Method and apparatus for fabricating composite fuselage structures

Abstract

To provide a method for fabricating a composite fuselage structure.SOLUTION: A stack body (112) is assembled from a thermoplastic braided outer plate and a plurality of thermoplastic braided members. The stack body is placed between an inner tool (108) and an outer tool (110). The inner tool, the stack body, and the outer tool are held together in place using a member holding part (117). The inner tool, the stack body, the outer tool, and the member holding part form a consolidation assembly (104). By heating the consolidation assembly, the composite structure is fabricated.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates generally to composite manufacturing, and more particularly to methods and apparatus for making composite fuselage structures incorporating fuselage skins and fuselage stringers made from overbraided material. [Background technology]

[0002] Many types of aircraft structures can be fabricated using composite materials. Currently, many aircraft structures are fabricated using thermosetting composite materials. However, large, three-dimensional aircraft structures, such as fuselage barrels, are not easily fabricated using thermosetting composite materials (e.g., thermosetting resins). In addition, the process of fabricating such structures using thermosetting composite materials can be excessively time-consuming and costly.

[0003] For example, the process of fabricating a fuselage barrel using thermosetting composite materials may require significant manufacturing resources (e.g., production equipment) and processing tools. In addition, traditional methods of using autoclaves to cure thermosetting composite materials to fabricate a fuselage barrel structure may take too long to meet the required production rates. Meeting production rate requirements may require significant investments in capital, supplies, equipment, or a combination thereof.

[0004] Therefore, there is a need for a method and apparatus that takes into account at least some of the above-mentioned problems, as well as other potential problems. Summary of the Invention

[0005] In one exemplary embodiment, a method for producing a composite structure is provided. A stack is assembled that includes a thermoplastic braided skin and a plurality of thermoplastic braided members. The stack is placed between an inner tool and an outer tool. The inner tool, the stack, and the outer tool are held together in position using a material constraint. The inner tool, the stack, the outer tool, and the material constraint form a consolidation assembly. The consolidation assembly is heated to produce the composite structure.

[0006] In another exemplary embodiment, a method is provided for producing a composite fuselage structure. Expanding an inner casing and a number of inner stringer casings in a stack tensions fibers in a thermoplastic braided skin and a number of thermoplastic braided members. Heating the stack melts the thermoplastic braided skin and the number of thermoplastic braided members. While the thermoplastic braided skin and the number of thermoplastic braided members are in a molten state, the thermoplastic braided skin and the number of thermoplastic braided members are bonded together. Cooling the stack produces the composite fuselage structure with the thermoplastic braided skin and the number of thermoplastic braided members integrated together.

[0007] In yet another exemplary embodiment, an apparatus is provided that includes an inner tool, a first smart susceptor, a stack, a second smart susceptor, an outer tool, and a member restraint. The first smart susceptor is disposed about the inner tool. The stack is disposed about the first smart susceptor and combines the thermoplastic braided skin and a plurality of thermoplastic braided members. The second smart susceptor is disposed about the stack. The outer tool is disposed about the second smart susceptor. The member restraint is used to hold the inner tool, the first smart susceptor, the stack, the second smart susceptor, and the outer tool in place.

[0008] In one aspect of the disclosure, a method for producing a composite structure (101) is provided, comprising assembling (2202) a stack (112) including a thermoplastic braided skin (210) and a plurality of thermoplastic braided members (206), placing (2204) the stack (112) between an inner tool (108) and an outer tool (110), holding the inner tool (108), the stack (112), and the outer tool (110) together in position using a member restraint (117), assembling (2206) a consolidation assembly (104) including the inner tool (108), the stack (112), the outer tool (110), and the member restraint (117), and heating the consolidation assembly (104) to produce the composite structure (101).

[0009] In the method, when assembling (2202) the stack body (112), the stack body (112) is assembled by combining an inner casing (202) having a plurality of recesses (216), a plurality of backing plates (204) inserted into the plurality of recesses (216), a plurality of thermoplastic braided members (206), a plurality of stringer inner casings (208), and a thermoplastic braided outer panel (210).

[0010] Advantageously, the method includes heating (2208) the consolidation mass (104) by inductively heating the consolidation mass (104) to crimp and mold the plurality of thermoplastic braided members (206) to the thermoplastic braided skin (210) to create an integrated composite structure (101).

[0011] Preferably, in the method, when heating (2208) the consolidation assembly (104), a first smart susceptor (114) located between the inner tool (108) and the stack body (112) and a second smart susceptor (115) located between the outer tool (110) and the stack body (112) are inductively heated to press-form the plurality of thermoplastic braided members (206) onto the thermoplastic braided outer plate (210).

[0012] The method preferably further includes passing a plurality of pressurized tubes (238) through the plurality of stringer enclosures (208).

[0013] The method preferably further includes securing (1722) the pressurized tubes (238) within the stringer enclosures (208) using plugs (106) disposed at ends of the stack (112).

[0014] Preferably, in the method, when assembling the stack (112), the inner tool (108) is supported by a support structure (116), a first smart susceptor (114) is positioned (1602) around the inner tool (108), and an inner container (202) is positioned (1702) around the first smart susceptor (114).

[0015] Preferably, in the method, when assembling (2202) the stack body (112), a plurality of backing plates (204) are placed (1604) into a plurality of recesses (216) of the inner container (202), wherein each of the plurality of backing plates (204) is made of an iron-nickel alloy.

[0016] Preferably, in the method, assembling (2202) the stack (112) further includes placing (1606) the plurality of thermoplastic braided members (206) on the plurality of backing plates (204), wherein a shape of a given thermoplastic braided member of the plurality of thermoplastic braided members (206) is substantially the same as a shape of a backing plate of the plurality of backing plates (204) on which the given thermoplastic braided member is placed.

[0017] Preferably, in the method, when assembling (2202) the stack (112), a plurality of stringer encapsulations (208) are placed (1608) on the plurality of thermoplastic braided members (206) and the thermoplastic braided skin (210) is placed around the plurality of stringer encapsulations (208) and the plurality of thermoplastic braided members (206) to complete (1610) the stack (112), where the thermoplastic braided skin (210) contacts end regions of the plurality of thermoplastic braided members (206).

[0018] The method preferably further includes positioning (1712) a second smart susceptor (115) around the thermoplastic braided skin (210) and positioning (1714) the outer tool (110) around the second smart susceptor (115), wherein the inner tool (108), the first smart susceptor (114), the stack (112), the second smart susceptor (115), and the outer tool (110) integrally form at least a portion of the consolidation assembly (104).

[0019] In the method, preferably, a first end (126) of the stack body (112) and a second end (128) of the stack body (112) are plugged (1722) using a plurality of plugs (106), wherein a first plug (1006) among the plurality of plugs (106) used in the first end (126) of the stack body (112) and a second plug (1008) among the plurality of plugs (106) used in the second end (128) of the stack body (112) each include a plug portion (1100, 1106), an insulating layer (1102, 1108), and a susceptor connection portion (1104, 1110).

[0020] The method preferably further includes securing (1724) an end tool (105) to the plurality of plugs (106) in preparation for crimping and molding the plurality of thermoplastic braided members (206) to the thermoplastic braided skin (210).

[0021] The method preferably further includes pressurizing the casing (202) and the plurality of stringer casings (208) in the stack (112) to substantially the same pressure while crimping and molding the plurality of thermoplastic braided members (206) to the thermoplastic braided skin (210).

[0022] The method preferably further includes providing mechanical strength and rigidity to the thermoplastic braided members (206) by a plurality of backing plates (204) in the stack (112) during compression molding of the thermoplastic braided members (206) to the thermoplastic braided skin (210).

[0023] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0024] In one aspect of the present disclosure, a method for making a composite fuselage structure (102) is provided. The method includes expanding the inner casing (202) and the plurality of stringer inner casings (208) in the stack (112) to tension (2102) the fibers in the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206), heating the stack (112) to melt (2104) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206), bonding (2106) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) while the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) are in a molten state, and cooling the stack (112) to integrate the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) to create the composite fuselage structure (102) (2108).

[0025] Advantageously, the composite fuselage structure (102) may be constructed by the methods described above.

[0026] In one aspect of the present disclosure, an apparatus is provided that includes an inner tool (108), a first smart susceptor (114) arranged around the inner tool (108), a stack body (112) arranged around the first smart susceptor (114), the stack body (112) combining a thermoplastic braided outer plate (210) and a plurality of thermoplastic braided members (206), a second smart susceptor (115) arranged around the stack body (112), an outer tool (110) arranged around the second smart susceptor (115), and a member restraint portion (117) that holds the inner tool (108), the first smart susceptor (114), the stack body (112), the second smart susceptor (115), and the outer tool (110) in a predetermined position.

[0027] Advantageously, the stack (112) further includes a plurality of backing plates (204), each of which imparts a predetermined contoured surface and stiffness to a corresponding one of the plurality of thermoplastic braided members (206).

[0028] Preferably, the apparatus further includes a plurality of pressurization tubes (238) passing through a plurality of stringer encapsulants (208) in the stack (112), and a pressurization tube (240) passing through an encapsulant (202) in the stack (112).

[0029] A composite aircraft barrel (102) can be made using the apparatus described above.

[0030] In one aspect of the present disclosure, a method for making a composite structure (101) is provided. The method includes holding (2002) the inner tool (108), the stack (112), and the outer tool (110) together in a predetermined position using a member restraint (117), pressurizing the inner casing (202) and the multiple stringer inner casings (208) in the stack (112) to expand the inner casing (202) and the multiple stringer inner casings (208), thereby pressing (2004) a thermoplastic braided skin panel (210) and the multiple thermoplastic braided members (206) in the stack (112) against each other, and forming (2006) the thermoplastic braided skin panel (210) and the multiple thermoplastic braided members (206) together while the inner casing (202) and the multiple stringer inner casings (208) are pressurized.

[0031] As an advantage, in the method, when integrally molding (2006) the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206), the first smart susceptor (114) and the second smart susceptor (115) in the stack body (112) are inductively heated to melt the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206), thereby bonding the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206).

[0032] Preferably, in the method, when inductively heating the first smart susceptor (114) and the second smart susceptor (115), a first induction coil (118) embedded in the inner tool (108) and a second induction coil (120) embedded in the outer tool (110) are used to generate magnetic energy, and the first smart susceptor (114) and the second smart susceptor (115) are used to convert the magnetic energy into thermal energy.

[0033] Preferably, in the method, when pressurizing (2004) the casing (202) and the plurality of stringer casings (208) in the stack (112), the plurality of stringer casings (208) are pressurized using inert gas flowing through a plurality of pressurization tubes (238) passing through the plurality of stringer casings (208).

[0034] Preferably, in the method, when pressurizing (2004) the inner casing (202) and the plurality of stringer inner casings (208) in the stack (112), the inner casing (202) is pressurized using inert gas flowing through a pressurization tube passing through the inner casing (202).

[0035] The method preferably further includes supporting each of the plurality of thermoplastic braided members (206) by a predetermined contoured surface defined by a corresponding one of the plurality of backing plates (204) in the stack (112) during induction heating.

[0036] The method preferably further includes cooling (2108) the stack (112) to bond the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) together to create an integrated composite structure (101).

[0037] The method preferably further comprises securing (1722) the first end (126) and second end (128) of the stack (112) with a plurality of plugs to inhibit longitudinal expansion of the encapsulation body (202) or the plurality of stringer encapsulation bodies (208) during induction heating.

[0038] The method preferably further includes assembling (2202, 2204) the stack body (112) on the inner tool (108), securing (2204) the outer tool (110) around the stack body (112), and applying a compressive load (2206) to the inner tool (108) while assembling the stack body (112) on the inner tool (108) and securing the outer tool (110) around the stack body (112).

[0039] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0040] In one aspect of the present disclosure, an apparatus is provided that includes an inner casing (202) having a plurality of recesses (212), a plurality of backing plates (204) disposed in the plurality of recesses (212), a plurality of thermoplastic braided members (206) disposed on the plurality of backing plates (204), a plurality of stringer inner casings (208) disposed on the plurality of thermoplastic braided members (206), and a thermoplastic braided outer panel (210) disposed on the plurality of stringer inner casings (208) and the plurality of thermoplastic braided members (206).

[0041] Advantageously, a given one of said plurality of caul plates (204) comprises an iron-nickel alloy.

[0042] Preferably, the iron-nickel alloy is an Invar alloy containing about 40% to about 43% nickel.

[0043] Preferably, the first coefficient of thermal expansion (227) of the plurality of backing plates (204) is sufficiently close to a second coefficient of thermal expansion (237) of the plurality of thermoplastic braided members (206).

[0044] Preferably, the inner casing (202), the plurality of backing plates (204), the plurality of thermoplastic braided members (206), the plurality of stringer inner casings (208), and the thermoplastic braided outer panel (210) form a stack (112).

