to expand to apply positive pressure to the restraint container and the workpiece.

2. The aforementioned restraint container further, Bass and, Includes a cover coupled to the base, The aforementioned cover includes multiple cover sections, The system according to claim 1, wherein two of the cover sections are coupled to each other by the pressure-operated coupling, and when the internal pressure reaches the operating pressure, the at least two cover sections are released from each other.

3. The cover includes multiple cover layers, Each of the cover layers is bonded to the base, Each of the cover layers and the base form one of the multiple internal spaces of the restraint container. The system according to claim 2, wherein each of the cover layers comprises two cover sections connected by one of a plurality of pressure-operated couplings, and the two cover sections of each cover layer are sequentially released from each other when each of the plurality of internal pressures reaches one of the plurality of operating pressures.

4. The first coupling of the pressure-operated coupling connects two cover sections of the first cover layer, and is configured to release the two cover sections when the first internal pressure reaches the first operating pressure. The second coupling of the pressure-operated coupling connects two cover sections of the second cover layer, and is configured to release the two cover sections when the second internal pressure reaches the second operating pressure. The system according to claim 3, wherein the first operating pressure and the second operating pressure are different.

5. The system according to claim 2, wherein at least one of the cover sections is rigid.

6. The system according to claim 2, wherein at least one of the cover sections is flexible.

7. The system according to claim 2, wherein the pressure-operated coupling includes a shear coupling.

8. The system according to claim 2, wherein the pressure-operated coupling includes a linear tension coupling.

9. The system according to claim 2, further comprising a tensioner configured to selectively apply tension between two of the cover sections to control the internal pressure.

10. The system according to claim 9, wherein the tensioner is further configured to indicate the internal pressure.

11. The restraining container further includes a pressure plug, a portion of which is located within the internal space. The system according to claim 1, wherein the pressure plug is movable relative to the restraining container in order to change the volume of the internal space.

12. Further including an inspection hatch, said inspection hatch is A viewport formed in the aforementioned constraint container, The system according to claim 1, further comprising a pressure-responsive shutter configured to cover the viewport when the internal pressure in the internal space of the restraint container reaches a processing pressure.

13. The pressure-responsive shutter is, A panel coupled to the restraint container and movable relative to the restraint container to cover the viewport, The system according to claim 12, comprising a pressure-relieving fastener configured to hold the panel in a position separated from the viewport, and configured to release the panel when the internal pressure in the internal space of the restraint container reaches the processing pressure.

14. The aforementioned expandable medium is A first expandable material configured to expand up to a first expansion volume, A second expandable material configured to expand up to a second expansion volume, The system according to claim 1, wherein the first expansion volume and the second expansion volume are different.

15. A constrained container comprising multiple container walls configured to enclose at least a portion of the workpiece to be processed and forming an internal space, A pressure-operated coupling is configured to fix two of the container walls, and to release the two container walls when the internal pressure in the internal space reaches an operating pressure, A pressure plug that is attached to one of the container walls and is movable relative to the container wall, wherein a part of the pressure plug is positioned in the internal space, thereby changing the volume of the internal space, A tensioner configured to selectively apply tension between two of the container walls to control the internal pressure, A viewport formed in one of the container walls, When the internal pressure in the internal space of the restraint container reaches the processing pressure, a pressure-response shutter configured to cover the viewport is activated, A system comprising: an expandable medium disposed between at least a portion of the container wall and at least a portion of the workpiece in the internal space, and configured to expand in such a way as to apply positive pressure to the container wall and the workpiece.

16. A method for processing workpieces, To house at least a portion of the aforementioned workpiece in the internal space of the restraining container, In the aforementioned internal space, an expandable medium is applied between at least a portion of the restraining container and at least a portion of the workpiece, The restraint container is fixed in a closed state using a pressure-operated coupling, The expandable medium is expanded to increase the internal pressure of the restraining container, and positive pressure is applied to the workpiece. A method comprising: automatically releasing the restraint container using the pressure-operated coupling when the internal pressure of the restraint container reaches an operating pressure.

17. The method according to claim 16, further comprising controlling the internal pressure of the restraint container.

18. The method according to claim 16, further comprising indicating the internal pressure of the restraint container.

19. The method according to claim 16, further comprising controlling the internal space of the restraint container.

20. The method according to claim 16, further comprising indicating that the internal pressure of the restraint container has reached the processing pressure.

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