System and method for portable manufacturing using expandable tools

Abstract

The present invention provides a system for portable manufacturing and a method for manufacturing workpieces. [Solution] A system for manufacturing a workpiece includes a case having an internal volume. The case is configured to enclose at least a portion of the workpiece 200 to be manufactured. The system includes an expandable medium 120 placed in the internal volume 112 between the case and at least a portion of the workpiece. The expandable medium is configured to expand within the case such that it exerts positive pressure on at least a portion of the workpiece enclosed by the case.

Description

Technical Field

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

Background Art

[0002] Artificially designed materials such as composite materials are used in many applications. Many manufacturing components include processing steps such as joining and curing that generally require high temperature and high pressure in the manufacturing process. These processes often use industrial autoclaves because the autoclave allows for the application of both temperature and pressure under controlled conditions. However, processes that require an autoclave can lead to bottlenecks in the manufacturing process. This is because the throughput depends on the capacity of the autoclave, and it is necessary to transport raw materials and uncured components into the autoclave and then transport the cured composite material out of the autoclave. Furthermore, autoclave processing is usually not available for spot processing, repair, and remote processing needs. Therefore, those skilled in the art continue to make research and development efforts in the field of material manufacturing.

Summary of the Invention

[0003] Examples of systems for portable manufacturing, methods for manufacturing workpieces, and portable manufacturing kits are disclosed. The following non-exclusively lists examples of the gist of the present disclosure, which may include those described in the claims and those not described.

[0004] In one embodiment, the system of the present disclosure includes a case having an internal volume. The case is configured to enclose at least a portion of a workpiece to be manufactured. The system includes an expandable medium disposed within the internal volume between the case and at least a portion of the workpiece. The expandable medium is configured to expand within the case such that it exerts positive pressure on at least a portion of the workpiece enclosed by the case.

[0005] In one embodiment, the method of the present disclosure includes (1) enclosing at least a portion of a workpiece within the internal volume of a case; (2) introducing an expandable medium into the internal volume between the case and at least the portion of the workpiece; (3) expanding the expandable medium; (4) applying positive pressure to at least the portion of the workpiece; and (5) processing the workpiece in response to the application of positive pressure.

[0006] In one embodiment, the kit of the present disclosure includes a case having an internal volume and configured to enclose at least a portion of the workpiece to be manufactured. The kit includes an expandable medium. The expandable medium is configured to be introduced into the internal volume between the case and at least the portion of the workpiece. The expandable medium is configured to expand to apply positive pressure to at least the portion of the workpiece enclosed by the case.

[0007] Other embodiments of the system, method, and kit will be revealed by the following detailed description, accompanying drawings, and claims. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic block diagram of an example of a system for manufacturing workpieces. [Figure 2] This is a flowchart illustrating one example of a method for manufacturing a workpiece. [Figure 3]This is a schematic diagram of an example of the system, showing the workpiece and expandable medium introduced into the case. [Figure 4] Figure 3 is a schematic diagram of an example system, showing an expandable medium in a non-expanding state. [Figure 5] Figure 4 is a schematic diagram of an example system, showing an expandable medium in an expanded state. [Figure 6] This is a schematic diagram illustrating an example of the system in question. [Figure 7] This is a schematic diagram of an example of a case and part of a workpiece. [Figure 8] This is a schematic diagram of an example of the system, showing the workpiece inside the case and the expandable medium in an expanded state. [Figure 9] This is a schematic diagram of an example of the system, showing the workpiece and the expandable medium in an expanded state, with the case changing its internal volume using its movable side. [Figure 10] This is a schematic diagram of an example of the system, showing how the case and the second case are connected to change the internal volume and accommodate the workpiece. [Figure 11] This is a schematic diagram of an example of the system, showing the workpiece on the mold and the non-expanding expandable medium inside the case. [Figure 12] Figure 11 is a schematic diagram of an example system, showing an expandable medium in an expanded state. [Figure 13] This is a schematic diagram of an example of the system, showing the workpiece, casting, and non-expanding expandable medium inside the case. [Figure 14] Figure 13 is a schematic diagram of an example system, showing an expandable medium in an expanded state. [Figure 15] This is a schematic diagram of an example of the system, showing the workpiece, overlay, and non-expanding expandable medium inside the case. [Figure 16] Figure 15 is a schematic diagram of an example system, showing an expandable medium in an expanded state. [Figure 17] This is a schematic diagram of an example of the system, showing a case containing a workpiece and an expandable medium in a non-expanded state, along with a surrounding element. [Figure 18] Figure 17 is a schematic diagram of an example system, showing an expandable medium in an expanded state. [Figure 19] This is a schematic diagram of an example of the system, showing the workpiece inside the case, the variable-volume element, the constant-volume element, and the expandable medium in an expanded state. [Figure 20] This is a schematic diagram of an example of a portable manufacturing kit. [Figure 21] This is a schematic diagram of an example aircraft. [Figure 22] This is a flowchart illustrating an example of how aircraft are manufactured and put into service. [Modes for carrying out the invention]

[0009] Referring to Figures 1 and 3-19, the present disclosure relates, for example, to a system 100 for portable manufacturing. The following are embodiments of system 100 according to the present disclosure. Embodiments of system 100 include multiple elements, features, and components. Not all elements, features, and / or components described or illustrated in one embodiment are essential in that embodiment. Some or all elements, features, and / or components described or illustrated in one embodiment can be combined in various ways with other embodiments, without requiring the inclusion of other elements, features, and / or components described in those other embodiments, and such combinations do not need to be explicitly described or illustrated in the embodiments herein.

[0010] Embodiments of System 100 utilize portable and modular restraint containers, expansion materials, and related components, thereby enabling the production of high-quality machined parts without the use of autoclaves. Embodiments of System 100 facilitate the application of at least approximately uniform, omnidirectional pressure to the surface of the component being machined. Embodiments of System 100 have the advantage of enabling the use of expansion materials for structural bonding, debulking, and / or curing, with or without adhesives. Embodiments of System 100 have the advantage of enabling material processing in locations where material processing was previously impossible.

[0011] Figures 3–5 and 7–19 show various examples of the illustrated system 100 used to machine at least a portion 202 of a workpiece 200. Generally, a portion 202 of a workpiece 200 refers to any part or all of the workpiece 200 that is machined using the system 100.

[0012] As shown in FIG. 1, in one or more embodiments, the workpiece 200 includes one or more materials 210 such as a first material 212 and a second material 214. In some embodiments, the materials 210 are the same. In some embodiments, the materials 210 are different. In one or more embodiments, the workpiece 200 can include any number of materials 210, including those joined to each other during a material processing step, such as a base material, material layers, components, accessories, etc. In one or more embodiments, one or more of the materials 210 are composite materials (e.g., composite components, parts, objects, etc.) including one or more composite layers (also referred to as plies). In one or more embodiments, one or more of the materials 210 are metal materials (e.g., metal components, parts, objects, etc.). In one or more embodiments, one or more of the materials 210 are ceramic materials (e.g., ceramic components, parts, objects, etc.). In one or more embodiments, one or more of the materials 210 are polymer materials (e.g., polymer components, polymer parts, polymer objects, etc.).

[0013] FIGS. 3-5 and FIGS. 7-19 show various examples of workpieces 200 processed or joined using the system 100 and / or according to the method 1000, as well as examples of materials 210. The workpiece 200 can include any suitable number of materials 210 (e.g., material types, material layers, material portions, material components or parts, etc.). In various embodiments, the workpiece 200 includes one or more composite materials, metal 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 joining structure.

[0014] In any of these embodiments, the material 210 is processed using the system 100 and / or according to the method 1000. In one or more embodiments, the material 210 is cured. In one or more embodiments, the materials 210 are joined to each other by co-curing (e.g., by applying heat and / or pressure). In one or more embodiments, the materials 210 are joined to each other by co-bonding (e.g., by applying heat and / or pressure). In one or more embodiments, the materials 210 are joined to each other by secondary bonding (e.g., by applying heat and / or pressure).

[0015] The workpiece 200 can have any suitable one of various cross-sectional shapes. The material 210 includes a plurality of material layers (e.g., uncured composite materials, cured composite materials, metallic materials, ceramic materials, polymeric materials, thermoplastic materials, thermosetting materials, fiber reinforced materials, etc.), and optionally an adhesive layer in addition to these, and these are joined to each other by utilizing the fact that the expandable medium 120 expands to apply a positive pressure 102 to the workpiece 200. In one or more embodiments, the workpiece 200 includes a plurality of layers (e.g., material layers) of the material 210 that are processed (e.g., cured or joined) by utilizing the fact that the expandable medium 120 expands to apply a positive pressure 102 to the workpiece 200.

[0016] In one or more embodiments, the expandable medium 120 is positioned or arranged relative to the workpiece 200 such that a positive pressure 102 (e.g., an omnidirectional force) is applied to at least one face or surface of the workpiece 200. As shown in Figures 3 to 5, in one or more embodiments, a first amount of expandable medium 120 is positioned above or on top of the workpiece 200 (e.g., a laminate of material layers), so that when the expandable medium 120 expands during processing, a positive pressure 102 is applied to the workpiece 200, compressing the material layers. As shown in Figure 8, in one or more embodiments, a first amount of expandable medium 120 is positioned above or on top of the workpiece 200, and a second amount of expandable medium 120 is positioned below or on top of the workpiece 200, so that when the expandable medium 120 expands during processing, a positive pressure 102 is applied to the workpiece 200, compressing the material layers.

[0017] As shown in Figures 1 and 3 to 19, in one or more embodiments, the system 100 includes a case 110 and an expandable medium 120. The case 110 includes or forms an internal volume 112. The case 110 is configured to surround at least a portion 202 of the workpiece 200 to be manufactured. The expandable medium 120 is located in the internal volume 112 between the case 110 and at least a portion 202 of the workpiece 200. The expandable medium 120 is configured to expand within the case 110, thereby applying a positive pressure 102 to at least a portion 202 of the workpiece 200 surrounded by the case 110. In one or more embodiments, the case 110 includes a base 114, a cover 116, and a plurality of sides 118. The sides 118 extend between the base 114 and the cover 116. The base 114, cover 116, and side portion 118 form the internal volume 112.

[0018] In one or more embodiments, the case 110 functions as a portable and modular spatial constraint container or tooling that encloses at least a portion (e.g., part 202) of a workpiece 200 to be processed (e.g., manufactured, repaired, joined). The portability and modularity of the case 110 enable the manufacture and / or material processing of the workpiece in locations where it would otherwise be impossible. In one or more embodiments, the case 110 is configured to house and / or enclose the entire workpiece 200 to be processed (e.g., of a defined size and shape). In one or more embodiments, the case 110 is configured to house and / or enclose a portion (e.g., less than the entire) of the workpiece 200 to be processed.