[0045] Preferably, the stack body (112) is disposed between a first smart susceptor (114) attached to an inner tool (108) and a second smart susceptor (115) attached to an outer tool (110), and the thermoplastic braided outer panel (210) is crimped and molded with the plurality of thermoplastic braided members (206) by induction heating via the first smart susceptor (114) and the second smart susceptor (115).

[0046] Preferably, the inner tool (108) has a first induction coil (118) embedded therein and the outer tool (110) has a second induction coil (120) embedded therein.

[0047] Preferably, the apparatus further includes a plurality of plugs (106) plugging a first end (126) of the stack body (112) and a second end (128) of the stack body (112).

[0048] Preferably, a first plug (1006) of the plurality of plugs (106) and a second plug (1008) of the plurality of plugs (106) each include a plug portion (1100, 1106) through which a pressurized tube (1112) passing through the plurality of stringer inner bodies (208) is inserted, an insulating layer (1102, 1108), and a susceptor connection portion (1104, 1110).

[0049] Preferably, the susceptor connections (1104, 1110) are water cooled.

[0050] Preferably, the apparatus further includes a plurality of pressurized tubes (238) passing through the plurality of stringer enclosures (208).

[0051] The above-described apparatus may be used to provide a method for making a composite aircraft barrel (102).

[0052] In one embodiment of the present disclosure, a system (103) is provided, which includes an inner tool (108) made of a dielectric material, the inner tool (108) having a first induction coil (118) embedded therein, an outer tool (110) made of the dielectric material, the outer tool (110) having a shape and size surrounding the inner tool (108) and a first smart susceptor (114) attached to the inner tool (108) and a second smart susceptor (115) attached to the outer tool (110). When a stack (112) disposed between the inner tool (108) and the outer tool (110) is inductively heated using the first induction coil (118) and the second induction coil (120), both the first smart susceptor (114) and the second smart susceptor (115) promote heat dispersion and heat uniformity.

[0053] The composite fuselage structure (102) may be fabricated using the system (103) described above.

[0054] In one embodiment of the present disclosure, a system (103) is provided that includes an inner tool (108), a first smart susceptor (114) disposed around the inner tool (108), and a stack body (112) disposed around the first smart susceptor (114). The stack (112) includes an inner casing (202) having a plurality of recesses (212), a plurality of backing plates (204) disposed in the plurality of recesses (212), a plurality of thermoplastic braided members (206) disposed on the plurality of backing plates (204), a plurality of stringer inner casings (208) disposed in contact with the plurality of thermoplastic braided members (206), a thermoplastic braided skin (210) disposed on the plurality of stringer inner casings (208) and the plurality of thermoplastic braided members (206), the thermoplastic braided skin (210) disposed to sandwich each of the plurality of stringer inner casings (208) between a corresponding one of the plurality of thermoplastic braided members (206), a second smart susceptor (115) disposed around the stack (112), and an outer tool (110) disposed around the second smart susceptor (115).

[0055] Advantageously, the system (103) further includes a plurality of plugs (106) plugging the first end (126) and the second end (128) of the stack (112).

[0056] Preferably, the inner tool (108) has a first induction coil (118) embedded therein and the outer tool (110) has a second induction coil (120) embedded therein, and the system further includes a plurality of connecting devices (107) for connecting the first induction coil (118) and the second induction coil (120).

[0057] Preferably, the system (103) further includes an end tool (105) for positioning and securing the plurality of plugs (106).

[0058] A composite aircraft barrel (102) may be fabricated using the system (103) described above.

[0059] In one aspect of the disclosure, a method of making a composite structure (101) is provided that applies a force to a plurality of thermoplastic braided members (206) and a thermoplastic braided skin (210) by expanding a plurality of stringer encapsulations (208) in a stack (112), constraining the stack (112) with a dielectric material having a non-dielectric material embedded therein during expansion of the plurality of stringer encapsulations (208), and constraining the non-dielectric material with the dielectric material during expansion of the plurality of stringer encapsulations (208).

[0060] Advantageously, the method further includes assembling the stack (112) including the inner casing (202), the plurality of stringer inner casings (208), the plurality of thermoplastic braided members (206), and the thermoplastic braided skin (210), and placing the stack (112) between an inner tool (108) and an outer tool (110), each including the dielectric material and the non-dielectric material.

[0061] Preferably, in the method, the expanding of the plurality of stringer encapsulations (208) in the stack (112) includes heating the plurality of stringer encapsulations (208).

[0062] Preferably, in the method, when expanding the plurality of stringer encapsulants (208) in the stack (112), the plurality of stringer encapsulants (208) are pressurized by inert gas flowing through a plurality of pressurization tubes to the plurality of stringer encapsulants (208).

[0063] In the method, preferably, the stack body (112) is restrained by pressing the stack body (112) against an outer tool (110) containing the dielectric material, wherein the dielectric material is a ceramic material and the non-dielectric material embedded in the dielectric material is a plurality of induction coils.

[0064] Preferably, in the method, when expanding the plurality of stringer encapsulations (208) in the stack (112), the plurality of stringer encapsulations (208) are expanded, and the expansion applies tension to the plurality of thermoplastic braided members (206).

[0065] Preferably, in the method, when the plurality of stringer encapsulations (208) in the stack (112) are expanded, the plurality of stringer encapsulations (208) are expanded to resist a compressive load on the plurality of thermoplastic braided members (206).

[0066] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0067] In one aspect of the disclosure, a method is provided for making a composite structure (101) by co-molding (2304) a plurality of crimp-molded thermoplastic braided preforms (206, 210) in a circumferentially restrained arc-shaped stack (112) and tensioning (2306) the fibers of the plurality of crimp-molded thermoplastic braided preforms (206, 210) during co-molding.

[0068] Advantageously, in the method, when the plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded (2304), the plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded by heating the arc-shaped stack (112).

[0069] Preferably, in the method, when the stack body (112) is heated, the arc-shaped stack body (112) is inductively heated to integrally mold the plurality of crimped thermoplastic braided preforms (206, 210).

[0070] Preferably, in the method, when integrally molding (2304) the plurality of crimped thermoplastic braided preforms (206, 210), the plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded by heating the arc-shaped stack (112) using a plurality of induction coils and a plurality of smart susceptors.

[0071] Preferably, in the method, when the plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded (2304), a force is applied to the plurality of crimped thermoplastic braided preforms (206, 210) by expanding a plurality of stringer encapsulants (208) and encapsulants (202) in the arc-shaped stack (112).

[0072] Preferably, in the method, when expanding the plurality of stringer encapsulations (208) and the encapsulation body (202), the plurality of stringer encapsulations (208) and the encapsulation body (202) in the arc-shaped stack (112) are pressurized with an inert gas.

[0073] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0074] In one embodiment of the present disclosure, an apparatus is provided for a tow tucking and trimming apparatus, the apparatus including a tucking and trimming system (1301) adapted for tucking and trimming a thermoplastic tow (1404) to a braid (1306), and a support system (1302) to which the tucking and trimming system (1301) is attached, the support system (1302) having a shape and size suitable for operatively positioning the tucking and trimming system (1301) relative to a cylindrical thermoplastic stack (306).

[0075] Advantageously, the support system (1302) includes a support ring (1303) sized and shaped to surround the entire circumference of an arcuate mounting surface (1304), and the tacking and trimming system (1301) is attached to the support ring (1303).

[0076] Preferably, the tacking and trimming system (1301) includes a tack weld (1400) secured to a portion of the support system (1302). The tack weld (1400) is heated by resistive heat.

[0077] Preferably, the tucking and trimming system (1301) includes a trimming portion (1402) secured to a portion of the support system (1302), the trimming portion (1402) trims the thermoplastic tow (1404) using laser energy.

[0078] Preferably, the tow tucking and trimming device further includes a conductive member (1308) disposed between the braid (1306) and the thermoplastic tow (1404).

[0079] Preferably, the conductive member (1308) has a wedge-shaped cross-sectional shape.

[0080] Preferably, the conductive member (1308) has thermal conductivity and is used to absorb the laser energy emitted from the trimming portion (1402) and protect the braided body (1306).

[0081] Preferably, the thermoplastic tow (1404) is received from a braid ring and passed over the conductive member (1308).

[0082] Preferably, the support system (1302) moves with the braided ring that feeds the thermoplastic tows (1404).

[0083] Preferably, the tucking and trimming system (1301) is one of a plurality of tucking and trimming systems distributed across the support system (1302).

[0084] The braid (1306) includes multiple thermoplastic plies that are braided together from continuous fibers of a thermoplastic composite material.

[0085] According to one aspect of the disclosure, a method is provided for tacking and trimming a thermoplastic tow (1404) comprising laying (2502) a thermoplastic tow (1404) received from a braiding system above a braid (1306) on a mounting surface (1304), tack welding (2504) the thermoplastic tow (1404) to the braid (1306), and trimming (2506) the thermoplastic tow (1404) received above the braid (1306) by trimming a portion of the thermoplastic tow (1404).

[0086] Advantageously, the method further includes receiving a portion of the thermoplastic tow (1404) above a conductive member (1308) disposed between the braid (1306) and the thermoplastic tow (1404).

[0087] Preferably, in the method, when tack welding (2504) the thermoplastic tow (1404) is performed, the thermoplastic tow (1404) is tack welded to the braid (1306) using a tack weld portion (1400) secured to a support ring (1303).

[0088] Preferably, the method includes tack welding (2504) the thermoplastic tows (1404) to the braid (1306) using a tack weld (1400) secured to a support ring (1303) surrounding the mounting surface (1304), the tack weld (1400) being heated by resistive heat.

[0089] Preferably, the method further comprises supporting the portion of the thermoplastic tow (1404) by a conductive member (1308).

[0090] Preferably, in the method, trimming (2506) the portion of the thermoplastic tow (1404) includes applying laser energy to the portion of the thermoplastic tow (1404) supported by the conductive member (1308).

[0091] Preferably, in the method, when the laser energy is applied, the laser energy is absorbed by the conductive member (1308) as the thermoplastic tow (1404) is trimmed, thereby protecting the braid (1306).

[0092] Preferably, in the method, when laying (2502) the thermoplastic tows (1404), the thermoplastic tows (1404) are laid onto the mounting surface (1304), wherein the mounting surface (1304) is formed by at least one of a tool face (1304), a backing plate (502), an encapsulation body (400), a stringer encapsulation body (702), an in-progress braided layup (1306), a preform (800, 600), or an integrated composite structure (101).

[0093] Preferably, in the method, when the thermoplastic tows (1404) are layered (2502), the thermoplastic tows (1404) are layered to add a unique portion to a portion of the braid (1306).

[0094] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0095] According to one aspect of the disclosure, a method is provided for tacking and trimming a thermoplastic tow (1404) comprising stacking (2602) a thermoplastic tow (1404) received from a braiding system above a braid (1306) on a mounting surface (1304), tack welding (2604) the thermoplastic tow (1404) provided from the braiding system to the braid (1306), and trimming (2606) the thermoplastic tow (1404) by applying laser energy to a portion of the thermoplastic tow (1404).

[0096] Advantageously, the method further comprises supporting the portion of the thermoplastic tow (1404) by a conductive member (1308).

[0097] Preferably, in the method, when trimming (2606) the portion of the thermoplastic tow (1404), the portion of the thermoplastic tow (1404) is supported by a conductive member (1308) and the portion is exposed to laser energy.

[0098] The components of the composite aircraft barrel (102) can be assembled by the methods described above.

[0099] A tacking and trimming assembly provided in one embodiment of the present disclosure includes a support ring (1303) having a size and shape that surrounds the entire circumference of an arc-shaped mounting surface (1304), and a tacking and trimming system (1301) that is fixed to the support ring (1303) and is used to tack a thermoplastic tow (1404) to a braided body (1306). The tacking and trimming system (1301) further includes a tack welding portion (1400) fixed to a portion of the support system (1303), the tack welding portion (1400) being heated by resistive heat, a trimming portion (1402) fixed to a portion of the support ring (1303), the trimming portion (1402) using laser energy to trim the thermoplastic tow (1404), and a conductive member (1308) disposed between the braided body (1306) and the thermoplastic tow (1404).

[0100] As an advantage, the conductive member (1308) has a wedge-shaped cross-sectional shape and is thermally conductive, and absorbs the laser energy emitted from the trimming portion (1402) during trimming of the thermoplastic tow (1404) to protect the braid (1306).

[0101] Preferably, the tacking and trimming system (1301) is one of a plurality of tacking and trimming systems (1301) distributed across the support ring (1303).

[0102] Preferably, the braid (1306) includes a plurality of thermoplastic plies braided together from continuous fibers of a thermoplastic composite material.

[0103] Preferably, the mounting surface (1304) is a surface formed by at least one of a tool face (1304), a backing plate (502), an encapsulation body (400), a stringer encapsulation body (702), a partially formed braided layup (1306), a preform (800, 600), or an integrated composite structure (101).

[0104] The above-described features and functions can be achieved individually in various embodiments of the present disclosure or can be combined in yet further embodiments, details of which will become apparent from the following description and the accompanying drawings. [Brief description of the drawings]

[0105] The novel features believed to be inherent to the exemplary embodiments are set forth in the appended claims. However, the exemplary embodiments and preferred modes of use, as well as their objects and features, will be best understood by reference to the following detailed description of exemplary embodiments of the present disclosure taken in conjunction with the accompanying drawings.

[0106] [Figure 1] 1 is a block diagram illustrating a manufacturing environment in accordance with an illustrative embodiment. [Diagram 2] FIG. 2 illustrates details of a stack according to an exemplary embodiment. [Figure 3A] FIG. 1 illustrates an isometric view of a consolidation assembly in accordance with an illustrative embodiment; [Figure 3B] FIG. 3B illustrates a cross-sectional view of the consolidation mass of FIG. 3A according to an exemplary embodiment. [Figure 4] 4 illustrates a portion of the inner tool shown in FIG. 3 taken along line 4-4 of FIG. 3 according to an exemplary embodiment. [Diagram 5] 5 illustrates an additional caul plate added to the stack of FIG. 4 according to an exemplary embodiment. [Figure 6] 6 illustrates a thermoplastic braided member added to the stack of FIG. 5 according to an exemplary embodiment. [Figure 7] 7 illustrates an internal stringer enclosure added to the stack of FIG. 6 according to an exemplary embodiment. [Figure 8] FIG. 8 illustrates a thermoplastic braided skin added to the stack of FIG. 7 according to an exemplary embodiment. [Figure 9] FIG. 9 illustrates a second smart susceptor and outer tool disposed around the stack of FIG. 8 according to an exemplary embodiment. [Figure 10] FIG. 1 illustrates a cross-sectional view of a system for supporting a consolidation mass during crimping in accordance with an exemplary embodiment. [Figure 11A] FIG. 11 illustrates a portion of the consolidation mass of FIG. 10 with the plug clearly shown, according to an exemplary embodiment. [Figure 11B] FIG. 11B is a close-up view illustrating one configuration of the pressurization tube of FIG. 11A according to an exemplary embodiment. [Figure 11C] FIG. 11B is a close-up view showing another configuration of the pressurization tube of FIG. 11A according to an exemplary embodiment. [Figure 11D] FIG. 11B is an enlarged view illustrating yet another configuration of the pressurization tube of FIG. 11A according to an exemplary embodiment. [Figure 12] 12 is a cross-sectional view of a stack according to an exemplary embodiment taken along line 12-12 of FIG. 11. [Figure 13A] FIG. 1 is an isometric view of a tacking and trimming assembly in accordance with an exemplary embodiment; [Figure 13B] FIG. 13B is a cross-sectional view of the tacking and trimming assembly of FIG. 13A according to an exemplary embodiment. [Figure 14] FIG. 14 is a cross-sectional view of a portion of the tacking and trimming assembly of FIG. 13 according to an exemplary embodiment. [Figure 15] 1 is a flowchart illustrating a process for making a composite structure in accordance with an illustrative embodiment. [Figure 16] 10 is a flowchart illustrating a process for assembling a stack in accordance with an exemplary embodiment. [Figure 17] 1 is a flowchart illustrating a process for assembling a system including a consolidation assembly in accordance with an illustrative embodiment. [Figure 18] 1 is a flowchart illustrating a process for assembling a system for producing a composite fuselage structure in accordance with an illustrative embodiment. [Figure 19] 4 is a flow chart illustrating a process for inductively crimping a thermoplastic braided skin and a thermoplastic braided member to create a composite fuselage structure in accordance with an illustrative embodiment. [Figure 20] 1 is a flowchart illustrating a process for making a composite structure in accordance with an illustrative embodiment. [Figure 21] 1 is a flowchart illustrating a process for fabricating a composite fuselage structure in accordance with an illustrative embodiment. [Figure 22] 1 is a flowchart illustrating a process for making a composite structure in accordance with an illustrative embodiment. [Figure 23] 1 is a flowchart illustrating a process for making a composite structure in accordance with an illustrative embodiment. [Figure 24] 1 is a flowchart illustrating a process for making a composite structure in accordance with an illustrative embodiment. [Diagram 25] 4 is a flowchart illustrating a process for tucking and trimming thermoplastic tows in accordance with an illustrative embodiment. [Figure 26] 4 is a flowchart illustrating a process for tucking and trimming thermoplastic tows in accordance with an illustrative embodiment. [Figure 27] FIG. 1 illustrates a method of manufacturing and using an aircraft in accordance with an illustrative embodiment. [Figure 28] FIG. 1 is a block diagram of an aircraft in accordance with an illustrative embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0107] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The exemplary embodiments described below provide methods, apparatus, and systems for quickly and efficiently fabricating composite structures, such as fuselage barrels, at lower cost and with less weight. In particular, fabricating composite structures, such as fuselage barrels, using thermoplastic materials helps reduce overall manufacturing costs and production times.

[0108] Exemplary embodiment methods, apparatus, and systems allow for hardening of fuselage barrel structures without the use of an autoclave, which is quite costly. Additionally, autoclaves are large and complex structures that require significant thermal mass, and their use increases the time and reduces the efficiency of fuselage barrel fabrication. Exemplary embodiments described herein allow for the avoidance of the use of an autoclave, thereby reducing the cost and time required to fabricate a fuselage barrel. For example, at least some of the exemplary methods for fabricating a fuselage barrel structure described herein require one-tenth the time required to use an autoclave.

[0109] Additionally, the systems described herein completely react the thermoplastic material, eliminating the need for a curing process and reducing overall heat requirements. The systems described herein require less equipment and materials to fabricate the fuselage barrel than systems that use an autoclave, and do not require overly complex equipment and materials.

[0110] In an exemplary embodiment, a thermoplastic braided stringer is bonded to a thermoplastic braided skin to create a composite structure, such as a fuselage barrel. The bonding is performed using induction heating, making it a relatively inexpensive, fast, and reliable process. As used herein, the term "consolidation" or "bonding process" refers to a process in which multiple components of a braided thermoplastic material are heated and melted so that they can be bonded, welded, or integrated together. The heating is performed using a smart susceptor, which allows for rapid heating to a set temperature and precise maintenance of the set temperature. The process further includes cooling the bonded or integrated components to form a fully bonded integrated structure.

[0111] With the fuselage barrel structure integrated, other fuselage components can be easily attached to the fuselage barrel structure by welding or other methods. For example, but not limited to, tear straps, pad-ups, door cutouts, and section reinforcements for service door areas can be attached to the fuselage barrel structure by induction welding, thereby utilizing the highly manufacturable fiber placement and layering of thermoplastic materials. The fuselage and window frames, as well as other components (e.g., tear straps, intercostals, doublers, shear ties, systems brackets, etc.) can also be induction welded into place.

[0112] Thus, in the exemplary embodiments described below, a method, apparatus, and system for fabricating a composite structure using thermoplastic materials and induction heating are provided. In one exemplary embodiment, a stack is assembled that includes a plurality of thermoplastic braided members and a thermoplastic braided skin. The stack further includes an inner enclosure having a plurality of recesses, a plurality of caul plates disposed in the plurality of recesses, and a plurality of stringer inner enclosures. The stack is placed between an inner tool and an outer tool. The inner tool, the stack, and the outer tool are fixed in place using a member restraint. The composite structure is fabricated by heating the consolidation assembly. This heating process can be performed using induction heating and a smart susceptor, and this heating process co-consolidates the plurality of thermoplastic braided members to the thermoplastic braided skin, thereby fabricating the composite structure.

[0113] Turning now to the drawings, Figure 1 is a block diagram illustrating a manufacturing environment 100 in accordance with an illustrative embodiment. Composite structure 101 is fabricated in manufacturing environment 100. In this illustrative example, composite structure 101 takes the form of a composite fuselage structure 102. Composite fuselage structure 102 is, for example, a composite barrel, although in other illustrative examples, composite structure 101 may take other forms.

[0114] The composite structure 101 is fabricated using a system 103. The system 103 includes a consolidation setup 104, an end tool 105, a number of plugs 106, and a number of connection devices 107. In this exemplary embodiment, the consolidation setup 104 includes an inner tool 108, an outer tool 110, a stack up 112, a first smart susceptor 114, a second smart susceptor 115, a support structure 116, and a load constraint 117.

[0115] The inner tool 108 includes a number of induction coils 118 embedded in the inner tool 108. In some embodiments, the inner tool 108 also includes a number of rods 119 embedded therein, such as, but not limited to, fiberglass rods. The rods 119 are used to strengthen the inner tool 108 and to load the inner tool 108 during compression.

[0116] Similar to the inner tool 108, the outer tool 110 includes a number of induction coils 120 embedded therein. The inner tool 108 and the outer tool 110 may be constructed of the same material or may be constructed of different types of materials. In one exemplary embodiment, the inner tool 108 and the outer tool 110 are both constructed of a ceramic material.

[0117] The stack body 112 is disposed between the inner tool 108 and the outer tool 110. Specifically, the stack body 112 is disposed between a first smart susceptor 114 and a second smart susceptor 115 disposed between the inner tool 108 and the outer tool 110. For example, the first smart susceptor 114 is disposed between the stack body 112 and the inner tool 108. The second smart susceptor 115 is disposed between the stack body 112 and the outer tool 110.

[0118] In this exemplary embodiment, the first smart susceptor 114 and the second smart susceptor 115 are separate from the inner tool 108 and the outer tool 110, respectively. However, in other exemplary embodiments, the first smart susceptor 114 can be integral with or part of the inner tool 108, and the second smart susceptor 115 can be integral with or part of the outer tool 110. For example, the first smart susceptor 114 and the second smart susceptor 115 can be provided as liners for the inner tool 108 and the outer tool 110, respectively.

[0119] Both the first smart susceptor 114 and the second smart susceptor 115 are electrically conductive and highly thermally conductive. Both smart susceptors absorb electromagnetic energy and convert the absorbed electromagnetic energy into heat. For example, the induction coil 118 and the induction coil 120 generate an electromagnetic field. The first smart susceptor 114 and the second smart susceptor 115 are disposed within this electromagnetic field and include a magnetically permeable material that responds to the electromagnetic field to generate heat.

[0120] A "smart susceptor," such as first smart susceptor 114 or second smart susceptor 115, is typically composed of one or more materials that efficiently generate heat until a threshold temperature (i.e., the Curie temperature) is reached. When a portion of a smart susceptor reaches the threshold temperature, the magnetic permeability of that portion decreases. The decreased magnetic permeability limits the heat generation in that portion of the smart susceptor, and electromagnetic flux is transferred to the cooler portion. In this way, heat generation in the cooler portion is accelerated, and the threshold temperature is reached more quickly.

[0121] As described above, the first smart susceptor 114 and the second smart susceptor 115 can be used to facilitate heat distribution and ensure thermal uniformity in the stack 112 during induction heating by the induction coils 118 and 120. This induction heating can thermally crimp and form the thermoplastic braided components in the stack 112, as described below with reference to FIG.

[0122] The support structure 116 is a structure that supports the consolidation mass 104 and holds the inner tool 108 in place. In some embodiments, the support structure 116 is also referred to as a mandrel or an inner mandrel. The inner tool 108 is disposed around the support structure 116.

[0123] The member restraints 117 are disposed along the circumference of the outer tool 110 and can hold the various components of the consolidation assembly 104 in place. In particular, the member restraints 117 function to hold the inner tool 108, the first smart susceptor 114, the stack 112, the second smart susceptor 115, and the outer tool 110 in position relative to one another during fabrication of the composite structure 101.

[0124] The consolidation assembly 104 has a first end 122 and a second end 124. The stack bodies 112 included in the consolidation assembly 104 have a first end 126 and a second end 128. In this exemplary embodiment, the plugs 106 are disposed at the first end 126 and the second end 128 of the stack bodies 112. The end tools 105 are disposed at the first end 122 and the second end 124 of the consolidation assembly 104 for supporting and securing the plugs 106.

[0125] The connecting devices 107 are used to connect the induction coil 118 to the induction coil 120. The connecting devices 107 are located at both the first end 122 and the second end 124 of the consolidation mass 104. The connecting devices 107 can take a variety of forms. In one exemplary embodiment, each connecting device 107 takes the form of a blade switch connector 127. The blade switch connector 127 includes, for example, a bar-shaped member made of copper or other highly conductive material that is rotatably disposed about a fixed pivot point 129.

[0126] The consolidation assembly 104 is inductively heated using induction coil 118 and induction coil 120. Specifically, first smart susceptor 114 and second smart susceptor 115 are inductively heated via induction coil 118 and induction coil 120. These smart susceptors allow the thermal uniformity of stack 112 to be maintained within a predetermined tolerance during compression forming. In an exemplary embodiment for making a composite fuselage structure 102, the compression forming may allow a number of fuselage stringers 130 and a fuselage skin 132 to be integrated together.