[0019] As shown in Figures 3 to 19, in one or more embodiments, the workpiece 200 is supported on or by the base 114. In one or more embodiments, the cover 116 is positioned relative to the base 114 and / or the workpiece 200 such that at least a portion 202 of the workpiece 200 and the expandable medium 120 are located within the cover 116, or otherwise constrained by the cover 116, or positioned between the cover 116 and the base 114. In one or more embodiments, the cover 116 allows the expandable medium 120 and the workpiece 200 to be loaded into the internal volume 112 of the case 110. In one or more embodiments, the cover 116 has or forms a cross-sectional contour corresponding to the cross-sectional shape of the workpiece 200. By providing the cover 116 with a cross-sectional contour that corresponds to (for example, at least roughly coincides with, or complements) the cross-sectional contour of the workpiece 200, the internal volume 112 of the case 110 can be reduced, and as a result, the amount of expandable medium 120 required can be reduced.

[0020] In one or more embodiments, at least a portion of the case 110 is rigid. In one or more embodiments, at least a portion of the case 110 is flexible and non-expandable. In one or more embodiments, at least a portion of the case 110 is flexible and expandable. In one or more embodiments, at least a portion of the case 110 substantially resists expansion when pressure is applied to the inner surface of the case 110 by the expandable medium 120. In this way, the pressure applied to the outer surface of the workpiece 200 acts in coordination with the case 110 to generate a compressive force on the workpiece 200.

[0021] In one or more embodiments, at least a portion of the base 114, cover 116, and side portions 118 are rigid (e.g., stiff or inflexible) and non-expandable. In these embodiments, at least a portion of the base 114, cover 116, and side portions 118 are formed from any suitable material, including, but not limited to, metallic materials, composite materials, cement materials, ceramic materials, polymer materials, and the like. In such embodiments, the case 110 restrains the expandable medium 120 and resists the positive pressure 102 generated by the expandable medium 120 during expansion. In these embodiments, the case 110 can withstand the pressure generated in the internal volume 112 when the expandable medium 120 expands.

[0022] In one or more embodiments, at least a portion of the base 114, cover 116, and side portion 118 is flexible. In one or more embodiments, at least a portion of the base 114, cover 116, and side portion 118 is flexible and non-expandable. In one or more embodiments, at least a portion of at least one of the base 114, cover 116, and side portion 118 is flexible and non-expandable or expandable. By making at least a portion of at least one of the base 114, cover 116, and side portion 118 flexible and non-expandable, the case 110 can be made to conform to the contour shape of the workpiece 200 and / or at least a portion of the expandable medium 120 (e.g., to be more tightly fitted) and / or can be easily adapted to the shape of at least a portion of the workpiece 200 before the expandable medium 120 expands. As a result, the internal volume 112 of the case 110 is reduced, thus decreasing the amount of expandable medium 120 required and improving the portability of the system 100. In these embodiments, at least a portion of the base 114, cover 116, and side 118 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, and the like.

[0023] In one or more embodiments, the workpiece 200 (e.g., portion 202) is placed inside the case 110 (e.g., on the base 114) during machining. In order to apply an appropriate compressive force (e.g., positive pressure 102) to the workpiece 200 while it is inside the case 110, it may be necessary to adequately support at least portion 202 of the workpiece 200 being machined. In one or more embodiments, the base 114 provides a substantially incompressible surface to support one face of the workpiece 200. In other embodiments, the system 100 includes a mold 148. The mold 148 is configured to be located within an internal volume 112. The mold 148 is configured to support at least portion 202 of the workpiece 200. In one or more embodiments, the mold 148 (e.g., a mandrel) gives the workpiece 200 a cross-sectional shape.

[0024] In one or more embodiments, the cover 116 is movable between an open and a closed position relative to the base 114. In one or more embodiments, the cover 116 includes any suitable elements or features that facilitate the introduction and / or removal of the expandable medium 120 into and / or from the internal volume 112. In one or more embodiments, the cover 116 includes a removable or openable panel (e.g., a door) that allows access to the internal volume 112 and the introduction of the expandable medium 120 after it has been positioned relative to the workpiece 200.

[0025] As shown in Figures 6 and 7, in one or more embodiments, at least one of the side portions 118 includes an opening 130. The opening 130 is configured to receive at least a portion 202 of a workpiece 200. For example, the system 100 can machine (e.g., repair) a specific portion or region of a large or elongated workpiece 200. In these embodiments, the portion 202 of the workpiece 200 is inserted into the internal volume 112 of the case 110 through the opening 130.

[0026] In one or more embodiments, the case 110 includes a cap 132. The cap 132 is configured to at least partially cover the opening 130. In one or more embodiments, the cap 132 is configured to restrain or hold the expandable medium 120 within the internal volume 112 (for example, before, during, and / or after the expandable medium 120 expands). In one or more embodiments, the cap 132 is configured to fill a portion of the opening 130 between the workpiece 200 and the side portion 118. In one or more embodiments, the cap 132 is configured to fit the workpiece 200 located within the opening 130.

[0027] As shown in Figure 9, in one or more embodiments, the internal volume 112 of the case 110 can be selectively (e.g., controllably) changed. In one or more embodiments, at least one of the sides 118 is movable relative to the base 114 and the cover 116. By moving one or more of the sides 118 relative to the base 114 and the cover 116, the internal volume 112, such as its size and / or shape, can be selectively changed. By selectively changing the internal volume 112, it is possible to reduce the internal volume 112, and accordingly, the amount of expandable medium 120 required to fill the internal volume 112 during expansion can be reduced. Furthermore, by selectively changing the internal volume 112, it is also possible to selectively or flexibly control and change the pressure 104 inside the case 110 (e.g., the pressure acting on the workpiece 200 inside the internal volume 112).

[0028] In one or more embodiments, one or more of the side sections 118 are connected to and detachable from the base 114 and the cover 116. In this way, the internal volume 112 of the case 110 can be customized based on the arrangement of the side sections 118. In one or more embodiments, the side sections 118 can be detachably connected to the base 114 and / or the cover 116 using any of a variety of mechanisms or methods such as tongue and groove connections, fasteners, and clamps. In one or more embodiments, one or more of the side sections 118 have two or more components, such as a primary wall or outer section 118a and a secondary wall or inner section 118b. In these embodiments, the inner section 118b can be moved relative to the outer section 118a to change the size and / or shape of the internal volume 112.

[0029] As shown in Figures 1 and 10, in one or more embodiments, the system 100 includes a second case 150. In one or more embodiments, the second case 150 is substantially the same as and / or includes substantially the same elements, features, and / or components as case 110. The second case 150 includes or forms a second internal volume 152. In one or more embodiments, the second case 150 includes a second base 154 and a second cover 156. The second case 150 is configured to be connected to case 110. The second case 150 is configured to surround a second portion 204 of the workpiece 200. The expandable medium 120 is located in the second internal volume 152 between the second case 150 and the second portion 204 of the workpiece 200. Figures 1 and 10 show an example of system 100 including two cases (for example, case 110 and second case 150), but in other embodiments, system 100 may include any number of cases arranged and connected in various configurations to accommodate workpieces of various sizes and shapes.

[0030] In one or more embodiments, a portion of case 110 and a second portion of the second case 150 are removable, thereby connecting the internal volume 112 and the second internal volume 152. For example, by removing one of the sides 118 of case 110 and one of the second sides 158 of the second case 150, and connecting these open sides of case 110 and the second case 150, the internal volume 112 and the second internal volume 152 are joined, thereby increasing the overall processing volume of the system 100 to accommodate workpieces 200 of various sizes and shapes. In these examples, case 110 and the second case 150 are connected or fixed to each other using appropriate mechanisms or methods, such as fasteners 138.

[0031] As shown in Figures 1, 13, and 14, in one or more embodiments, the system 100 includes a casting 134. The casting 134 is configured to be applied over an expandable medium 120 and at least a portion 202 of the workpiece 200 and solidify. The casting 134 and a portion of the case 110 form an internal volume 112. The expandable medium 120 is located within the internal volume 112 between the casting 134 and at least a portion 202 of the workpiece 200. The casting 134 is configured to surround at least the above portion of the workpiece 200 by solidifying. In one or more embodiments, the expandable medium 120 is configured to expand so that it applies a positive pressure 102 to the workpiece 200 and the casting 134. In one or more embodiments, the casting 134 is located or positioned between the expandable medium 120 and the surface of at least a portion 202 of the workpiece 200 being processed. In such embodiments, the casting 134, upon solidification, forms a pressure equalization mechanism or pressure equalization layer that converts the potentially non-uniform pressure arising from the expanding expandable medium 120 into a substantially uniform pressure on the workpiece 200, thereby improving the quality of the workpiece and surface, and / or promoting consolidation. In such embodiments, the expansion of the expandable medium 120 applies a positive pressure 102 to the outside of the casting 134 and (e.g., indirectly) to the workpiece 200 through the casting 134. In one or more embodiments, the casting 134 is located or positioned on the expandable medium 120 and at least a portion 202 of the workpiece 200 to be manufactured. In such embodiments, the casting 134 forms at least a portion of the internal volume 112. In such embodiments, upon solidification, the casting 134 functions as a space-constraining container, with the rigid casting shell acting as the container wall. For example, the casting 134 can function as part of the cover 116 and / or side portion 118.In such embodiments, the expansion of the expandable medium 120 creates positive pressure inside the casting 134 and (for example, directly) on the workpiece 200. In one or more embodiments, the system 100 includes two or more layers of casting 134, such as a first or outer casting and a second or inner casting. The inner casting is located or positioned between the expandable medium 120 and the workpiece 200 and, upon solidification, forms a pressure equalization mechanism or pressure equalization layer that converts the potentially non-uniform pressure arising from the expanding expandable medium 120 into a substantially uniform pressure on the workpiece 200. The outer casting is located or positioned on top of the inner casting, the expandable medium 120, and at least a portion 202 of the workpiece 200 and, upon solidification, functions as part of a space-constrained container, with the rigid outer casting shell acting as the container wall.