[0127] In these exemplary embodiments, fuselage skin 132 is a circumferential skin. For example, fuselage skin 132 may be used to form a full circumference of a fuselage barrel. In other exemplary embodiments, fuselage skin 132 may be a curved skin used to form a portion of a half circumference of a fuselage barrel, a quarter circumference of a fuselage barrel, or some other type of fuselage barrel.

[0128] Figure 2 is a diagram illustrating details of the stack 112 of Figure 1 in accordance with an exemplary embodiment. The stack 112 includes an inner casing 202, a number of caul plates 204, a number of thermoplastic braided members 206, a number of inner stringer casings 208, and a thermoplastic braided outer panel 210. These components of the stack 112 are arranged in specific relative positions in a system 103 for use in constructing a composite structure 101.

[0129] In this exemplary embodiment, the inner container 202 is configured to have a shape including a plurality of recesses 212 and a plurality of cap portions 214. Each recess 212 is provided between two cap portions 214. The recess 216 is an example of one recess among the plurality of recesses 212. Each recess 216 is provided between a cap portion 218 and a cap portion 220 among the plurality of cap portions 214. The recess 216 has a main portion 222, a step portion 224, and a step portion 226. The step portion 224 is provided on a first edge of the recess 216 on the cap portion 218 side. The step portion 226 is provided on a second edge of the recess 216 on the cap portion 220 side. The main portion 222 is a portion extending from the step portion 224 to the step portion 226. In some embodiments, main portion 222 includes a base portion (that forms the "cap" portion of the hat stringer) and two web portions extending from the base portion to stepped portions 224 and 226, respectively.

[0130] The inner casing 202 is constructed of a material that exhibits a desired level of flexibility and pliability at elevated temperatures. In one such exemplary embodiment, the inner casing 202 may be constructed of aluminum (or an aluminum alloy). Aluminum exhibits a desired level of flexibility and pliability at elevated temperatures (e.g., at approximately 500 degrees Fahrenheit). In one exemplary embodiment, the inner casing 202 is constructed of an aluminum alloy, such as, for example, 5083 aluminum alloy, which combines aluminum with magnesium and trace amounts of manganese and chromium. In another embodiment, the inner casing 202 may also be described as an inner mold line (IML) casing.

[0131] The backing plates 204 are placed in the recesses 212 of the inner housing 202. For example, each backing plate 204 fits into one of the recesses 212. The backing plates 204 are used to provide a rigid, smooth, and stable surface for the thermoplastic braided member 206. The material of each backing plate 204 is selected to provide the backing plate 204 with a desired level of strength without excessively increasing the thickness of the backing plate 204. Furthermore, the material of each backing plate 204 is selected to provide the backing plate 204 with a first coefficient of thermal expansion 227.

[0132] The backing plate 228 is an example of one of the backing plates 204. When the backing plate 228 is used with the stack 112, it is disposed in the recess 216. The backing plate 228 has a thickness between about 1 / 6 inch and about 1 / 10 inch. In one exemplary embodiment, the backing plate 228 has a thickness of about 1 / 8 inch. In such an exemplary embodiment, the backing plate 228 is comprised of an iron-nickel alloy. In one exemplary embodiment, the backing plate 228 is comprised of an Invar alloy (e.g., Invar 42) containing about 40% to about 43 percent nickel. In some exemplary embodiments, the backing plate 228 may also be described as an Invar cowl.

[0133] The backing plate 228 is shaped to substantially fit or conform to the recess 216 of the inner container 202. For example, the backing plate 228 has a main portion 230, a flange portion 232, and a flange portion 234. The shape of the main portion 230 generally conforms to the shape of the main portion 222 of the recess 216. Thus, in some cases, the main portion 230 includes a bottom portion and two web portions extending from the bottom portion to the flange portions 232 and 234, respectively. The flange portion 232 is shaped to fit or conform to the stepped portion 224. Similarly, the flange portion 234 is shaped to fit or conform to the stepped portion 226.

[0134] The thermoplastic braided members 206 are disposed on the backing plates 204. Specifically, each thermoplastic braided member 206 is disposed on one of the backing plates 204. The thermoplastic braided members 206 have a shape similar to that of the backing plates 204. In this exemplary embodiment, the thickness of the backing plates 204 and the thermoplastic braided members 206 is set such that the thermoplastic braided members 206 do not protrude beyond a cross-sectional contour (e.g., a circumferential contour) of the inner envelope 202 defined by the cap portion 214 of the inner envelope 202.

[0135] The thermoplastic braided member 206 can be made using existing overbraiding equipment and techniques for interweaving continuous fibers of thermoplastic composite material. Overbraiding techniques allow for the interweaving of continuous fibers of thermoplastic material from multiple spools at once. For example, overbraiding techniques allow for the use of hundreds of spools, allowing for high speed application of material.

[0136] Thermoplastic braided member 206 has a second coefficient of thermal expansion 235. In this illustrative example embodiment, first coefficient of thermal expansion 227 of caul plate 204 is within a desired range of second coefficient of thermal expansion 235 of thermoplastic braided member 206.

[0137] For example, the backing plate 204 is constructed from a material such that the first coefficient of thermal expansion 227 of the backing plate 204 is closer to the second coefficient of thermal expansion 235 of the thermoplastic braided member 206 than the third coefficient of thermal expansion 237 of the encapsulation body 202. In some cases, the material of construction of the backing plate 204 is selected such that the first coefficient of thermal expansion 227 of the backing plate 204 is as close as possible to the second coefficient of thermal expansion 235 of the thermoplastic braided member 206.

[0138] Since the thermal expansion coefficients of the backing plate 204 and the thermoplastic braided member 206 are close to each other, the strength and rigidity of the backing plate 204 can be maintained at a desired level during induction heating, and therefore the thermoplastic braided member 206 can maintain a smooth surface and shape during induction heating. For example, the third thermal expansion coefficient 237 of the aluminum constituting the casing 202 is significantly different from the second thermal expansion coefficient 235 of the thermoplastic braided member 206. For example, the third thermal expansion coefficient 237 is significantly smaller than the second thermal expansion coefficient 235. Thus, the casing 202 is softened by induction heating. If the backing plate 204 is not provided, the softening of the casing 202 would cause unnecessary undulations in the thermoplastic braided member 206. Thus, by providing the backing plate 204, it is possible to form a desired well-defined surface on the thermoplastic braided member 206 while reducing or eliminating problems caused by the difference in thermal expansion coefficient between the casing 202 and the thermoplastic braided member 206.

[0139] The stringer casing 208 is placed over the thermoplastic braided member 206. The stringer casing 208 is molded to a shape that fits into the space left in the recess 212 of the casing 202 without protruding beyond the cross-sectional profile (e.g., the circumferential profile) of the casing 202.

[0140] In such an exemplary embodiment, the stringer encapsulation 208 is constructed from aluminum (or an aluminum alloy). Aluminum exhibits a desired level of flexibility and pliability at high temperatures (e.g., approximately 500 degrees Fahrenheit). For example, aluminum softens and becomes pliable when heated inductively, allowing the stringer encapsulation 208 to apply substantially uniform pressure to the thermoplastic braided member 206. In other words, the stringer encapsulation 208 being constructed from aluminum allows for uniform air pressure to be applied without creating pressure gradients. In one exemplary embodiment, the stringer encapsulation 208 is constructed from an aluminum alloy, such as 5083 aluminum alloy, which combines aluminum with magnesium and trace amounts of manganese and chromium.

[0141] The thermoplastic braided skin 210 is placed over the stringer encapsulation 208 such that the thermoplastic braided skin 210 is in contact with the portion 236 of the thermoplastic braided member 206 and also with the cap portion 214 of the encapsulation 202. During induction heating, the thermoplastic braided skin 210 is compression molded to the thermoplastic braided member 206.

[0142] Specifically, the thermoplastic braided panel 210 and the thermoplastic braided member 206 are integrally molded. The thermoplastic braided panel 210 and the thermoplastic braided member 206 are heated using induction heating, which melts the thermoplastic braided panel 210 and the thermoplastic braided member 206 and integrates or bonds them together. In this manner, the thermoplastic braided panel 210 and the thermoplastic braided member 206 are integrated into a single piece structure through crimp forming and cooling to form the composite structure 101 of FIG. 1. In some cases, one or more additional crimp forming processes can be used to integrate or bond further structural components to the composite structure 101.

[0143] More specifically, thermoplastic braided skin 210 is compression molded with portion 236 of thermoplastic braided member 206 to form integral composite structure 101. When composite structure 101 is a composite fuselage structure 102, thermoplastic braided skin 210 forms fuselage skin 132 and thermoplastic braided member 206 forms fuselage stringer 130.

[0144] In such an exemplary embodiment, a number of pressurization tubes 238 are inserted or threaded through the stringer casing 208. The pressurization tubes 238 are positioned to pass through at least a portion of the stringer casing 208. The pressurization tubes 238 allow for pressurization of the interior of the stringer casing 208. For example, a pressurization system (not shown) may be connected to the pressurization tubes 238 to inject an inert gas through the pressurization tubes 238.

[0145] In some embodiments, each pressurizing tube is inserted so as not to penetrate the corresponding stringer casing 208. For example, the pressurizing tube 238 opens into the corresponding stringer casing 208. In this way, the inert gas flowing through the pressurizing tube 238 is injected from the pressurizing tube 238 into the stringer casing 208 to pressurize the stringer casing 208. In other embodiments, each pressurizing tube 238 penetrates the length of the corresponding stringer casing 208. In such a case, the pressurizing tube 238 is provided with an opening hole (e.g., a punched hole, a slit, a hole, or other type of hole) so that the inert gas is injected into the stringer casing 208 through the opening hole. The pressurizing system controls the flow of the inert gas and uses the inert gas to control the internal pressure of the stringer casing 208.

[0146] In one exemplary embodiment, the pressurizing tube 238 is made of aluminum. In other embodiments, the pressurizing tube 238 is made of stainless steel, other types of materials, or combinations thereof. The pressurizing system uses an inert gas to increase the internal pressure of the pressurizing tube 238, thereby increasing the internal pressure of the stringer encapsulation 208. During induction heating, this pressurization causes the stringer encapsulation 208 to expand and support the thermoplastic braided member 206, preventing the thermoplastic braid from denting (or collapsing inward) or otherwise deviating from a desired shape. Additionally, this pressurization causes the stringer encapsulation 208 to expand, providing a smooth surface for the thermoplastic braided member 206 and the thermoplastic braided skin 210.

[0147] Additionally, the internal pressure of the inner envelope 202 can also be controlled using a pressure tube 240 that passes through the inner envelope 202 and the pressure system described above. For example, the pressure tube 240 is also made of aluminum. In other embodiments, the pressure tube 240 is made of stainless steel, other types of materials, or combinations thereof. The pressure system increases the internal pressure of the inner envelope 202 by increasing the internal pressure of the pressure tube 240 using an inert gas, similar to that of the pressure tube 238.

[0148] In one exemplary embodiment, the pressurizing tube 240 is inserted into the inner container 202 without penetrating the inner container 202, thereby allowing the inert gas to be injected from the pressurizing tube 240 into the inner container 202 to pressurize the inner container 202. In another embodiment, the pressurizing tube 240 has an open hole (e.g., a punched hole, a slit, a hole, or other type of hole) so that the inert gas can be injected from the pressurizing tube 240 into the inner container 202.

[0149] During crimping, each of the stringer encapsulations 208 is pressurized to substantially the same pressure (i.e., within a predetermined tolerance). This allows all of the stringer encapsulations 208 to expand uniformly during crimping, providing a uniform force to the thermoplastic braided member 206. In some cases, the encapsulations 202 and stringer encapsulations 208 are pressurized to substantially the same pressure when the thermoplastic braided member 206 is crimped to the thermoplastic braided skin 210. Increasing the internal pressure of the encapsulations 202 and stringer encapsulations 208 to cause some expansion places the preform (i.e., the thermoplastic braided member 206 and the thermoplastic braided skin 210) in tension during processing. This expansion also allows the stack 112 to be molded together as it is pressed or compressed against the outer tool 110 during processing.

[0150] 1 and 2 in the system 103 of FIG 1, the thermoplastic braided member 206 can be crimped to the thermoplastic braided skin 210 to efficiently and quickly produce the composite structure 101. In particular, induction heating using induction coil 118, induction coil 120, first smart susceptor 114, and second smart susceptor 115 allows for a fast and reliable crimping process.

[0151] The manufacturing environment 100 and system 103 illustrated in FIG. 1 and the stack 112 illustrated in FIG. 1 and FIG. 2 are not intended to impose any physical or architectural limitations on the manner in which example embodiments may be implemented. Additional or alternative components may be used other than those illustrated. Some components may be optional. Additionally, while blocks representing functional components are presented, one or more of these blocks may be combined or combined and then separated into separate blocks in example embodiments.

[0152] 3A and 3B show a consolidation assembly according to an example embodiment. Fig. 3A is an isometric view of a cross section of the consolidation assembly. The consolidation assembly 300 is an example of an implementation of the consolidation assembly 104 of Fig. 1.

[0153] The consolidation assembly 300 includes a support structure 302, an inner tool 304, a stack body 306, an outer tool 308, and a member restraint portion 310. The consolidation assembly 300 further includes a first smart susceptor 311 and a second smart susceptor 312. The first smart susceptor 311 is disposed between the inner tool 304 and the stack body 306, and the second smart susceptor 312 is disposed between the stack body 306 and the outer tool 308.

[0154] The support structure 302, the inner tool 304, the stack 306, the outer tool 308, and the member restraint 310 are examples of the embodiment of the support structure 116, the inner tool 108, the stack 112, the outer tool 110, and the member restraint 117, respectively, of FIG. 1. The first smart susceptor 311 and the second smart susceptor 312 are examples of the embodiment of the first smart susceptor 114 and the second smart susceptor 115, respectively, of FIG. 1. The support structure 302, the inner tool 304, the stack 306, the outer tool 308, the member restraint 310, the first smart susceptor 311, and the second smart susceptor 312 are aligned with respect to the longitudinal axis 301 (e.g., the central longitudinal axis). In an exemplary embodiment, these components are aligned concentrically with respect to the longitudinal axis 301.

[0155] Figure 3B is a diagram illustrating a cross-section of the consolidation aggregate of Figure 3A. The cross-section of the consolidation aggregate 300 shown in Figure 3B is a cross-section of the consolidation aggregate 104 taken along a plane perpendicular to the longitudinal axis 301. Specifically, the cross-section of the consolidation aggregate 300 shown in Figure 3B is taken along line 3B-3B in Figure 3A.

[0156] In these illustrative examples, the support structure 302 supports the inner tool 304 and is a separate member from the inner tool 304. In other illustrative examples, the support structure 302 may be part of or integral with the inner tool 304. The inner tool 304 includes a number of induction coils 313 embedded therein. The induction coils 313 are an example of an implementation of the induction coils 118 of FIG. 1. The outer tool 308 includes a number of induction coils 314 embedded therein. The induction coils 314 are an example of an implementation of the induction coils 118 of FIG. 1.

[0157] In one or more exemplary embodiments, the inner tool 304, stack 306, outer tool 308, and member restraint 310 are all substantially cylindrical structures. For example, the inner tool 304, stack 306, outer tool 308, and member restraint 310 are concentrically aligned about the longitudinal axis 301. In one exemplary embodiment, the inner tool 304 is a single-piece cylinder. In other exemplary embodiments, the inner tool 304 is a cylindrical structure made up of two or more halves joined together.

[0158] Both the inner tool 304 and the outer tool 308 are made of ceramic material. The ceramic material is a dielectric material and has a "permeability" that does not react to the magnetic energy generated by the induction coil 313 and the induction coil 314. Therefore, the magnetic energy penetrates the ceramic material and acts on the first smart susceptor 311 and the second smart susceptor 312. The first smart susceptor 311 and the second smart susceptor 312 convert the magnetic energy into thermal energy, but the ceramic material is said to be "impermeable" to thermal energy, so the ceramic material does not transmit the thermal energy. In this way, the ceramic material can act as an insulator during induction heating to prevent the loss of thermal energy. Furthermore, the ceramic material has a low thermal expansion coefficient, so that the inner tool 304 and the outer tool 308 have sufficient resistance to the thermal gradients that occur in relation to other components in the consolidation assembly 300 during induction heating.

[0159] In these exemplary embodiments, the ceramic material of the inner tool 304 includes a plurality of rods 316 embedded therein. The rods 316 are disposed substantially parallel to the longitudinal axis 301. Additionally, the rods 316 may be disposed circumferentially around the longitudinal axis 301. As shown in FIG. 3, the rods 316 are disposed on the longitudinal axis 301 side of the induction coil 313. The rods 316 are an example of an embodiment of the rods 119 of FIG. 2. In these embodiments, the rods 316 are fiberglass rods. When the rods 316 are constructed of fiberglass, which is a dielectric material, the rods 316 function to apply a compressive load to the inner tool 304. The rods 316 function to maintain the ceramic material of the inner tool 304 in compression as the various components of the consolidation assembly 300 are sequentially placed into the inner tool 304, thereby improving the long-term durability of the inner tool 304. In this manner, the rods 316 are used to stiffen the inner tool 304 as well as to load the inner tool 108 during compression.

[0160] The stack body 306 is assembled to surround the inner tool 304. The outer tool 308 is disposed around the stack body 306. Specifically, the outer tool 308 is disposed around a second smart susceptor 312 that is disposed around the stack body 306. Similar to the inner tool 304, the outer tool 308 is also made of a ceramic material.

[0161] In this exemplary embodiment, the outer tool 308 is made up of two halves joined together to surround the stack body 306. For example, the two halves constituting the outer tool 308 are joined together using a fastening mechanism (not shown). In some cases, the two halves of the outer tool 308 are held in place using a member restraint 310. Similarly, the member restraint 310 is made up of two halves joined together to surround the outer tool 308, thereby holding the outer tool 308, the stack body 306, and the inner tool 304 together. The two halves constituting the member restraint 310 can be joined together using a fastening mechanism (not shown). In some cases, the halves of the outer tool 308 and the member restraint 310 can be joined together using the same type of fastening mechanism. For example, the fastening mechanism can be a clamping mechanism (e.g., a hydraulic clamp) that can be easily secured and released by tightening. In other exemplary embodiments, the outer tool 308, the member restraint 310, or both, comprise a single-piece cylinder.

[0162] 4-8 show an exemplary embodiment of assembling the stack 306 onto the inner tool 304 shown in FIG. 3. FIG. 4 shows a cutaway view of a portion of the inner tool 304 shown in FIG. 3 along line 4-4 in FIG. 3 according to an exemplary embodiment. The first smart susceptor 311 is disposed around the inner tool 304 such that the first smart susceptor 311 is located within the electromagnetic field generated by the induction coil 118 when a current is applied to the induction coil 118.

[0163] The inner envelope 400 is disposed around the first smart susceptor 311. The inner envelope 400 is an example of an embodiment of the inner envelope 202 of FIG. 2. The inner envelope 400 is the first component placed in the assembly of the stack 306 of FIG. 3. In this illustrative embodiment, the inner envelope 400 is an aluminum inner envelope. The inner envelope 400 is pressurized during the induction heating crimping process. When the inner envelope 400 is not pressurized, it is in a "contracted state." When pressure is applied to the inner envelope 400, it is in an "expanded state." The inner envelope 400 is pressurized by supplying an inert gas to a pressure tube (not shown in this figure) passing through the inner envelope 400 or to a passageway in the inner envelope 400.

[0164] The inner envelope 400 has recesses 402 formed between the cap portions 404. The recesses 402 are used to index the locations for creating the fuselage stringers. The recesses 406 are an example of one recess among the recesses 402. Each recess 406 is disposed between the cap portion 408 and the cap portion 410 of the cap portions 404.

[0165] The shape of recess 406 is formed such that recess 406 has a main portion 412, a step portion 414, and a step portion 415. Step portion 414 is located between main portion 412 and cap portion 408, and step portion 415 is located between main portion 412 and cap portion 410. Step portion 414 has a depth 416, and step portion 415 has a depth 418. Depth 416 is the distance between cap portion 408 and main portion 412, and depth 418 is the distance between cap portion 410 and main portion 412. In this exemplary embodiment, depth 416 and depth 418 are substantially equal.

[0166] In this illustrative embodiment, recess 406 (i.e., main portion 412, stepped portion 414, and stepped portion 415) are shaped to correspond to a backing plate having a shape to form a "hat" stringer. For example, main portion 412 includes a bottom portion 420 (which forms the "cap portion" of the hat stringer) and web portions 422 and 424 that extend from bottom portion 420 to stepped portions 414 and 415, respectively. In other illustrative embodiments, recess 406 is shaped to correspond to other types of backing plates.

[0167] Figure 5 illustrates the addition of caul plates to the stack 306 of Figure 4 according to an exemplary embodiment. The caul plates 500 are positioned to fit into the recesses 402 of the inner envelope 400. The caul plates 500 are an example implementation of the caul plates 204 of Figure 2. Specifically, each caul plate 500 is positioned in a corresponding one of the recesses 402.

[0168] Additionally, each caul plate 500 is formed with a shape that substantially matches or corresponds to the shape of the corresponding recess in which it is placed. In this exemplary embodiment, caul plate 500 is shaped to form a "hat" stringer.

[0169] As previously discussed, the coefficient of thermal expansion of the backing plate 500 is sufficiently close to the coefficient of thermal expansion of the thermoplastic braided member disposed thereon to reduce or eliminate the possibility of overstressing the thermoplastic material. As the encapsulant 400 is softened by induction heating, the backing plate 500 provides strength and rigidity.

[0170] For example, backing plate 502 of the plurality of backing plates 500 is disposed in a corresponding recess 406. Backing plate 502 is an example of an embodiment of backing plate 228 of FIG. 2. Backing plate 502 is formed into a shape that substantially matches or corresponds to recess 406. Specifically, backing plate 502 is formed into a shape that substantially matches or corresponds to each of main portion 412, step portion 414, and step portion 415 of recess 406.

[0171] For example, the backing plate 502 includes a main portion 504, a flange portion 506, and a flange portion 508. The main portion 504 is shaped to fit closely into the main portion 412 of the recess 406. As described above, the main portion 412 is a portion that constitutes at least a portion of the hat-shaped cross-sectional shape. Thus, like the main portion 412, the main portion 504 includes a base portion 510, a web portion 512, and a web portion 514. The flange portion 506 and the flange portion 508 are shaped to fit closely into the stepped portion 414 and the stepped portion 415, respectively, of the recess 406. In this exemplary embodiment, the thickness of the flange portion 506 is less than the depth 416 of the stepped portion 414. Additionally, the thickness of the flange portion 508 is less than the depth 418 of the stepped portion 415.

[0172] Figure 6 illustrates the addition of a thermoplastic braided member to the stack 306 of Figure 5 in accordance with an exemplary embodiment. The thermoplastic braided members 600 are disposed over the backing plates 500. The thermoplastic braided members 600 are an example of an implementation of the thermoplastic braided member 206 of Figure 2. Each thermoplastic braided member 600 is disposed over a corresponding one of the backing plates 500.

[0173] In some exemplary embodiments, the thermoplastic braided member 600 is laminated directly onto the backing plate 500 after the backing plate 500 is added to the stack 306. In other exemplary embodiments, the thermoplastic braided member 600 is added to the stack 306 simultaneously with the backing plate 500. For example, the thermoplastic braided member 600 is laminated to the backing plate 500 before being placed in the stack 306. The backing plate 500 can then be used to carry and place the thermoplastic braided member 600 into each recess of the inner envelope 400.

[0174] Additionally, each thermoplastic braided member 600 is formed to substantially match the shape of a corresponding caul plate, ultimately forming a "hat" stringer.

[0175] As an example, the thermoplastic braided member 602 is placed on the backing plate 502 that is placed in the recess 406 of the inner enclosure 400. The thermoplastic braided member 602 is formed to substantially match the shape of the corresponding backing plate 502. Specifically, the thermoplastic braided member 602 is formed to a shape that substantially matches each of the main portion 504, the flange portion 506, and the flange portion 508 of the backing plate 502. By shaping the thermoplastic braided member 60 in this manner, the thermoplastic braided member 602 having the main portion 604, the flange portion 606, and the flange portion 608 is formed.

[0176] In this exemplary embodiment, the combined thickness of the flange portion 606 of the thermoplastic braided member 602 and the flange portion 506 of the backing plate 502 is substantially equal to the depth 416 of the step 414 of the recess 406 of the inner container 400. Similarly, the combined thickness of the flange portion 608 of the thermoplastic braided member 602 and the flange portion 508 of the backing plate 502 is substantially equal to the depth 418 of the step 415 of the recess 406 of the inner container 400. In this embodiment, the thermoplastic braided member 602 does not protrude outside the circumferential contour of the cap portion 408 or cap portion 410.

[0177] Figure 7 illustrates the addition of stringer encapsulations to the stack 306 of Figure 6 in accordance with an exemplary embodiment. The stringer encapsulations 700 are positioned over the thermoplastic braided member 600. The stringer encapsulations 700 are an example implementation of the stringer encapsulation 208 of Figure 1. Each of the stringer encapsulations 700 is shaped to allow the thermoplastic braided member 600 to maintain a shape suitable for forming a "hat" stringer.