[0032] As shown in Figures 1, 15, and 16, in one or more embodiments, the system 100 includes an overlay 136. The overlay 136 is configured to cover the expandable medium 120 and at least a portion 202 of the workpiece 200 and to be connected to the case 110. The overlay 136 and a portion of the case 110 form an internal volume 112. The expandable medium 120 is located within the internal volume 112 between the overlay 136 and at least a portion 202 of the workpiece 200. In one or more embodiments, the overlay 136 forms or defines at least a portion of the internal volume 112. In one or more embodiments, the overlay 136 replaces the cover 116 and / or functions as part of a spatially constrained container corresponding to the cross-sectional shape or contour of the workpiece 200. In such embodiments, the expandable medium 120 is positioned between the overlay 136 and the workpiece 200 within an internal volume 112 formed by the overlay 136. In at least one embodiment, at least a portion of the overlay 136 is flexible and non-expandable. The overlay 136 allows the space-constrained container to conform to the contour shape of the workpiece 200 and / or the expandable medium 120 (e.g., to a tighter fit) before the expandable medium 120 expands. In these embodiments, at least a portion of the overlay 136 can be formed from any suitable material, including, but not limited to, metal mesh (e.g., chainmail), ceramic mesh, polymer mesh, etc. In such embodiments, the overlay 136 constrains the expandable medium 120 and resists the positive pressure 102 generated by the expandable medium 120 during expansion. In these embodiments, the overlay 136 can withstand the pressure generated when the expandable medium 120 expands.

[0033] As shown in Figures 1, 17, and 18, in one or more embodiments, the system 100 includes a wrapping element 122. The wrapping element 122 is configured to enclose at least a portion (e.g., a given amount) of the expandable medium 120. The wrapping element 122 is located within an internal volume 112 between the case 110 and at least a portion 202 of the workpiece 200. In one or more embodiments, at least a portion of the expandable medium 120 is located within the wrapping element 122. In one or more embodiments, the expandable pellets are located within or contained within the wrapping element 122. In one or more embodiments, the wrapping element 122, by enclosing the expandable medium 120 (e.g., the expandable pellets), not only facilitates the handling of the expandable medium 120 but also facilitates the removal of the expandable medium 120 after processing is complete. The wrapping element 122 can take any suitable form, such as a sealing film, a sealed material layer, a bag, or a bladder. In one or more embodiments, the wrapping element 122 is non-expandable. In one or more embodiments, the wrapping element 122 is expandable. In one or more embodiments, the wrapping element 122 is formed from a nylon or polyester fabric (e.g., fire hose material).

[0034] In one or more embodiments, 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 120 within the internal volume 112. The type and configuration of element 124, or the mechanism used by the activating element 124, may vary depending on the type and configuration of the expandable medium 120. In one or more embodiments, the activating element 124 is a chemical, water, a heater, etc.

[0035] As shown in Figures 1 and 19, in one or more embodiments, the system 100 includes at least one volumetric element 192. The volumetric element 192 is configured to expand and / or contract within the internal volume 112, thereby selectively controlling or changing the internal volume 112 and / or selectively increasing or decreasing the pressure 104 within the case 110. The volumetric element 192 can have any feasible cross-sectional shape, such as circular, elliptical, or polygonal. The volumetric element 192 can be extended along at least one axis. In one or more embodiments, the volumetric element 192 is an intermediate layer provided within the internal volume 112 of the case 110. In one or more embodiments, the volumetric element 192 includes or takes the form of a bladder or other expansion element. In one or more embodiments, the volumetric element 192 is filled with a fluid (e.g., gas or liquid) and is configured to equalize the positive pressure 102 applied to the workpiece 200, thereby ensuring a more uniform application of the positive pressure 102. The volumetric element 192 can be selected to be heat-resistant and easily removable after the workpiece 200 has been manufactured. In one or more embodiments, the volumetric element 192 is an expansion element or other volume-changing component of the system 100 and is configured to selectively expand and / or contract in order to selectively increase or decrease the internal volume 112 of the case 110 into which the expandable medium 120 is filled when the expandable medium 120 expands. In one or more embodiments, the volumetric element 192 includes or takes the form of a sealed bladder or balloon having some type of expandable material (e.g., expandable medium 120). In one or more embodiments, a chemical substance (e.g., baking soda powder) can be filled into the volumetric element 192. When this chemical is heated to generate a gas, the volume-variable element 192 expands, reducing the fillable volume (internal volume 112) of the case 110 and / or adding an additional positive pressure 102 within the confined space. In other examples, the volume-variable element 192 is one example of various types of expandable media 120 (e.g., a wrapping element 122).In one or more embodiments, the volumetric element 192 takes the form of a pressure-increasing element or functions as a pressure-increasing element and is located within the internal volume 112 of the case 110 together with the expandable medium 120 and the workpiece 200. In one or more embodiments, the volumetric element 192 is another type or example of the expandable medium 120, or a different type of expandable material. In one or more embodiments, the volumetric element 192 is selectively expandable to increase or enhance the pressure acting on one or more locations on the workpiece 200. For example, the volumetric element 192 can be placed near a predetermined location or area of ​​the workpiece 200 (e.g., its position or vicinity), such as a cavity or contour between different parts of the workpiece 200, thereby increasing the pressure applied to the curved portion of the contour during manufacturing (e.g., curing and / or bonding).

[0036] As shown in Figures 1 and 19, in one or more embodiments, the system 100 includes at least one volume-constant element 194. The volume-constant element 194 is configured to maintain a constant size and volume so as to fill a portion of the internal volume 112. The volume-constant element 194 can have any feasible cross-sectional shape, such as circular, elliptical, or polygonal. The volume-constant element 194 can be extended along at least one axis.

[0037] As shown in Figure 1, in one or more embodiments, the system 100 includes a caul plate 196. The caul plate 196 is located within an internal volume 112 between the expandable medium 120 and at least the portion of the workpiece 200. In one or more embodiments, the caul plate 196 is positioned between the expandable medium 120 and the workpiece 200. In such embodiments, the caul plate 196 contributes to improved compaction and surface condition of the workpiece 200. The caul plate 196 can be selected to be heat-resistant and easily removable after the manufacture of the workpiece 200. Examples of materials for the caul plate 196 include hard or semi-hard materials, metallic materials, composite materials, etc. In at least one embodiment, the caul plate 196 includes or is formed of multiple caul portions. In such embodiments, each caul portion is separated from each other and movable (e.g., can be shifted or slid) relative to adjacent caul portions. In one or more embodiments, the ends of adjacent coal portions overlap. The separated coal portions of the coal plate 196 contribute to compaction and improvement of the surface condition.

[0038] As shown in Figure 1, in one or more embodiments, the system 100 includes a bagging material 198. The bagging material 198 is positioned on at least the above portion of the workpiece 200. In one or more embodiments, the bagging material 198 includes or takes the form of a vacuum bagging material, a vacuum laminate bagging material, or other sheet material which utilizes atmospheric pressure during the manufacturing process to clamp and hold components of the workpiece 200 in place under the bagging material 198.

[0039] As shown in Figures 1, 3-5, and 10, in one or more embodiments, the system 100 includes at least one fastener 138. The fastener 138 is configured to fasten the base 114 and the cover 116. The fastener 138 is configured to hold the case 110 in a closed position. For example, in the manufacturing process after the workpiece 200 and the expandable medium 120 are loaded into the internal volume 112 of the case 110, the fastener 138 is configured to press and hold the cover 116 against the base 114, or in other embodiments to fasten the base 114 and the cover 116 together. The fastener 138 includes any suitable mechanism that can fasten the case 110 in a closed position. In one or more embodiments, the fastener 138 includes at least one clamp configured to fasten or secure the cover 116 to the base 114 or the side 118 in a predetermined position. The clamp may include any suitable type of clamping and fastening device, such as, but is not limited to, mechanical clamps, magnetic clamps, pneumatic clamps, spring clamps, latches, pins, fasteners, and weights. The fastener 138 may include any number of clamps.

[0040] As shown in Figure 1, in one or more embodiments, the system 100 includes at least one pressure sensor 162. The pressure sensor 162 is configured to detect the pressure 104 in the internal volume 112. In one or more embodiments, the pressure sensor 162 enables monitoring of the pressure 104 in the internal volume 112 within the case 110, thereby enabling monitoring of the positive pressure 102 or omnidirectional force applied to the workpiece 200 by the expandable medium 120 during and after the expansion of the expandable medium 120. In one or more embodiments, the pressure sensor 162 also functions as a fail-safe to limit the pressure 104 in the case 110. In one or more embodiments, the pressure sensor 162 generates a display (e.g., an alarm) when the pressure 104 in the internal volume 112 exceeds a predetermined threshold. In one or more embodiments, the pressure sensor 162 provides real-time pressure detection and fail-safe functionality. In one or more embodiments, if the detected pressure value (e.g., magnitude) is higher than the alarm pressure or threshold pressure, the system 100 is configured to initiate an automatic shutoff, along with other safety measures such as forced air cooling, internal pressure release, or opening the case 110. In such embodiments, the pressure sensor 162 may include, but is not limited to, any suitable type or number of sensors, such as pressure sensors, load sensors, strain gauges, other sensor devices, and combinations thereof.

[0041] As shown in Figure 1, in one or more embodiments, the system 100 includes at least one shear pin 164. The shear pin 164 is configured to break when the pressure 104 in the internal volume 112 exceeds a predetermined threshold. In one or more embodiments, the shear pin 164 includes, or takes the form of, a fail-safe mechanism configured to prevent overpressure and / or regulate the pressure in the internal volume 112 of the case 110. For example, the shear pin 164 is used to connect the cover 116 to the base 114 in a closed position, or to connect multiple segments or parts of the case 110 to each other. In one or more embodiments, the shear pin 164 is configured to break when a predetermined pressure higher than the pressure required for the manufacturing process or a desired pressure is applied, thereby releasing the pressure inside the case 110. In one or more embodiments, the shear pin 164 is a sacrificial pin with a known breaking strength, which corresponds to the maximum allowable internal pressure that serves as an alarm criterion. In such embodiments, if the shear pin 164 breaks, the system 100 enters alarm mode. In other embodiments, the system 100 includes multiple safety control functions.

[0042] In one or more embodiments, the fastener 138, pressure sensor 162, and / or shear pin 164 are integrated into a single component. For example, the shear pin 164 can be used as the fastener 138 to secure the case 110 in a closed position (e.g., to fasten the base 114 and the cover 116 together). In an optional configuration, the pressure sensor 162 can be used to detect the pressure 104 and / or load applied to the fastener 138 and / or shear pin 164.

[0043] As shown in Figure 1, in one or more embodiments, the system 100 includes at least one temperature sensor 166. The temperature sensor 166 is configured to detect the temperature of at least one of the following: the expandable medium 120, the workpiece 200, and the internal volume 112.