[0178] Each of the stringer wraps 700 is disposed over a corresponding thermoplastic braided member of the thermoplastic braided member 600. For example, the stringer wrap 702 is disposed over the thermoplastic braided member 602.

[0179] In this illustrative embodiment, the stringer encapsulation 702 has a shape that is adapted to maintain the shape of the thermoplastic braided member 602 during heating. The recess 406 of the encapsulation 400, the backing plate 502, and the stringer encapsulation 702 collectively support the thermoplastic braided member 602 from both sides while holding the thermoplastic braided member 602 in place. The stringer encapsulation 702 is shaped and sized such that the sides 704 of the stringer encapsulation 702 conform to the circumferential contour generally defined by the cap portion 404 of the encapsulation 400.

[0180] Similar to the casing 400, the stringer casing 700 is placed under pressure during the induction heating crimping process. When unpressurized, the stringer casing 700 is in a "contracted state." When pressurized, the stringer casing 700 is in an "expanded state."

[0181] 8 illustrates the addition of a thermoplastic braided skin to the stack 306 of FIG. 7 in accordance with an exemplary embodiment. The thermoplastic braided skin 800 is disposed over the cap portion 404 of the inner casing 400, the inner stringer casing 700, and a predetermined portion of the thermoplastic braided member 600. Specifically, the thermoplastic braided skin 800 is disposed such that the thermoplastic braided skin 800 contacts the flange portions of the thermoplastic braided member 600. For example, the thermoplastic braided skin 800 is disposed such that the thermoplastic braided skin 800 contacts the flange portions 606 and 608 of the thermoplastic braided member 602.

[0182] In this exemplary embodiment, the thermoplastic braided skin 800 is placed around the entire perimeter of the stack 306, which includes the casing 400, the backing plate 500, the thermoplastic braided member 600, and the stringer casing 700. The placement of the thermoplastic braided skin 800 completes the stack 306 in these exemplary embodiments.

[0183] 9 illustrates a second smart susceptor 312 and outer tool 308 disposed around the stack 306 of FIG. 8 according to an exemplary embodiment. The second smart susceptor 312 is disposed around the thermoplastic braided skin 800. The outer tool 308 is disposed around the second smart susceptor 312. This positioning places the second smart susceptor 312 within the electromagnetic field generated by the induction coil 314 when a current is applied to the induction coil 314.

[0184] Heating can be performed using induction coils 313 and 314 and first smart susceptor 311 and second smart susceptor 312 to crimp and mold thermoplastic braided panel 800 and thermoplastic braided member 600. This crimp and mold process can produce the final fuselage structure consisting of fuselage skin panels with integrated fuselage stringers.

[0185] 10 is a longitudinal cross-sectional view of a system for supporting a consolidation mass 300 during crimping according to an exemplary embodiment. This cross-section of the system 1000, and thus the consolidation mass 300, is taken along a plane substantially parallel to the longitudinal axis 301. Specifically, this cross-section is taken along line 10-10 in FIG. 3A, and includes additional components not shown in FIG. 3A. System 1000 is an example implementation of system 113 in FIG. 1.

[0186] 10, the stack body 306 has a first end 1002 and a second end 1004. The system 1000 includes a plurality of plugs 1005 for plugging these ends. Specifically, plug 1006 and plug 1008 are used to plug the first end 1002 and the second end 1004 of the stack body 306, respectively.

[0187] The plugs 1005 can hold the various components of the stack 306 in place during induction heating. For example, the plugs 1005 can inhibit the longitudinal expansion of the inner casing 400 and the stringer casing 700 by not expanding longitudinally as much as the inner casing 400 and the stringer casing 700. For example, the plugs 1005 can not expand at all or can only expand slightly compared to the inner casing 400 and the stringer casing 700. The plugs 1005 are sized appropriately to maintain the various components of the stack 306 in place during induction heating.

[0188] Additionally, the plugs 1005 facilitate easy installation and removal of the components of the system 1000. Removal of the plugs 1005 allows for longitudinal removal of various components of the stack 306. For example, removal of the plugs 1005 allows the enclosure 400 and the stringer enclosure 700 to be slid longitudinally and removed from the system 1000.

[0189] The system 1000 further includes an end tool 1010 for positioning and securing the plugs 1006 and 1008. The end tool 1010 may be, for example, a structural frame or system for securing the plugs 1006 and 1008 to the stack 306.

[0190] The connecting devices 1012 are used to connect the induction coils 313 and 314. In one exemplary embodiment, each connecting device 1012 is used to connect one of the induction coils 313 embedded in the inner tool 304 to a corresponding one of the induction coils 314 embedded in the outer tool 308 at either end of the consolidation assembly 300. In some exemplary embodiments, each connecting device 1012 is a blade switch connector. For example, each blade switch connector 1012 includes a bar-shaped member formed of copper or other highly conductive material rotatably disposed about a fixed pivot point.

[0191] In this embodiment, the connecting device 1012 includes a connecting device 1014, a connecting device 1016, a connecting device 1018, and a connecting device 1020. The connecting device 1014 connects the coil 1022 of the induction coil 313 to the coil 1024 of the induction coil 314 at the end 1026 of the consolidation assembly 300. The connecting device 1016 connects the coil 1022 to the coil 1024 at the end 1028 of the consolidation assembly 300. The connecting device 1018 connects the coil 1030 of the induction coil 313 to the coil 1032 of the induction coil 314 at the end 1026 of the consolidation assembly 300. The connecting device 1020 connects the coil 1030 to the coil 1032 at the end 1028 of the consolidation assembly 300.

[0192] In some illustrative embodiments, the consolidation assembly 300 further includes a pressure bladder 1038. Each pressure bladder 1038 is used to apply pressure to a corresponding plug 1005. The pressure bladder 1040 is an example of one of the pressure bladder 1038. The pressure bladder 1040 is used to improve electrical contact between the first smart susceptor 311 and the second smart susceptor 312 (not labeled in this figure) and the connection device 1014 by applying pressure. The pressure bladder 1040 may be made of stainless steel.

[0193] 11A is a diagram of a portion of the consolidation assembly 300 of FIG. 10 in accordance with an exemplary embodiment, more clearly illustrating the plugs 1006 and 1008 in the exemplary embodiment. In this view, the backing plate 502 is visible. The stringer enclosure 702 is located in a recess in the backing plate 502, but is not visible in this view.

[0194] The plug 1006 and the plug 1008 are used to plug the first end 1002 and the second end 1004 of the stack body 306, respectively. The plug 1006 and the plug 1008 have a similar configuration. In these embodiments, the plug 1006 includes a plug portion 1100, a thermal barrier 1102, and a susceptor connection portion 1104. Similarly, the plug 1008 includes a plug portion 1106, a thermal barrier 1108, and a susceptor connection portion 1110.

[0195] The thermal insulation layers 1102 and 1108 provide a means for insulating the susceptor connection 1104 and the susceptor connection 1110, respectively. These thermal insulation layers may be made of, for example, a dielectric material. In these embodiments, the susceptor connection 1104 and the susceptor connection 1110 are water-cooled susceptor connections. If the temperature of the susceptor connection 1104 and the susceptor connection 1110 becomes too high, undesirable heating, oxide build-up, or both may occur. Thus, the susceptor connection 1104 and the susceptor connection 1110 are configured to be water-cooled to prevent overheating.

[0196] The pressurized tube 1112 is an example of an embodiment of the pressurized tube 238 of FIG. 2. In this illustrative embodiment, the pressurized tube 1112 is inserted through the stringer casing 702 (not shown in this figure) of the stack 306, and extends through both ends of the stringer casing 702 and from both the first end 1002 and the second end 1004 of the stack 306. As shown, the pressurized tube 1112 has an end 1114 and an end 1116. In these embodiments, the end 1114 and the end 1116 of the pressurized tube 1112 reach into the plug portion 1100 and the plug portion 1106, respectively, but do not penetrate the plug portions. In other words, both ends of the pressurized tube 1112 do not reach the insulation layer 1102 or the insulation layer 1108. However, in some cases, both ends of the pressurized tube 1112 can be configured to penetrate the plug 1006 and the plug 1008.

[0197] A pressurization system (not shown) can be used to inject inert gas through the pressurization tube 1112 into the stringer enclosure 702 (not shown in this figure). For example, both ends 1114 and 1116 are open ends and can be connected to piping of a pressurization system to inject inert gas into the pressurization tube 1112. The pressurization tube 1112 can be implemented in a variety of ways.

[0198] Figure 11B is a close-up view of one configuration of the pressure tube 1112 of Figure 11A in accordance with an exemplary embodiment. In Figure 11B, the backing plate 502 of Figure 11 has been removed to more clearly show the stringer casing 702 nested within the backing plate 502. In this exemplary embodiment, the pressure tube 1112 is not a continuous tube, but rather is inserted into the stringer casing 702 and terminates therein without penetrating the stringer casing 702.

[0199] Specifically, the pressurizing tube 1112 has an open end 1118 and an open end 1120 that communicate with the stringer casing 702. With this configuration, the inert gas flowing through the pressurizing tube 1112 is injected directly into the stringer casing 702 from the open ends 1118 and 1120 of the pressurizing tube 1112, thereby pressurizing the stringer casing 702. The size of the open ends 1118 and 1120 can be set according to the required pressure.

[0200] 11C is a close-up view of another configuration of the pressurizing tube 1112 of FIG. 11A according to an exemplary embodiment. In FIG. 11C, the backing plate 502 of FIG. 11 is omitted to more clearly show the stringer casing 702 nested within the backing plate 502. In this exemplary embodiment, the pressurizing tube 1112 is a continuous tube that passes through the stringer casing 702. In this embodiment, the pressurizing tube 1112 has one or more open holes 1122 through which the inert gas flowing through the pressurizing tube 1112 is injected into the stringer casing 702 to pressurize the stringer casing 702. The open holes 1122 can have a variety of configurations. For example, the open holes 1122 can be slits, perforations, holes, or other types of holes in the pressurizing tube 1112.

[0201] Figure 11D is a close-up view of yet another configuration of the pressure tube 1112 of Figure 11A in accordance with an exemplary embodiment. In Figure 11D, the backing plate 502 of Figure 11 has been omitted to more clearly show the stringer enclosure 702 nested within the backing plate 502. In this exemplary embodiment, the pressure tube 1112 is a multi-tube pressure tube.

[0202] Specifically, the pressure tube 1112 includes a first tube 1123 and a second tube 1124. The first tube 1123 is a discontinuous tube that terminates inside the stringer enclosure 702, with ends 1126 and 1128 located within the stringer enclosure 702, while the second tube 1124 is a tube inserted within the first tube 1123 and continues from end 1114 to end 1116. For example, the second tube 1124 has a smaller diameter than the first tube 1123 and is made of a stiffer material than the pressure tube 1112 and serves as a support structure for the second tube 1124. In one embodiment, the first tube 1123 is made of aluminum and the second tube 1124 is made of stainless steel. The second tube 1124 has one or more open holes 1130 (eg, perforations, slits, holes) to allow inert gas to be injected through the second tube 1124 into the stringer enclosure 702 .

[0203] When the inert gas is injected into the stringer encapsulation 702, it pressurizes the stringer encapsulation 702, thereby expanding the stringer encapsulation 702. This expansion can compress the thermoplastic braided member 602, shown in Figures 7-9, into a smooth surface with a predetermined contour shape.

[0204] Figure 12 is a cross-sectional view of an exemplary embodiment of stack 306 taken along line 12-12 of Figure 11. In this exemplary embodiment, stringer enclosure 702 is omitted so that plug portion 1100 can be seen.

[0205] A groove 1200 is formed through the stringer casing 702 and the plug portion 1100 of the plug 1008. The groove 1200 is formed to accommodate the passage of the pressurizing tube 1112 of FIG. 11. The groove 1202 extends through the plug 1006 and the casing 400 (not shown in this view). A pressurizing casing or pressurizing tube is passed through the groove 1202 and is used to pressurize the casing 400 during the induction heating crimping process. The groove 1202 can be located in any location suitable for injecting gas into the casing 400.

[0206] 13A and 13B show a tacking-trimming setup according to an exemplary embodiment. FIG. 13A is an isometric view of a tacking-trimming setup 1300 according to an exemplary embodiment. The tacking-trimming setup 1300 is also referred to as a tucking and trimming device for tow. FIG. 13B is a cross-sectional view of the tacking-trimming setup 1300 according to an exemplary embodiment. Specifically, the cross-section of the tacking-trimming setup 1300 is taken along line 13B-13B in FIG. 13A. The following description refers to both FIG. 13A and FIG. 13B.

[0207] The tucking and trimming assembly 1300 is used to "tuck" and "trim" each braided ply of a thermoplastic braided component, such as the thermoplastic braided member 600 or the thermoplastic braided skin 800 shown in Figures 6-10.