[0044] As shown in Figure 1, in one or more embodiments, the system 100 includes a heater 142. The heater 142 is in thermal conductivity with the expandable medium 120. In one or more embodiments, the heater 142 is configured to heat the expandable medium 120 to an activation temperature at which the expandable medium 120 expands within the internal volume 112 and applies positive pressure 102 to the workpiece 200. In one or more embodiments, the heater 142 is configured to heat the workpiece 200 to a desired processing temperature (e.g., a curing or bonding temperature). In one or more embodiments, the heater 142 is an internal heater and is configured to be located within the internal volume 112 of the case 110 together with the expandable medium 120. In one or more embodiments, the heater 142 is an external heater and is configured to be located outside the case 110. In one or more embodiments, the heater 142 is integrally formed with the case 110 and / or the expandable medium 120, for example, using a smart susceptor heating element. The heater 142 may take any suitable form or include any suitable heating device. In various examples in which the expandable medium 120 is activated and expands by heat, the case 110 can be heated externally. Alternatively, or in addition to this, the system 100 may include one or more exothermic elements configured to heat the expandable medium 120 to a predetermined temperature in which the expandable medium 120 expands.

[0045] As shown in Figure 1, in one or more embodiments, the system 100 includes at least one battery 144. The battery 144 is configured to store power. In one or more embodiments, the battery 144 supplies power to any electrical element or component of the system 100, thereby enabling the system 100 to be used in locations where power or infrastructure is not readily available.

[0046] As shown in Figure 1, in one or more embodiments, the system 100 includes at least one solar collector 146. The solar collector 146 is configured to generate power. In one or more embodiments, this one solar collector 146 is configured to charge a battery 144. In one or more embodiments, this one solar collector 146 powers any electrical element or component of the system 100, thereby enabling the system 100 to be used even in locations where power and infrastructure are not readily available.

[0047] In one or more embodiments, at least a portion of the case 110 is heat-reflective. In at least one embodiment, at least one of the side portion 118, the cover 116, and / or the base 114 is heat-reflective. In at least one embodiment, at least a portion of the inner surface of the case 110 contains or is coated with a heat-reflective material. The heat reflectivity improves the heating efficiency of the expandable medium 120 and promotes the expansion of the expandable medium 120 during the manufacturing process.

[0048] As shown in Figure 1, in one or more embodiments, the system 100 includes a controller 170. In one or more embodiments, the controller 170 monitors the pressure 104 and / or temperature 106 inside the case 110 by receiving input signals or input data from a pressure sensor 162, a temperature sensor 166, a heater 142, and / or other sensors, and can then increase or decrease them as necessary to achieve and / or maintain a desired magnitude of positive pressure 102 applied to the workpiece 200 by the expansion of the expandable medium 120.

[0049] In one or more embodiments, the controller 170 includes or takes the form of a closed-loop controller, or utilizes closed-loop control for the pressure 104 and / or temperature 106 applied to the case 110 and / or workpiece 200 during the machining process. In one or more embodiments, the controller 170 controls or adjusts the pressure 104 and / or temperature 106 applied to the case 110 and / or workpiece 200 using real-time pressure measurements from the pressure sensor 162 and / or temperature sensor 166.

[0050] In one or more embodiments, the controller 170 includes a computer or other data processing system including a processor 174, memory 176, and program code 178 stored in memory 176 and executable by the processor 174. In one or more embodiments, the controller 170 generates and provides operational instructions or commands to the functional components of the system 100. In one or more embodiments, the controller 170 accepts user commands from an operator. In one or more embodiments, the system 100 includes a communication module 172. The communication module 172 is communicative with the processor 174 and / or constitutes part of the controller 170. The communication module 172 is configured to transmit data representing the state within the internal volume 112, for example, at least one of the pressure 104 and temperature 106 within the internal volume 112. In such embodiments, data representing the state of the manufacturing process can be displayed to the operator by the controller 170.

[0051] In one or more embodiments, before processing, the expandable medium 120 is in a non-expanded state (e.g., Figures 3, 4, 11, 13, 15, and 17). In the non-expanded state (e.g., before expansion), the expandable medium 120 may be referred to as the non-expanded state or the non-expanded element. During the manufacturing process, the expandable medium 120 is expanded to an expanded state (e.g., Figures 5, 8-10, 12, 14, 16, 18, and 19). In the expanded state, the expandable medium 120 may be referred to as the expanded state or the expanded element. In one or more embodiments, in the expanded state, the expandable medium 120 applies pressure to the inner surface of the case and the surface of part 202 of the workpiece 200. In one or more embodiments, the expanded expandable medium 120 in an expanded state applies a positive pressure 102 (caused by the expansion of the expandable medium 120) to the workpiece 200 during part or all of the manufacturing process, thereby promoting compression. In one or more embodiments, after the joining of the workpiece 200 is complete, the expandable medium 120 can be removed from the case 110 either before, simultaneously with, or after the manufactured workpiece 200 is removed from the case 110.

[0052] In one or more embodiments, the expandable medium 120 is configured to expand to an expanded volume 126 in response to a first predetermined change occurring in the attribute 129 of the expandable medium 120. When the expandable medium 120 expands, it applies or exerts a positive pressure 102 on the workpiece 200 and the case 110. Generally, the expanded volume 126 is known or can be calculated based on the material composition, attribute 129, and / or activation temperature of the expandable medium 120. In one or more embodiments, the expanded volume 126 of the expanded medium 120 in the expanded state is greater than the internal volume 112 of the case 110. In this disclosure, internal volume 112 refers to the internal volume of the case 110 that is actually available and fillable. In various embodiments, the expanded volume 126 is substantially the same as, or slightly larger than, the internal volume 112 defined by the case 110, the workpiece 200, and other components located within the case 110. Therefore, when the expandable medium 120 expands, it applies a positive pressure 102 to the workpiece 200 unless the internal volume 112 is altered (e.g., by moving the sides 118 or controlling the volume-variable element 192). In one or more embodiments, the amount (e.g., volume) of the unexpanded expandable medium 120 loaded into the internal volume 112 of the case 110 is determined by tests or models that predict the pressure during and after expansion within the constrained volume.

[0053] In one or more embodiments, the expandable medium 120 is configured to shrink to a shrink volume 128 in response to a second predetermined change occurring in the attribute 129 of the expandable medium 120. When the expandable medium 120 shrinks, it reduces or eliminates the positive pressure 102 applied to the workpiece 200 and case 110. Generally, the shrink volume 128 is known or can be calculated based on the material composition, attribute 129, and / or activation temperature of the expandable medium 120. In various embodiments, the shrink volume 128 of the expandable medium 120 is smaller than the expanded volume 126. In one or more embodiments, the shrink volume 128 is smaller than the expanded volume 126 but larger than the volume of the expandable medium 120 when it is not expanded (e.g., before expansion).

[0054] The expandable medium 120 may contain any one or more of a variety of suitable materials or material compositions, which are configured to expand and optionally contract upon activation or in response to a change in at least one of the attributes 129. As shown in the figures, in one or more embodiments, the expandable medium 120 includes expansion pellets. In one or more embodiments, the expansion pellets are activated by heat at the activation temperature. In such embodiments, the expansion pellets are configured to expand when their temperature rises to the activation temperature. In one or more embodiments, the expansion pellets are chemically activated, for example, by using an activation element 124. In one or more embodiments, any suitable number of expansion pellets may be placed in the internal volume 112 of the case 110, provided that when these expansion pellets expand, sufficient positive pressure 102 can be applied to the workpiece 200 to perform the desired processing steps. The number of expansion pellets depends on the size of the internal volume 112. In other words, the closer the case 110 is to the outer shape of the workpiece 200, the fewer expansion pellets are required. In various examples, each expansion pellet can have any suitable dimensions. In one or more embodiments, the length of the expansion pellet is less than about 1 centimeter. The expansion pellets can be substantially uniform in size, or they can include pellets of different sizes. In one or more embodiments, the expandable medium 120, such as the expansion pellets, includes or takes the form of foaming pellets. In at least one embodiment, the foaming pellets are configured to foam when heated to at least a predetermined foaming temperature (e.g., activation temperature). In one or more embodiments, the foaming pellets include foaming materials such as thermoplastic materials treated with a foaming agent, gas-filled balloons, hollow microspheres, metals, any other suitable components configured to expand when heated, or any combination thereof.

[0055] In one or more embodiments, the expandable medium 120 generates heat during expansion and / or contraction. In one or more embodiments, the expandable medium 120 absorbs heat during expansion and / or contraction. In such embodiments, the activation, and consequently the expansion or contraction, of the expandable medium 120 can be used to control the temperature 106 during manufacturing (e.g., the temperature inside the workpiece 200, the expandable medium 120, and / or the case 110). In one or more embodiments, the expandable medium 120 neither generates nor absorbs heat during expansion and / or contraction (i.e., no heat is released or absorbed).

[0056] Referring to Figure 2, as an example, this disclosure also covers a method 1000 for manufacturing a workpiece 200, also referred to herein as a portable manufacturing method. The following are embodiments of method 1000 according to this disclosure. In one or more embodiments, method 1000 is carried out using system 100 (Figure 1). Embodiments of method 1000 include multiple elements, steps, operations, or processes. Not all elements, steps, operations, or processes described or illustrated in one embodiment are essential in that embodiment. Some or all elements, steps, operations, or processes described or illustrated in one embodiment can be combined in various ways with other embodiments, without requiring the inclusion of other elements, steps, operations, or processes described in those other embodiments, and such combinations do not need to be explicitly described or illustrated in the embodiments herein.

[0057] In one or more embodiments, Method 1000 includes step 1002 of enclosing at least a portion 202 of a workpiece 200 within an internal volume 112 of a case 110. Method 1000 includes step 1004 of introducing an expandable medium 120 into the internal volume 112 between the case 110 and at least a portion 202 of the workpiece 200. Method 1000 includes step 1018 of expanding the expandable medium 120. Method 1000 includes step 1020 of applying a positive pressure 102 to at least a portion 202 of the workpiece 200. Method 1000 includes step 1030 of machining the workpiece 200 in response to the application of the positive pressure 102.

[0058] In one or more embodiments, Method 1000 includes a step 1006 to change the internal volume 112. The internal volume 112 can be changed by the arrangement of the sides 118 and / or by any combination of using one or more of the volume variable elements 192 and / or volume constant elements 194.

[0059] In one or more embodiments, method 1000 includes the steps of: 1008 applying a casting 134 over at least a portion 202 of a workpiece 200; and 1010 solidifying the casting 134. In one or more embodiments, the casting 134 and a portion of the case 110 form an internal volume 112. In one or more embodiments, the casting 134 is located on the workpiece 200, between the workpiece 200 and the expandable medium 120.

[0060] In one or more embodiments, method 1000 includes the steps of applying an overlay 136 to at least a portion 202 of a workpiece 200 and connecting the overlay 136 to a case 110. In one or more embodiments, the overlay 136 and a portion of the case 110 form an internal volume 112.

[0061] In one or more embodiments, Method 1000 includes step 1016 of connecting the second case 150 to the case 110 such that the internal volume 112 of the case 110 and the second internal volume 152 of the second case 150 are in communication. In such embodiments, Method 1000 includes step 1002 of enclosing at least a second portion 204 of the workpiece 200 in the second internal volume 152 of the second case 150, step 1004 of introducing an expandable medium 120 into the second internal volume 152 between the second case 150 and at least a second portion 204 of the workpiece 200, step 1018 of expanding the expandable medium 120, step 1020 of applying a positive pressure 102 to at least a second portion 204 of the workpiece 200, and step 1030 of processing the workpiece 200 in response to the application of the positive pressure 102.

[0062] In one or more embodiments, method 1000 includes step 1022 of detecting the pressure 104 in the internal volume 112. In one or more embodiments, the pressure 104 is detected and / or monitored using a pressure sensor 162.

[0063] In one or more embodiments, method 1000 includes a step 1024 to control the pressure 104 within the internal volume 112. In one or more embodiments, the pressure 104 is controlled by increasing or decreasing the internal volume 112 of the case 110, for example, by selectively changing the position of one or more of the sides 118 of the case 110. In one or more embodiments, the pressure 104 is controlled by selectively expanding or contracting an expandable medium 120 within the internal volume 112. In one or more embodiments, the pressure 104 is controlled by selectively expanding or contracting a volume-variable element 192, also located within the internal volume 112, and / or by inserting or removing a volume-constant element 194 into or from the internal volume 112.

[0064] In one or more embodiments, the expansion and / or contraction of the expandable medium 120 is selectively controllable. For example, the expandable medium 120 is configured to expand and / or contract selectively or controllably as a way to control the pressure inside the case 110 and / or the pressure applied to the workpiece 200 during processing. In various embodiments, the expansion and / or contraction of the expandable medium 120 can be controlled by any of a variety of methods, such as heating or cooling the expandable medium 120.

[0065] In one or more embodiments, method 1000 includes a step 1026 for detecting the temperature 106 in the internal volume 112. In one or more embodiments, the temperature 106 is detected and / or monitored using a temperature sensor 166.

[0066] In one or more embodiments, method 1000 includes a step 1028 to control the temperature 106 within the internal volume 112. In one or more embodiments, the temperature 106 can be controlled using either a combination of the exothermic and / or endothermic properties of the heater 142 and / or the expandable medium 120.

[0067] In embodiments of System 100 and Method 1000, an expandable material is used for structural bonding and debulking of composite materials, such as secondary bonding, which may or may not involve the use of an adhesive, and includes, for example, bonding of composite materials under pressure (e.g., co-bonding), in which case at least one component of the bonded structure is pre-cured. Furthermore, in embodiments 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 bonded by using an epoxy adhesive or any polymer adhesive (e.g., thermosetting or thermoplastic).

[0068] In one or more embodiments, the processing step 1030 includes a step of curing the workpiece 200. In one or more embodiments, the processing step 1030 includes a step of joining the workpiece 200. In one or more embodiments, the joining step includes or takes the form of co-curing the workpiece 200. In one or more embodiments, the joining step includes or takes the form of co-joining the workpiece 200. In one or more embodiments, the joining step includes or takes the form of secondarily joining the workpiece 200.

[0069] In one or more embodiments, System 100 and Method 1000 achieve co-curing for joining workpieces 200. In such embodiments, the material 210 of the workpiece 200 (e.g., first material 212 and second material 214) includes uncured composite material. In one or more embodiments, this uncured composite material is a thermosetting composite material. In one or more embodiments, this uncured composite material is a plastic composite material. In one or more embodiments, co-curing is achieved without the use of an adhesive. As an example, the workpiece 200 includes a first wet prepreg cloth ply (e.g., first material 212) and a second wet prepreg cloth ply (e.g., second material 214). In one or more embodiments, co-curing is performed within an adhesive (e.g., adhesive film). As an example, the workpiece 200 includes a first wet prepreg cloth ply (e.g., a first material 212), a second wet prepreg cloth ply (e.g., a second material 214), and an adhesive (e.g., a third material) located or positioned between the first and second wet prepreg cloth plies. In one or more co-curing embodiments, the uncured composite material (e.g., a thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature up to the curing temperature of the thermosetting composite material. At the activation temperature, the expandable medium is configured to expand such that the positive pressure 102 reaches or exceeds the curing pressure. In one or more co-curing embodiments, the uncured composite material (e.g., a thermoplastic composite material) has a compaction temperature and a compaction pressure. The expandable medium 120 is configured to expand when its temperature rises to the activation temperature, which is the compaction temperature of the thermoplastic composite material. At the activation temperature, the expandable medium 120 is configured to expand so that the positive pressure 102 reaches the curing pressure.

[0070] In one or more embodiments, System 100 and Method 1000 achieve co-bonding for joining workpieces 200. In such embodiments, at least one of the materials 210 of the workpiece 200 (e.g., first material 212) comprises a cured composite material. At least another of the materials 210 of the workpiece 200 (e.g., second material 214) comprises an uncured composite material. In one or more embodiments, the uncured composite material is a thermosetting composite material. In one or more embodiments, the uncured composite material is a thermoplastic composite material. In one or more embodiments, co-bonding is performed using an adhesive, such as an adhesive film. As an example, the workpiece 200 comprises a pre-cured laminate (e.g., first material 212), a wet prepreg cloth ply (e.g., second material 214), and an adhesive (e.g., third material) located or positioned between the pre-cured laminate and the wet prepreg cloth ply. In one or more co-bonding embodiments, the uncured composite material (e.g., a thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature up to the curing temperature. At the activation temperature, the expandable medium 120 is configured to expand so that the positive pressure 102 reaches the curing pressure. In one or more co-bonding embodiments, the uncured composite material (e.g., a thermoplastic composite material) has a compaction temperature and a compaction pressure. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature up to the compaction temperature. At the activation temperature, the expandable medium is configured to expand so that the positive pressure 102 reaches the compaction pressure.

[0071] In one or more embodiments, System 100 and Method 1000 provide secondary bonding for joining workpieces 200. In such embodiments, the material 210 of the workpiece 200 (e.g., first material 212 and second material 214) includes, but is not limited to, any suitable material or combination of materials, such as metallic materials, metallic alloy materials, ceramic materials, polymer materials, hybrid materials, metal matrix composites, ceramic matrix composites, polymer matrix composites, etc. In one or more embodiments, secondary bonding is performed using 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 212), a second pre-cured laminate or material layer (e.g., second material 214), and an adhesive (e.g., third material) located or positioned between the first and second pre-cured laminates or material layers. In one or more embodiments, the adhesive is located between the first material 212 and the second material 214. In such embodiments, the system 100 enables secondary bonding, co-bonding, or co-curing using the adhesive between the first material 212 and the second material 214. In one or more of the co-curing, co-bonding, and / or secondary bonding embodiments, the adhesive has at least one of a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when the temperature of the expandable medium 120 rises to an activation temperature up to the curing temperature. At the activation temperature, the expandable medium 120 is configured to expand so that the positive pressure 102 reaches the curing pressure. In one or more embodiments, the curing temperature and / or curing pressure of the uncured composite material and the adhesive are at least substantially the same. In one or more embodiments, the curing temperature and / or curing pressure of the uncured composite material and the adhesive are different.

[0072] Referring to Figures 1 and 3-20, the Disclosure also covers, for example, a portable manufacturing kit 300. The following are embodiments of the portable manufacturing kit 300 as described herein. The embodiments of the portable manufacturing kit 300 include a number of elements, features, and components. In one or more embodiments, the portable manufacturing kit 300 is one or more embodiments of System 100 (Figure 1). In one or more embodiments, the portable manufacturing kit 300 is carried out or used in accordance with Method 1000 (Figure 2). Not all elements, features, and / or components described or illustrated in one embodiment are essential in that embodiment. Some or all elements, features, and / or components described or illustrated in one embodiment can be combined in various ways with other embodiments, without requiring the inclusion of other elements, features, and / or components described in those other embodiments, and such combinations do not necessarily have to be explicitly described or illustrated in the embodiments herein.

[0073] As shown in Figures 1 and 3 to 20, in one or more embodiments, the portable manufacturing kit 300 includes a case 110. The case 110 includes or forms an internal volume 112. The case 110 is configured to surround at least a portion 202 of the workpiece 200 to be manufactured. The portable manufacturing kit 300 includes an expandable medium 120. The expandable medium 120 is configured to be introduced into the internal volume 112 between the case 110 and at least the aforementioned portion of the workpiece 200. The expandable medium 120 is configured to expand to apply a positive pressure 102 to at least a portion 202 of the workpiece 200 surrounded by the case 110.

[0074] In one or more embodiments of the portable manufacturing kit 300, the case 110 includes a base 114, a cover 116, and a plurality of side portions 118 extending between the base 114 and the cover 116. In one or more embodiments, the base 114, the cover 116, and the side portions 118 form an internal volume 112. In one or more embodiments, at least one of the side portions 118 is movable relative to the base 114 and the cover 116 so as to selectively change the internal volume 112.

[0075] In one or more embodiments of the portable manufacturing kit 300, at least one of the side portions 118 includes an opening 130. The opening 130 is configured to receive at least a portion 202 of a workpiece 200. In one or more embodiments of the portable manufacturing kit 300, the case 110 includes a cap 132. The cap 132 is configured to cover the opening 130 and to contain the expandable medium 120 within the internal volume 112. In one or more embodiments, the cap 132 is configured to fit a workpiece 200 located within the opening 130.

[0076] In one or more embodiments, the portable manufacturing kit 300 includes a second case 150. The second case 150 includes or forms a second internal volume 152. The second case 150 is configured to be connected to case 110. The second case 150 is configured to surround a second portion 204 of the workpiece 200. In such embodiments, the expandable medium 120 is configured to be introduced into the second internal volume 152 between the second case 150 and at least the second portion 204 of the workpiece 200. The expandable medium 120 is configured to expand to apply a positive pressure 102 to at least the second portion 204 of the workpiece 200 surrounded by the second case 150.

[0077] In one or more embodiments, the portable manufacturing kit 300 includes a casting 134. The casting 134 is configured to be applied over the expandable medium 120 and at least a portion 202 of the workpiece 200 and to solidify. In one or more embodiments, the portable manufacturing kit 300 includes an overlay 136. The overlay 136 is configured to cover the expandable medium 120 and at least a portion 202 of the workpiece 200 and to be connected to the case 110.