[0208] In this illustrative embodiment, the tacking and trimming assembly 1300 includes a tacking and trimming system 1301. The tacking and trimming system 1301 is secured to a support system 1302 that is disposed around a mounting surface 1304. In this illustrative embodiment, the tacking and trimming system 1301 can be secured to the support system 1302 using fasteners, clamps, mounting structures, other types of attachment devices, or combinations thereof. A braided layup 1306 is an example of a braid and is disposed around the mounting surface 1304. The braided layup 1306 is a stack of thermoplastic plies that are made of continuous fibers of a thermoplastic composite braided together. The braided layup 1306 is disposed around a conductive member 1308.

[0209] Although only one tacking and trimming system 1301 is shown secured to the support system 1302, any number of tacking and trimming systems may be secured to the support system 1302. In this illustrative embodiment, the support system 1302 includes a support ring 1303. The support ring 1303 is sized and shaped to surround the entire periphery of the mounting surface 1304.

[0210] The support system 1302 moves with the braiding ring or machine (not shown in this figure) so that the braided layup 1306 can be created and added to by adding or subtracting plies along the longitudinal axis 1307. In other words, the number of plies can be increased or decreased in the longitudinal direction. Furthermore, the support system 1302 can be rotated about the longitudinal axis 1307 or the tucking and trimming system 1301 can be moved about the support system 1302, so that the number of plies can be increased or decreased in the circumferential direction of the mounting surface 1304. The conductive member 1308, also referred to as a "shoe," is also configured to move with the braiding ring or machine.

[0211] In one exemplary embodiment, the mounting surface 1304 is the surface formed by the inner casing 400, inner stringer casing 700, and thermoplastic braided member 600 shown in Figure 7 without the addition of the thermoplastic braided panel 800 shown in Figure 8. In this embodiment, the thermoplastic braided panel 800 is a braided layup 1306 that is laid up against the mounting surface 1304. The tacking and trimming system 1301 is used to tack weld and trim the thermoplastic braided panel 800 during or after layup.

[0212] In another exemplary embodiment, the mounting surface 1304 is a surface formed by the backing plate 500. In such an embodiment, the thermoplastic braided member 600 shown in FIG. 6 is laid up on the mounting surface 1304 to form the braided layup 1306. The tacking and trimming system 1301 is used to tack and trim the thermoplastic braided member 600 during or after laying up, and prior to crimping the thermoplastic braided member 600 to the thermoplastic braided skin 800. In some cases, the thermoplastic braided member 600 of FIG. 6 is pre-formed and delivered to the stack 306 with the backing plate 500, and tack and trimming can be used with the tacking and trimming system 1301 for such thermoplastic braided member 600. For example, the support system 1302 is configured and sized to operatively position the tacking and trimming system 1301 relative to the stack 306, also referred to as a cylindrical thermoplastic stack.

[0213] Tack welds can be longitudinal, circumferential, or both. Additionally, tack welds can be used to add or remove plies to create complex shaped preforms. For example, braided layup 1306 includes multiple plies, including discontinuous layers. Some plies are partial layers. In some cases, braided layup 1306 includes padups and paddowns. Thus, the thickness and profile of braided layup 1306 is not constant, but rather varies when viewed as a whole of braided layup 1306. Tack welds can be used to maintain braided layup 1306 as a cohesive structure.

[0214] In yet another exemplary embodiment, the tucking and trimming system 1301 may be used to add an irregularity to a portion of the braided layup 1306. For example, if the braided layup 1306 is in the form of the thermoplastic braided panel 800 shown in FIG. 8, the tucking and trimming system 1301 may be used to add an irregularity (e.g., a thickening) to a portion of the thermoplastic braided panel 800.

[0215] In this manner, the tacking and trimming system 1301 is used to form and maintain the braided layup 1306 in a desired configuration. In this exemplary embodiment, the tacking and trimming system 1301 is used to perform tack welding prior to crimp forming, while in other exemplary embodiments, the tacking and trimming system 1301 may be used to perform tack welding and trimming as singular features are added in layers to a structure (e.g., a fuselage barrel) that has already been subjected to at least one crimp forming process to create an integrated structure.

[0216] Figure 14 is a cross-sectional view of a portion of the tacking and trimming assembly 1300 of Figure 13 in accordance with an exemplary embodiment. Specifically, the cross-section of the tacking and trimming assembly 1300 is taken along line 14-14 in Figure 13A.

[0217] As shown, the tacking and trimming system 1301 is secured to a support system 1302. The tacking and trimming system 1301 includes a tack welder 1400 and a trimmer 1402. The tack welder 1400 is positioned to lay up thermoplastic tows onto a mounting surface 1304 to form a braided layup 1306 of thermoplastic plies. The tows 1404 are an example of thermoplastic tows delivered from a braiding ring or machine. The tack welder 1400 resistively heats the tows 1404 to tack them to the braided layup 1306.

[0218] The trimming portion 1402 is used to trim the tow 1404. The trimming portion 1402 may be, for example, but not limited to, a laser trimming portion. A conductive member 1308 may be disposed between the tow 1404 and the braided layup 1306 to absorb laser energy emitted from the trimming portion 1402 and protect the braided layup 1306. In this embodiment, the conductive member 1308 is thermally conductive.

[0219] 3-14 are not meant to impose physical or architectural limitations on the manner in which example embodiments may be implemented. Additional or alternative components may be used other than those illustrated. Some components may be optional.

[0220] The various components shown in Figures 3-14 are examples of physical structural realizations of the components shown in the blocks of Figures 1-2. In addition, some of the components shown in Figures 3-14 can be combined with and / or used with the components shown in Figures 1-2.

[0221] Figure 15 is a flow chart illustrating a process for fabricating a composite structure in accordance with an exemplary embodiment. The process 1500 illustrated in Figure 15 can be performed, for example, using the system 113 illustrated in Figure 1 to fabricate the composite structure 101. In some examples, the composite structure 101 is fabricated using the consolidation mass 300 illustrated in Figures 3-11.

[0222] In process 1500, a stack is first assembled (step 1502) that includes an inner casing having a plurality of recesses, a plurality of backing plates disposed in the plurality of recesses, a plurality of thermoplastic braided members, a plurality of stringer casings, and a thermoplastic braided skin, the stack being positioned between an inner tool and an outer tool. The stack, inner tool, and outer tool are configured in a manner similar to stack 112, inner tool 108, and outer tool 110 of FIG. 1, or in a manner similar to stack 306, inner tool 304, and outer tool 308 of FIG. 3-8.

[0223] In some embodiments, the stack is assembled in process 1502 by placing each component in turn onto the inner tool, and then the outer tool is secured to the stack, while in other embodiments, the stack is preassembled and then placed onto the inner tool, and then the outer tool is placed onto the stack.

[0224] Thereafter, a member restraint is placed around the outer tool to assemble a consolidation assembly including the inner tool, stack, outer tool, and member restraint (operation 1504). The consolidation assembly is inductively heated to crimp and mold the thermoplastic braided members to the thermoplastic braided skin to produce a composite structure (operation 1506). This completes the process. Specifically, an integrated composite structure is produced by operation 1506.

[0225] In some demonstrative embodiments, operation 1506 is performed by inductively heating a first smart susceptor located between the inner tool and the stack body and a second smart susceptor located between the outer tool and the stack body, thereby crimping and forming the thermoplastic braided members to the thermoplastic braided skin. This process can form an arc-shaped skin having a plurality of fuselage stringers integrated therein. The plurality of thermoplastic braided members form the fuselage stringers, and the thermoplastic braided skin forms the arc-shaped skin, which together form a composite fuselage structure, such as composite fuselage structure 102 of FIG. 1.

[0226] Fig. 16 is a flow chart illustrating a process for assembling a stack according to an exemplary embodiment. The process 1600 illustrated in Fig. 16 can be used to assemble, for example, the stack 112 of Fig. 1 or the stack 306 of Figs. 3-8. Furthermore, the process 1600 can be used to perform the operation 1502 illustrated in Fig. 15.

[0227] The process 1600 begins by placing an enclosure around a first smart susceptor that surrounds the inner tool (operation 1602). The enclosure may be made of aluminum, for example. In this exemplary embodiment, the first smart susceptor is attached to the inner tool as a liner for the inner tool.

[0228] A plurality of caul plates are then placed into the plurality of recesses of the casing (operation 1604). In one such exemplary embodiment, each caul plate is comprised of an iron-nickel alloy. In one exemplary embodiment, each caul plate is comprised of an Invar alloy (e.g., Invar 52).

[0229] Next, a plurality of thermoplastic braided members are disposed on the plurality of backing plates (operation 1606). Specifically, each of the plurality of thermoplastic braided members is disposed in a recess in a corresponding one of the plurality of backing plates. Each of the plurality of thermoplastic braided members has a shape similar to that of the corresponding backing plate. The backing plate provides mechanical strength and rigidity, and allows the plurality of thermoplastic braided members to maintain the proper shape and smoothness during heating.

[0230] A plurality of stringer encapsulants are then placed over the plurality of thermoplastic braided members (operation 1608). A thermoplastic braided skin is then placed around the plurality of stringer encapsulants and the plurality of thermoplastic braided members, such that the thermoplastic braided skin contacts end regions of the plurality of thermoplastic braided members, such that the thermoplastic braided skin and the plurality of thermoplastic braided members, when inductively crimped, form a composite fuselage structure (operation 1610). This concludes the process. The thermoplastic braided skin and the thermoplastic braided members are crimped or molded together during the inductive crimping. The thermoplastic braided skin forms a fuselage skin of the composite fuselage structure, and the thermoplastic braided members form the fuselage stringers.

[0231] Fig. 17 is a flow chart illustrating a process for assembling a system including a consolidation aggregate according to an exemplary embodiment. According to the process 1700 illustrated in Fig. 17, the system 103 including the consolidation aggregate 104 illustrated in Fig. 1 or the system 1000 including the consolidation aggregate 300 illustrated in Figs. 3-11 can be assembled.

[0232] The process 1700 begins by placing an inner enclosure around a first smart susceptor that surrounds an inner tool (operation 1702). The inner tool has a number of inductive coils embedded therein. The inner tool is supported by a support structure. In such an embodiment, the shape of the inner tool is arcuate (e.g., cylindrical or nearly cylindrical, tapered cylindrical, conical, etc.). In one exemplary embodiment, the inner tool has a shape such that the cross section at any location along the longitudinal axis of the inner tool is substantially circular (circular or nearly circular).

[0233] In operation 1702, the enclosure is an aluminum enclosure having a plurality of recesses, which is disposed around the first smart susceptor so as to surround the first smart susceptor and thus the inner tool.

[0234] A backing plate is placed in the cavity of the casing (operation 1704). In operation 1704, the backing plate is made of an iron-nickel alloy, such as an Invar alloy. Each backing plate is formed to a shape that substantially matches or corresponds to the shape of the cavity of the casing in which it is to be placed. In one exemplary embodiment, the shape of the cavity of the casing, and therefore the shape of the backing plate, is an upside-down hat shape.

[0235] A thermoplastic braided member is then placed over the caul plate (operation 1706). In operation 1706, the thermoplastic braided member is formed into a shape that substantially conforms to or matches the shape of the caul plate. A stringer encapsulation is then placed over the plurality of thermoplastic braided members (operation 1708). The stringer encapsulation is shaped to be disposed in the recesses or spaces defined by the thermoplastic braided members. In this exemplary embodiment, the stringer encapsulation is made of aluminum.

[0236] The thermoplastic braided skin is then wrapped around the stringer encapsulation to assemble the integral stack of encapsulation, backing plate, thermoplastic braided member, stringer encapsulation, and thermoplastic braided skin (operation 1710). In operation 1710, the thermoplastic braided skin is placed in contact with at least a portion of the thermoplastic braided member, such as a flange portion of the thermoplastic braided member.

[0237] A second smart susceptor is then placed around the thermoplastic braided skin (operation 1712). A consolidation assembly is assembled by placing an outer tool around the second smart susceptor (operation 1714). Like the inner tool, the outer tool has multiple induction coils embedded therein. A member restraint is then used to secure the outer tool, stack, and inner tool together (operation 1716).

[0238] The pressurization tubes are then threaded through the bladder and the stringer encapsulation (operation 1718). This concludes the process. In one exemplary embodiment, one pressurization tube is threaded through the groove in the bladder and multiple other pressurization tubes are threaded through the stringer encapsulation (e.g., one pressurization tube per stringer encapsulation). Thus, the consolidation assembly includes the inner tool, stack, outer tool, member restraint, and pressurization tubes. In another exemplary embodiment, the pressurization tubes are separate members from the consolidation assembly.

[0239] Next, the first induction coil embedded in the inner tool and the second induction coil embedded in the outer tool are connected via connecting devices (operation 1720). These connecting devices can take the form of, for example, blade switch connectors. The ends of the stack are plugged (operation 1722). The plugs are positioned and secured using an end tool (operation 1724). The process then ends.