[0078] In other embodiments, the portable manufacturing kit 300 includes any one or more of the various elements, features and / or components used in the System 100 or in the implementation of Method 1000. In one or more embodiments, the portable manufacturing kit 300 also includes a mold 148, a heater 142, a battery 144, a solar collector 146, a wrapping element 122, a volume variable element 192, a volume constant element 194, a coal plate 196, a bagging material 198, a temperature sensor 166, a pressure sensor 162, a fastener 138, a shear pin 164, a controller 170, a communication module 172, and at least one or any combination thereof of any other suitable elements, features and / or components.

[0079] In this disclosure, the terms “expandable,” “expanding,” “inflating,” and similar terms refer to the ability to expand, or the possibility or ability to increase in size and / or volume. An expandable material or individual element may, for example, increase in size or volume symmetrically or asymmetrically. If an expandable material is capable of symmetrical expansion, it expands substantially equally along each axis. If an expandable material exhibits asymmetrical expansion, it expands relatively more along the first axis, or along the first and second axes, than along the other axis. In various embodiments, the expandable medium 120 is configured to expand when a predetermined change occurs in the expandable medium 120. This predetermined change is typically a change in the physical or chemical properties of the expandable medium 120, or a combination thereof, and / or any other suitable properties related to the expansion of the expandable medium 120. Unless otherwise specified, expansion of the expandable medium 120 refers to an increase in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. For example, the expandable medium 120 can be configured to expand when its temperature is raised from a low temperature, such as ambient temperature, to a predetermined high temperature (e.g., activation temperature). Therefore, if the manufacturing of the workpiece 200 involves raising the temperature of the workpiece 200, the expandable medium 120 expands within the internal volume 112 during the manufacturing process. During the joining process, the expandable medium 120 (e.g., during or after expansion) applies pressure to the inside of the case 110 and to the workpiece 200.

[0080] 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 may, for example, be able to reduce size or volume symmetrically or asymmetrically. If a shrinkable material is capable of symmetric shrinkage, it shrinks substantially equally along each axis. If a shrinkable material exhibits asymmetric shrinkage, it shrinks relatively more along the first axis, or along the first and second axes, than along the other axes. In various embodiments, the expandable medium 120 is configured to shrink when a predetermined change occurs in the expandable medium 120. This predetermined change is typically a change in the physical or chemical properties of the expandable medium 120, or a combination thereof, and / or any other suitable properties, related to the shrinkage of the expandable medium 120. Unless otherwise specified, contraction of the expandable medium 120 refers to a decrease in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. As an example, the expandable medium 120 can be configured to contract when its temperature is lowered from a high temperature to a predetermined low temperature.

[0081] In one or more embodiments, the expandable medium 120 is selected to exert sufficient pressure to effectively compress the material 210 of the workpiece 200 for proper curing or bonding when it expands within the internal volume 112 of the case 110. Depending on the material 210, a pressurization of less than 1 atmosphere may be sufficient for bonding, while for other materials 210, a pressurization of 1 atmosphere or more may be more effective for bonding. In one or more embodiments, the expandable medium 120 is selected to exert sufficient pressure to allow for the application of pressures that would conventionally require an autoclave (e.g., 1 to 5 atmospheres).

[0082] In one or more embodiments, the expandable medium 120 comprises one or more different types, varieties, or compositions of expandable material (e.g., different types or compositions of expandable pellets). In such embodiments, each type of expandable material is configured to expand and / or contract (e.g., to a predetermined volume) when heated to a predetermined temperature. In one or more embodiments, the compositions of different types of expandable medium 120 (e.g., different types of expandable pellets) can be designed such that a desirable relationship as a function of time exists between the expansion volume of each type and the temperature of each type. In one or more embodiments, the degree of expansion of a given type or composition of expandable medium 120 (e.g., expandable pellets) can be measured and recorded, as well as the force produced by that expansion. This allows the composition to be modified to obtain a desired degree of expansion and expansion force. In this way, the amount and / or composition of the expandable medium 120 to be used can be selected so that expansion and / or contraction within a known sealed volume (e.g., internal volume 112) applies a desired pressure to the workpiece 200 at one or more stages of the manufacturing process.

[0083] The expandable medium 120 can take any suitable form. In one or more embodiments, the expandable medium 120 is added to the case 110 as, for example, pellets, beads, particles, powder, or foam. Alternatively, or in addition to the above, the expandable medium 120 may be added to the case 110 as a solid or semi-solid separate portion, such as a layer of expandable medium 120 that can be placed over a portion 202 of a workpiece 200. The layer of expandable medium 120 can be added by adding individual packaging elements 122 (e.g., bags or pouches) filled with pellets, beads, or other small pieces of expandable medium 120. In Figures 3-5 and 8-19, the expandable medium 120 is depicted as multiple expandable pellets, but this is for illustrative purposes only and should not be interpreted as limiting the structure or composition of the expandable medium 120. In various embodiments, the expandable medium 120 is added to the internal volume 112 of the case 110 in an unexpanded state. As shown in the figure, before and / or during the manufacturing process, the expandable medium 120 is expanded (e.g., its volume is increased) to at least partially fill the internal volume 112, thereby applying a positive pressure 102 directly or indirectly to at least a portion of the surface of the case 110 (or casting 134, or overlay 136) and at least a portion of the surface (e.g., the outer surface) of the workpiece 200. The pressure exerted by the expandable medium 120 as it expands contributes to the compression and consolidation of a portion 202 of the workpiece 200 during processing. In various embodiments, the expandable medium 120 is configured to expand (e.g., to a predetermined volume and / or pressure) when a predetermined change occurs in the attributes 129 of the expandable medium 120 (e.g., in the expanded state). In one or more embodiments, the expandable medium 120 is introduced (e.g., inserted or added) into the internal volume 112 of the case 110 in a non-expanded state. This predetermined change occurs in the attributes 129 of the unexpanded expandable medium 120 while it is inside the internal volume 112. The expandable medium 120 expands in response to the predetermined change that has occurred. The attributes 129 of the expandable medium 120 can be physical and / or chemical attributes.In one or more embodiments, the expandable medium 120 is configured to expand in volume when it interacts with water. For example, the expandable medium 120 is or contains a desiccant that can increase in volume when it absorbs moisture. For example, anhydrous calcium sulfate (anhydrous gypsum) increases in volume by about 61% when it absorbs moisture to form gypsum. In such embodiments, water can be added directly to the expandable medium 120, for example, by adding liquid water or steam inside the case 110. Alternatively, or in addition to this, water or steam can be generated inside the case 110, for example, by a suitable chemical reaction. In one or more embodiments, a predetermined change in the attribute 129 of the expandable medium 120 includes a change in the temperature of the expandable medium 120 and / or a change in the temperature of one or more parts of the expandable medium 120. Therefore, causing a predetermined change in the attribute 129 of the expandable medium 120 may include raising the temperature of a non-expanding expansion element from a low temperature such as ambient temperature (e.g., room temperature) to at least a predetermined temperature higher than the initial temperature or ambient temperature (e.g., a predetermined temperature several degrees higher than ambient temperature that is suitable for causing a predetermined expansion in the expansion element). As a result of this temperature increase, the expansion element undergoes thermal expansion. In one or more embodiments, the expandable medium 120 is a heat-activated expansion element. In such embodiments, the heat-activated expandable element is configured to expand when the temperature of the expandable medium 120 is raised to at least a predetermined temperature. Alternatively, or in addition to this, a predetermined pressure is generated on the workpiece 200 by heating the expandable medium 120 to at least a predetermined temperature to expand the expandable medium 120. Typically, this predetermined pressure is sufficient to sufficiently cure the composite material. In one or more embodiments, the predetermined change occurring in the attribute 129 of the expandable medium 120 is a combination of two or more properties of the expandable medium 120, such as a ratio or product of quantitative values ​​related to the properties of the expandable medium 120, for example, two materials having different coefficients of thermal expansion. In various embodiments, the process of manufacturing the workpiece 200 includes causing a predetermined change in the attribute 129 of the expandable medium 120.In one or more embodiments, the expansion of the expandable medium 120 occurs automatically during the manufacturing process. For example, attribute 129 may be the temperature of the expandable medium 120, and heat applied during the manufacturing process can cause a predetermined change in the temperature of the expandable medium 120. That is, the heat applied to the workpiece 200 during the bonding process raises the temperature of the expandable medium 120 to at least a predetermined temperature associated with a desired volume and / or desired volume increase. One or more properties of the expandable medium 120 can be set so that the expandable medium 120 expands by a desired predetermined amount due to thermal expansion caused by a temperature change in the expandable medium 120 during the manufacturing of the workpiece 200. Alternatively, or in addition to this, further steps may be required to expand the expandable medium 120, in addition to the steps required to cure the workpiece 200. For example, expanding the expandable medium 120 may include applying an electric field, injecting a liquid, gas, and / or other suitable material, and / or causing any other suitable change in the expandable medium 120. In various embodiments, the expandable medium 120 includes any material that is thermally expandable and can expand when it reaches a given temperature. As a specific example, a group of plastic polymers that have the ability to soften when heated are called thermoplastic materials. When heated to a temperature above the glass transition temperature and below the melting point, solid thermoplastic materials soften and become a viscous liquid. In this state, the thermoplastic material 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, the expandable medium 120 containing acrylonitrile butadiene styrene (ABS) polymer can exhibit advantageous physical properties when used in combination with the examples described herein. In one or more examples, the expandable medium 120 (e.g., expandable pellets) may further contain a blowing agent. The blowing agent is selected such that, when heated to at least a predetermined temperature, it forms a plurality of holes, pockets, or voids within the material of the expandable medium 120, thereby increasing the volume of the expandable medium 120. As an example, a suitable blowing agent may be an inert gas impregnated into the expandable medium 120 under pressure. Such a blowing agent may be configured to expand at multiple locations within the expandable medium 120 when the temperature of the expandable medium 120 rises from the ambient temperature or initial temperature to a predetermined high temperature, and the expanded gas forms holes, pockets, or voids within the pellets. The blowing agent may be added to the expandable medium 120 before heating. In examples in which the expandable medium 120 contains a blowing agent, the blowing agent may be any suitable substance capable of producing expansion to a desired degree. The blowing agent may include physical blowing agents such as chlorofluorocarbons, hydrochlorofluorocarbons, hydrocarbons, and liquid CO2. Alternatively, or in addition to these, the blowing agent may include chemical blowing agents selected to react with one or more components of the expandable medium 120, such as 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 embodiments in which the expandable medium 120 contains a blowing agent, the blowing agent may include a foaming agent. In such embodiments, 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 may 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). During the process of manufacturing the workpiece 200, the expandable medium 120 is expanded from a non-expanding state to an expanded state.In one or more embodiments, the expandable medium 120 is configured to expand in response to heat applied during curing or bonding. The expandable medium 120 expands to fill the internal volume 112 of the case 110, and the expansion of the expandable medium 120 applies positive pressure to the workpiece 200. In one or more embodiments, the expandable medium 120 is configured (e.g., formulated) to be at least partially deformable after expansion, during expansion, and / or before expansion. Due to some degree of deformability, the expandable medium 120 can fill small gaps that may exist, for example, between pellets, between pellets and the inner surface of the case 110, and / or between pellets and the workpiece 200. By filling such gaps, the expandable medium 120 can provide the workpiece 200 with a substantially smooth surface. In various embodiments, after a portion 202 of the workpiece 200 has been manufactured, the case 110 can be unsealed or opened as needed, and the expandable medium 120 can be removed. The expandable medium 120 can usually be easily removed after the workpiece 200 has been manufactured. However, in some cases, the expandable medium 120 may remain expanded and densely packed even after the workpiece 200 has been processed and cooled, making removal difficult. In such cases, the expandable medium 120 can be configured to be more easily separated from the workpiece 200 and case 110 by one or more methods. For example, the expandable medium 120 can be configured to change shape and / or size as desired, thereby making removal easier. For instance, the expandable medium 120 can be configured to shrink when cooled, so that after the workpiece 200 has been processed and cooled, the expandable medium 120 shrinks within the internal volume 112, making removal of the expandable medium easier. In one or more embodiments, the expandable medium 120 is modified to minimize sintering (self-adhesion) during heating and expansion. Alternatively, or in addition to this, the expandable medium 120 is configured to minimize adhesion to the surface, such as by coating the expandable pellets with an appropriate agent configured to prevent adhesion and / or promote separation.In one or more embodiments, suitable agents to be added to the expandable medium 120 include lubricants. For example, adding a lubricant to the expandable pellets can reduce adhesion between 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 substantial adhesion between the expandable pellets, the case 110, and / or components of the workpiece 200. Suitable lubricants are liquids, powders, or combinations thereof. It may be included. When added as a powder, suitable lubricants may include nanopowder. Alternatively, or in addition to this, suitable lubricants may include silicon-based materials, fluorinated polymers, or other substantially inert substances. For example, suitable lubricants may include polytetrafluoroethylene (PTFE) powder, PTFE nanopowder, silicone, perfluoropolyether (PFPE), perfluoroalkyl ether (PFAE), perfluoropolyalkyl ether (PFPAE), etc. Such lubricants can be applied to the expansion pellets before they are placed in case 110. Alternatively, or in addition to this, the suitable lubricant can be applied to the expansion pellets while they are placed in case 110. Coating at least some of the expansion pellets with a suitable lubricant may include mixing the lubricant with the pellets and / or pouring the lubricant onto the pellets. In addition, or alternatively, at least some of the expansion pellets can be coated with the desired lubricant and then mixed with the uncoated pellets. In one or more embodiments, crystalline and / or semi-crystalline properties along the outer surface of the expanded pellets can be used to prevent the pellets from sintering with each other. In one or more embodiments, at least some of the expanded pellets are configured to have crystalline regions along the outer surface of the pellets by pretreatment, etc., and therefore, adding the expandable medium 120 involves adding a plurality of expanded pellets having surface regions with increased crystallineity to suppress adhesion between pellets before and / or after the volume expansion of the expanded pellets. In one or more embodiments, the expanded pellets can be used when the outer surface of the pellets exhibits a high degree of crystallinity (for example, when the proportion of the crystalline portion in the volume of the region near the outer surface of each pellet is high). Crystallinity can be induced in the expanded pellets by controlling one or more factors, such as the material composition of the pellets, the manufacturing temperature at which the pellets are heated during manufacturing, the time the pellet temperature is maintained at the manufacturing temperature during manufacturing, the electric and / or magnetic fields applied during manufacturing, the distribution of the foaming agent in the pellets, and the composition and / or concentration of the foaming agent.The outer surface of the expanded pellet can be crystalline before, during, and / or after foaming.

[0084] As shown in Figures 1 and 11, in one or more embodiments, the system 100 includes additional elements configured to change or relieve the pressure applied by the expandable medium 120, which include, for example, one or more volume-constant elements 194 (e.g., substantially incompressible elements) and / or one or more volume-variable elements 192 (e.g., expandable and contractible elements), the volume-variable elements being able to increase in volume before or during manufacturing and / or decrease in volume after manufacturing.

[0085] In this disclosure, the term “hard” means a solid, rigid, and / or non-expandable state. In some examples, the term “hard” includes rigidity. Similarly, in this disclosure, “solidify,” “solidify,” and similar terms mean that a casting or casting material can change from a state in which it is flexible, moldable, pliable, fluid, conformable, and / or expandable to a solid, rigid, and / or non-expandable state. In some examples, a casting or casting material is also rigid when solidified.

[0086] In one or more embodiments, the casting 134 comprises a casting material. In one or more embodiments, the casting material is configured to solidify when a predetermined change occurs in the attributes of the casting material. For example, the casting material may solidify in response to changes in temperature, time, chemical composition, pressure, or other attributes of the material of the casting 134. As an example, the casting 134 is applied or formed on a portion 202 of the workpiece 200 before the addition of the expandable medium 120. As another example, the casting 134 is applied or formed on a portion 202 of the workpiece 200 and the expandable medium 120 after the addition of the expandable medium 120. In one or more embodiments, the casting 134 is configured to solidify before or during the manufacturing process. The casting 134 may be selected to be heat resistant and easily removable after the workpiece 200 has hardened. Examples of casting materials include, but are not limited to, gypsum, cement, fiber (e.g., glass fiber) reinforced plastics, polyvinyl chloride, epoxy, rubber, thermosetting or thermoplastic resins, composite materials, and ceramics. In one or more embodiments, the casting material is heat reflective or includes a heat reflective material, liner, or layer. For example, the casting 134 may include at least one heat reflective film as one of the layers in the cast. The heat reflective film may be the innermost layer, intermediate layer, or middle layer, and / or outermost layer of the cast. The heat reflectivity of the casting 134 promotes the heating of the expandable medium 120 during the manufacturing process, thereby inducing the expansion of the expandable medium 120.

[0087]

[0088] Next, referring to Figures 21 and 22, embodiments of the System 100, Method 1000, and Portable Manufacturing Kit 300 described herein may relate to, or be used in connection with, an aircraft 1200 as schematically shown in Figure 21, and an aerospace manufacturing and commissioning method 1100 as shown in the flowchart of Figure 22. As an example, the aircraft 1200 and / or the manufacturing and commissioning method 1100 may include, or utilize, components, parts, or workpieces manufactured or repaired using the System 100 or Kit 300 and / or in accordance with Method 1000.

[0089] As shown in Figure 21, in one or more embodiments, the aircraft 1200 can be any aerospace vehicle or platform. In one or more embodiments, the aircraft 1200 includes an airframe 1202 having an interior 1206. The aircraft 1200 includes a number of onboard systems 1204 (e.g., higher-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 embodiments, the onboard systems 1204 also include one or more control systems connected to the airframe 1202 of the aircraft 1200. In yet another embodiment, the onboard systems 1204 also include one or more other systems 1216, examples of which include, but are not limited to, communication systems, avionics systems, software distribution systems, network communication systems, passenger information / entertainment systems, guidance systems, radar systems, and weapon systems. The aircraft 1200 may have any number of components or parts manufactured or repaired using the system 100 or the portable manufacturing kit 300 and / or according to method 1000.

[0090] As shown in Figure 22, prior to the start of production of aircraft 1200, the manufacturing and commissioning method 1100 includes specification and design 1102 of aircraft 1200 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 the commissioning period 1112. Periodic maintenance and upkeep 1114 includes improvements, reconfigurations, and modifications of one or more systems of aircraft 1200.

[0091] Each step of the manufacturing and operational method 1100 shown in Figure 22 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). System integrators include, but are not limited to, any number of aircraft manufacturers and major system subcontractors. Third parties include, but are not limited to, any number of sellers, subcontractors, and suppliers. Operators include, for example, airlines, leasing companies, military organizations, service organizations, etc.

[0092] Embodiments of the system 100, method 1000, and portable manufacturing kit 300 illustrated and described herein may be employed in any one or more steps of the manufacturing and commissioning method 1100 shown in the flowchart of Figure 22. For example, components of the aircraft 1200 can be manufactured using the system 100 or kit 300 and / or according to method 1000 as part of the manufacturing of parts and subassemblies 1106 and / or system integration 1108. Furthermore, components of the aircraft 1200 can be manufactured and / or repaired using the system 100 or kit 300 and / or according to method 1000 during the commissioning of the aircraft 1200 1112. In addition, components of the aircraft 1200 can be manufactured and / or repaired using the system 100 or kit 300 and / or according to method 1000 during system integration 1108 and certification and delivery 1110. Similarly, components of the aircraft 1200 can be manufactured and / or repaired during maintenance and servicing 1114 using the system 100 or kit 300 and / or in accordance with method 1000.

[0093] 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. Similar 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, and several elements may be referred to collectively as an element and referred to by the same reference numeral. Furthermore, features, elements, components, or processes described in the singular form herein do not preclude multiple features, elements, components, or processes unless otherwise specified.

[0094] Exemplary and non-exclusive examples of the gist of this disclosure, including those described in the claims and those not described, are presented above. In this specification, “Example” means that one or more functions, structures, elements, components, features, and / or operating steps described in relation to that example are included in at least one aspect, embodiment, and / or embodiment of the gist of this disclosure. Accordingly, “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.

[0095] 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, “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.

[0096] Unless otherwise indicated, terms such as “first,” “second,” and “third” are used herein solely as identifiers and do not impose any requirements regarding order, position, or hierarchy on the elements referred to by these terms. 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.

[0097] In this specification, when the phrase "at least one" is used with respect to an enumeration of elements, it means that one or more of the enumerated elements may be used in various combinations, and that only one of the enumerated elements may be required. For example, "at least one of elements A, B, and C" includes, but is not limited to, the case of element A, or the case of elements A and B. This example also includes the case of 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 suitable combination. In this specification, the phrase "and / or," and the symbol " / ," include any and all combinations of one or more of the elements enumerated in relation thereto.

[0098] In this disclosure, the terms “connected,” “linked,” and similar terms refer to two or more elements being related to each other by joining, linking, fastening, attaching, connecting, communicating, or otherwise (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various embodiments, these elements may be related directly or indirectly. For example, element A may be directly related to element B. For another example, element A may be indirectly related to element B, for example, via another element C. Not all possible connections between elements in this disclosure are necessarily shown. Therefore, connections other than those illustrated may also exist.

[0099] In this specification, the term "approximately" refers to a state that is not exactly the same as the described state, but is close to it and capable of performing the desired function or achieving the desired result. For example, "approximately" refers to 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 the same as the described state. Also in this specification, the term "substantially" refers to a state that is essentially the same as the described state and capable of performing the desired function or achieving the desired result.

[0100] Figures 1 and 3-21, referenced above, represent functional elements, features, or components and do not necessarily suggest a specific structure. Therefore, modifications, additions, and / or omissions may be made to the illustrated structures. Furthermore, as those skilled in the art will know, not all elements, features, and / or components shown and described in Figures 1 and 3-21 are necessarily included in all embodiments, nor are all elements, features, and / or components described herein shown in every exemplary embodiment. Therefore, some of the elements, features, and / or components shown and described in Figures 1 and 3-21 can be combined in various ways without including other features shown in Figures 1 and 3-21 or other drawings and / or accompanying disclosures, and such combinations do not need to be explicitly shown herein. Similarly, additional features, not limited to the presented embodiments, may 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 3-21 are not intended to suggest any structural limitations on the exemplary embodiments. Rather, they show one exemplary structure, which should be understood to be modifiable as appropriate. Accordingly, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, elements, features, and / or components that serve similar purposes, or at least substantially similar purposes, are denoted by the same reference numerals in Figures 1 and 3-21, respectively, and such elements, features, and / or components may not be described in detail herein with reference to Figures 1 and 3-21. Similarly, not all elements, features, and / or components are denoted by reference numerals in Figures 1 and 3-21, but the associated reference numerals may be used herein for consistency.

[0101] In Figures 2 and 22 referenced above, the blocks represent, for example, operations, processes, and / or parts thereof, and the lines connecting the various blocks do not suggest a specific order or dependency between these operations or parts thereof. Furthermore, not all dependencies between the various operations in the disclosure are necessarily shown. Figures 2 and 22, and any accompanying disclosures describing the operations in the methods described herein, do not necessarily determine the order in which these operations are performed. Rather, while they suggest one exemplary order, it should be understood that the order of these operations may be changed as appropriate. Therefore, modifications, additions, and / or omissions may be made to the exemplary operations, and some operations may be performed in different orders or simultaneously. Also, as will be apparent to those skilled in the art, it is not necessarily required to perform all of the operations described.

[0102] Furthermore, references to features, advantages, or similar terms throughout this specification do not imply that all features and advantages that may be realized by the embodiments disclosed herein should or are included in any one of the embodiments. Rather, descriptions of features and advantages mean that a particular feature, advantage, or characteristic described in relation to an embodiment is included in at least one embodiment. Thus, descriptions of features, advantages, and similar terms used in this disclosure may, but not necessarily, refer to the same embodiment.

[0103] The features, advantages, and characteristics described in one embodiment can be incorporated in one or more other embodiments in any preferred manner. Those skilled in the art will see that various embodiments described herein can be implemented without having one or more of the specific features or advantages of a particular embodiment. Also, in other cases, additional features and advantages not present in all embodiments may be recognized in a particular embodiment. Furthermore, while various embodiments of System 100, Method 1000, and Portable Manufacturing Kit 300 have been illustrated and described, those skilled in the art will be able to conceive of modifications by reading this specification. This application includes such modifications and is limited only by the claims.

Claims

1. A system for portable manufacturing, A case that includes an internal volume and is configured to enclose at least a portion of the workpiece being manufactured, A system comprising: an expandable medium disposed within the internal volume between the case and at least the portion of the workpiece, wherein the expandable medium is configured to expand within the case such that it exerts positive pressure on at least the portion of the workpiece surrounded by the case.

2. At least some of the aforementioned cases are, Is it hard? Is it flexible and non-expandable? The system according to claim 1, wherein it is either flexible and expandable.

3. The aforementioned case is, base, Cover, and, The present invention further includes a plurality of side portions extending between the base and the cover, The base, the cover, and the side portion form the internal volume. The cover is movable between an open state and a closed state relative to the base. The system according to claim 1, wherein the case comprises a fastener configured to fasten the base and the cover together.

4. At least one of the aforementioned side portions includes an opening, The opening is configured to receive at least a portion of the workpiece, The case further includes a cap configured to cover the opening and to restrain the expandable medium within the internal volume, The system according to claim 3, wherein the cap is configured to fit the workpiece located within the opening.

5. The system according to claim 3, wherein at least one of the side portions is movable relative to the base and the cover in order to selectively change the internal volume.

6. It further includes a second case which includes a second internal volume and is connected to the case and configured to surround a second portion of the workpiece, The expandable medium is further disposed within the second internal volume between the second case and the second portion of the workpiece. The system according to claim 3, wherein a part of the case and a second part of the second case are removable so as to connect the internal volume and the second internal volume.

7. A casting configured to be applied and solidified on the expandable medium and at least a portion of the workpiece, wherein the casting and a portion of the case form the internal volume, and the expandable medium is disposed within the internal volume between the casting and at least a portion of the workpiece. An overlay configured to cover at least a portion of the expandable medium and the workpiece and to be connected to the case, wherein the overlay and the portion of the case form the internal volume, and the expandable medium is disposed within the internal volume between the overlay and at least a portion of the workpiece. A mold configured to be located within the internal volume and to support at least a portion of the workpiece, A wrapping element configured to surround at least a portion of the expandable medium and positioned within the internal volume between the case and at least a portion of the workpiece, A volume-variable element disposed within the internal volume between the case and at least a portion of the workpiece, A volume-constant element disposed within the internal volume between the case and at least a portion of the workpiece, A coal plate is disposed within the internal volume between the expandable medium and at least a portion of the workpiece, Bagging material placed on at least a portion of the workpiece, The system according to claim 1, further comprising at least one of the following.

8. The system according to claim 1, further comprising an activating element configured to initiate the expansion or contraction of the expandable medium within the internal volume.

9. A pressure sensor configured to detect the pressure within the internal volume, A shear pin configured to break when the pressure within the internal volume exceeds a predetermined threshold, Under the condition that at least a part of the case is heat reflective, a heater in a state of thermal conductivity with the expandable medium, A temperature sensor configured to detect the temperature of at least one of the following: the expandable medium, the workpiece, and the internal volume. A battery configured to store electricity, A solar collector configured to generate electricity, and A communication module configured to transmit data representing at least one of the pressure and temperature conditions within the internal volume, The system according to claim 1, further comprising at least one of the following.

10. The expandable medium is configured to expand to an expanded volume in response to a first predetermined change occurring in the attributes of the expandable medium. The system according to claim 1, wherein the expandable medium is configured to contract to a contracted volume in response to a second predetermined change occurring in the attributes of the expandable medium.

11. The aforementioned expandable medium is Is it generating heat during expansion? The system according to claim 1, wherein it is either endothermic during expansion or otherwise.

12. A method for manufacturing a workpiece, Enclosing at least a portion of the workpiece within the internal volume of the case, Introducing an expandable medium into the internal volume between the case and at least a portion of the workpiece, To expand the aforementioned expandable medium, Applying positive pressure to at least a portion of the workpiece, and Processing the workpiece in response to the application of the aforementioned positive pressure, Methods that include...

13. Changing the aforementioned internal volume, Casting is performed on at least the portion of the workpiece such that the casting and the portion of the case form the internal volume, and the casting is solidified, and Applying an overlay to at least the portion of the workpiece and connecting the overlay to the case such that the overlay and the portion of the case form the internal volume, The method according to claim 12, further comprising one of the following.

14. Connecting the second case to the first case such that the internal volume of the first case and the second internal volume of the second case are in communication with each other. To enclose at least a second portion of the workpiece within the second internal volume of the second case, Introducing the expandable medium into the second internal volume between the second case and at least the second portion of the workpiece, To expand the aforementioned expandable medium, Applying positive pressure to at least the second portion of the workpiece, and Processing the workpiece in response to the application of the aforementioned positive pressure, The method according to claim 12, further comprising:

15. To detect the pressure within the aforementioned internal volume, Controlling the pressure within the internal volume, To detect the temperature within the internal volume, and, To control the temperature within the internal volume, The method according to claim 12, further comprising at least one of the following.

16. Processing includes one of joining the workpieces or hardening the workpieces. Joining means co-hardening the workpiece, co-joining the workpiece, or secondarily joining the workpiece. The method according to claim 12, comprising one of the following.

17. A case that includes an internal volume and is configured to enclose at least a portion of the workpiece being manufactured, A portable manufacturing kit comprising an expandable medium, The expandable medium is configured to be introduced into the internal volume between the case and at least a portion of the workpiece, A portable manufacturing kit, wherein the expandable medium is configured to expand in order to apply positive pressure to at least a portion of the workpiece enclosed by the case.

18. The aforementioned case is, base, Cover, and, The present invention further includes a plurality of side portions extending between the base and the cover, The base, the cover, and the side portion form the internal volume. At least one of the side portions is movable relative to the base and the cover in order to selectively change the internal volume. At least one of the aforementioned side portions includes an opening, The opening is configured to receive at least a portion of the workpiece, The case further includes a cap configured to cover the opening and to restrain the expandable medium within the internal volume, The portable manufacturing kit according to claim 17, wherein the cap is configured to fit the workpiece located within the opening.

19. It further includes a second case which includes a second internal volume and is connected to the case and configured to surround a second portion of the workpiece, The expandable medium is configured to be introduced into the second internal volume between the second case and at least the second portion of the workpiece, The portable manufacturing kit according to claim 18, wherein the expandable medium is configured to expand in order to apply positive pressure to at least the second portion of the workpiece surrounded by the second case.

20. A casting configured to be applied to and solidified on the expandable medium and at least a portion of the workpiece, An overlay configured to cover at least a portion of the expandable medium and the workpiece and to be connected to the case, A mold configured to be located within the internal volume and to support at least a portion of the workpiece, Bagging material placed on at least a portion of the workpiece, A coal plate is placed in the internal volume between the expandable medium and at least a portion of the workpiece. Volume variable element, Volume-invariant elements, An activation element configured to initiate the expansion or contraction of the expandable medium within the internal volume, A wrapping element configured to surround the aforementioned expandable medium, A communication module configured to transmit data representing at least one of the pressure and temperature conditions within the internal volume, A heater in a state of thermal conductivity with the aforementioned expandable medium, A pressure sensor configured to detect the pressure within the internal volume, A temperature sensor configured to detect the temperature of at least one of the following: the expandable medium, the workpiece, and the internal volume. A battery configured to store electricity, and A solar collector configured to generate electricity, The portable manufacturing kit according to claim 17, further comprising at least one of the following.

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