[0240] 18 is a flowchart illustrating a process for assembling a system for fabricating a composite fuselage structure in accordance with an exemplary embodiment. The process 1800 illustrated in FIG. 18 may be used to assemble, for example, the system 113 illustrated in FIG.

[0241] Process 1800 begins by assembling a consolidation assembly (operation 1802). Process 1802 can be performed, for example, using process 1700 of Figure 17. For example, the consolidation assembly assembled in operation 1802 can include an inner tool including an embedded first induction coil, an outer tool including an embedded second induction coil, a first smart susceptor, a second smart susceptor, and a stack disposed between the first and second smart susceptors, the stack including a plurality of thermoplastic braided members and a thermoplastic braided skin.

[0242] The consolidation mass is then inductively heated using the first induction coil, the second induction coil, the first smart susceptor, and the second smart susceptor to crimp and form the thermoplastic braided skin and the plurality of thermoplastic braided members into a composite fuselage structure (operation 1804), at which point the process ends.

[0243] Figure 19 is a flow chart illustrating a process for inductively crimping a thermoplastic braided skin and a thermoplastic braided member to form a composite fuselage structure according to an exemplary embodiment. According to the process 1900 shown in Figure 19, for example, the thermoplastic braided skin 210 and the thermoplastic braided member 206 shown in Figure 2 may be inductively crimped. Moreover, the process 1900 may be performed using a system 103 including a consolidation assembly 104 including the stack 112 shown in Figures 1-2.

[0244] The process 1900 begins by connecting a first induction coil embedded in an inner tool of the consolidation assembly with a second induction coil embedded in an outer tool of the consolidation assembly (operation 1902). A connecting device such as the connecting device 107 shown in FIG. 1 can be used in operation 1902. In one or more exemplary embodiments, the first induction coil and the second induction coil are connected to ultimately form a toroidal solenoid.

[0245] Thereafter, a predetermined amount of pressure is applied to the encapsulated material in the consolidation mass (operation 1904). For example, operation 1904 may involve connecting a pressurization system to the encapsulated material and applying pressure with an inert gas. In one exemplary embodiment, a pressure tube of the pressurization system is disposed within the encapsulated material or in a channel through the encapsulated material. The pressurization system applies pressure with an inert gas. The pressure applied in operation 1904 may be small (e.g., about 15 psi).

[0246] The first and second induction coils are energized to heat the first and second smart susceptors in the consolidation assembly, thereby heating the thermoplastic material in the consolidation assembly to a temperature within a predetermined tolerance of a set temperature (operation 1906), for example a temperature above 350 degrees F. The thermoplastic material heated in operation 1906 is the thermoplastic braided skin and thermoplastic braided members in the stack that form the fuselage skin and fuselage stringers in the composite fuselage structure.

[0247] Pressurization is performed (operation 1908) using the casing and the stringer casing. In operation 1908, a pressurization system applies a pressure of, for example, about 250 psi, which allows the thermoplastic material to be uniformly stretched. In operation 1908, the thermoplastic braided skin and the thermoplastic braided member are inductively heated and crimped to form a composite fuselage structure, for example a composite barrel. The temperature of the thermoplastic material is then reduced (operation 1910). If the temperature falls below a predetermined threshold temperature, the pressure is reduced (operation 1912). For example, in operation 1912, if the temperature falls below about 300 degrees Fahrenheit, the pressure is reduced to about 15 psi.

[0248] The composite fuselage structure is then removed (operation 1914). A vacuum is applied to the casing to create a gap between the composite fuselage structure and the inner tooling of the consolidation assembly (operation 1916). The outer tooling of the consolidation assembly is removed to allow the composite fuselage structure to be removed from the inner tooling (operation 1918). This concludes the process.

[0249] In other exemplary embodiments, the process 1900 includes additional processing to customize the composite fuselage structure after it is removed from the inner tool. For example, cutouts can be added to the composite fuselage structure or other components can be added. In one exemplary embodiment, a window belt cutout is formed. In another embodiment, a fuselage frame and window frames are added using induction joining or induction welding techniques. For example, but not limited to, shear ties, system brackets, antenna reinforcements, service pan reinforcements, other types of parts, or combinations thereof can be added to the composite fuselage structure using induction joining or induction welding.

[0250] 20 is a flow chart illustrating a process for making a composite structure according to an exemplary embodiment. The process 2000 shown in FIG. 20 may be used to make a composite structure, such as the composite structure 101 shown in FIG.

[0251] In the process 2000, first, the inner tool, the stack, and the outer tool are held together in a predetermined position using a member restraint (step 2002). Next, the casing and the multiple stringer casings in the stack are pressurized to expand the casing and the multiple stringer casings, thereby pressing the thermoplastic braided skin and the multiple thermoplastic braided members against each other (step 2004).

[0252] The thermoplastic braided skin and the thermoplastic braided members in the stack are then co-molded with each other while the casing and the plurality of stringer casings are pressurized to form a composite structure (operation 2006). This completes the process. The application of pressure in operation 2004 ensures that the thermoplastic braided skin and the plurality of thermoplastic braided members are co-molded uniformly and smoothly.

[0253] 21 is a flow chart illustrating a process for making a composite structure according to an exemplary embodiment. The process 2100 shown in FIG. 21 may form a composite structure, such as the composite structure 101 shown in FIG.

[0254] Process 2100 begins by expanding the encapsulation and the plurality of stringer encapsulations in the stack to tension the fibers in the thermoplastic braided skin and the plurality of thermoplastic braided members (operation 2102). Operation 2102 can be performed, for example, by pressurizing the encapsulation and the plurality of stringer encapsulations. In some embodiments, the encapsulation and the stringer encapsulations are pressurized by flowing an inert gas through a pressurization tube. The pressurization tube is expanded by injecting the inert gas, thereby expanding the encapsulation and the stringer encapsulations.

[0255] The stack is heated to melt the thermoplastic braided skin and the plurality of thermoplastic braided members (operation 2104). Operation 2104 may be performed by inductively heating a smart susceptor. The thermoplastic braided skin and the plurality of thermoplastic braided members are then bonded together (operation 2106) while the thermoplastic braided skin and the plurality of thermoplastic braided members are in a molten state. The stack is cooled to produce a composite fuselage structure with the thermoplastic braided skin and the plurality of thermoplastic braided members integrated together (operation 2108). This concludes the process.

[0256] 22 is a flow chart illustrating a process for making a composite structure according to an exemplary embodiment. The process 2200 illustrated in FIG. 22 may form a composite structure, such as the composite structure 101 illustrated in FIG.

[0257] In process 2200, a stack is first assembled, which includes a plurality of thermoplastic braided members and a thermoplastic braided skin (operation 2202). The stack is placed between an inner tool and an outer tool (operation 2204). A member restraint is used to hold the inner tool, stack, and outer tool together in place, thereby assembling a consolidation assembly including the inner tool, stack, outer tool, and member restraint (operation 2206). The consolidation assembly is heated to create a composite structure (operation 2208). This concludes the process.

[0258] 23 is a flow chart illustrating a process for making a composite structure according to an exemplary embodiment. The process 2300 shown in FIG. 23 may be used to make a composite structure, such as the composite structure 101 shown in FIG.

[0259] The process 2300 includes creating a plurality of crimp-formed thermoplastic braided preforms (operation 2302). The plurality of crimp-formed thermoplastic braided preforms includes a plurality of thermoplastic braided members and a thermoplastic braided skin. The process 2300 further includes consolidating the plurality of crimp-formed thermoplastic braided preforms in a circumferentially restrained arc stack (operation 2304). During consolidation, tension is applied to the fibers of the plurality of crimp-formed thermoplastic braided preforms (operation 2306).

[0260] In process 2300, operation 2304 can be performed without the use of an autoclave. Operation 2304 can achieve autoclave-like pressurization by using a bladder to generate a reaction force against an outer member restraint. Additionally, operation 2304 can achieve autoclave-like heating by using an induction coil and smart susceptors.

[0261] 24 is a flow chart illustrating a process for making a composite structure according to an exemplary embodiment. The process 2400 shown in FIG. 24 may be used to make a composite structure, such as the composite structure 101 shown in FIG.

[0262] Process 2400 begins by expanding the stringer encapsulations in the stack to apply a force to the thermoplastic braided members and the thermoplastic braided skin (operation 2402). Operation 2402 is performed by heating the stringer encapsulations and pressurizing the stringer encapsulations by supplying an inert gas to the stringer encapsulations via pressurized tubes. Expanding the stringer encapsulations applies tension to the thermoplastic braided members to resist a compressive load on the thermoplastic braided members.

[0263] The stack is constrained by the dielectric material with the non-dielectric material embedded therein while the stringer encapsulants expand (operation 2404). Operation 2404 may be performed by pressing the stack against an outer tool containing the dielectric material, the dielectric material being a ceramic material and the non-dielectric material being the induction coils used for heating in operation 2402. The non-dielectric material is constrained by the dielectric material while the stringer encapsulants expand (operation 2406).

[0264] 25 is a flow chart illustrating a process for tucking and trimming thermoplastic tows in accordance with an exemplary embodiment. The thermoplastic tows that are tucked and trimmed in this process are ultimately used to form the thermoplastic braided skin 210 and thermoplastic braided member 206 shown in FIG. 2.

[0265] In the process 2500, the thermoplastic tows are first received and stacked from a braid ring over the braid on the mounting surface, with a portion of the thermoplastic tow being received over the conductive member (operation 2502). The thermoplastic tows may be braided thermoplastic tows. The mounting surface may be a surface formed by at least one of a tool face, a backing plate, an enclosure, a stringer enclosure, a partially formed braided layup, a preform, an integrated composite structure, or other type of surface. The braid may be, for example, a braided layup of thermoplastic material, a partially formed braided layup, a preform, an integrated structure formed from braided thermoplastic tows, or another braid. In operation 2502, the thermoplastic tows are placed over the partially formed braid on the mounting surface. The conductive member in operation 2502 may also be referred to as a "shoe."

[0266] The thermoplastic tows are tack welded to the braid using tack welds secured to the support ring (operation 2504). In operation 2504, the tack welds are heated by resistive heat to uniformly tack the thermoplastic tows to the braid. The thermoplastic tows received above the braid are trimmed by trimming a portion of the thermoplastic tow (operation 2506). This ends the process. In operation 2506, laser energy is applied to the portion of the thermoplastic tow supported by the conductive member to trim the thermoplastic tow. The conductive member absorbs the laser energy, protecting the braid located below the conductive member.

[0267] 26 is a flow chart illustrating a process for tucking and trimming thermoplastic tows in accordance with an exemplary embodiment. The thermoplastic tows that are tucked and trimmed in this process, shown in FIG. 26, will ultimately form the thermoplastic braided skin 210 and thermoplastic braided member 206 shown in FIG.

[0268] In the process 2600, a thermoplastic tow is first received from a braiding system and stacked above the braid on a mounting surface (operation 2602). The received thermoplastic tow is tack welded to the braid (operation 2604). The received thermoplastic tow is trimmed by irradiating a portion of the thermoplastic tow with laser energy (operation 2606). This completes the process.

[0269] An example embodiment of the present disclosure may be described in relation to aircraft manufacturing and service method 2700 shown in Figure 27 and aircraft 2800 shown in Figure 28. Referring initially to Figure 27, an example embodiment of an aircraft manufacturing and service method is shown. As a pre-production step, aircraft manufacturing and service method 2700 includes specification and design 2702 of aircraft 2800 in Figure 28 and material procurement 2704.

[0270] During production, component and subassembly manufacturing 2706 and system integration 2708 of the aircraft 2800 of Figure 28 occurs. The aircraft 2800 of Figure 28 then undergoes, for example, certification and delivery 2710 and enters service 2712. While in service 2712 by the customer, the aircraft 2800 of Figure 28 is scheduled for routine maintenance and service 2714, which may also include modification, reconfiguration, retrofit, etc.

[0271] Each step of method 2700 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). In these examples, the operator may be a customer. Note that the system integrator may include, but is not limited to, any number of aircraft manufacturers and major-system subcontractors. The third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers. The operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0272] Referring now to FIGURE 28, an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft 2800 is manufactured according to aircraft manufacturing and service method 2700 as shown in FIGURE 27 and includes an airframe 2802 with a number of systems 2804 and an interior 2806. Example systems 2804 include one or more of propulsion system 2808, electrical system 2810, hydraulic system 2812, and environmental system 2814, as well as any number of other systems. It is noted that although an aerospace example has been described, other illustrative embodiments may be applicable to other industries, such as the automotive industry.

[0273] The apparatus and method embodied in this specification can be employed in one or more of the steps in the method 2700 for manufacturing and using an aircraft in FIG. 27. Specifically, in any one or more steps in the method 2700 for manufacturing and using an aircraft, the system 103 shown in FIGS. 1-2 can be used to fabricate the composite structure 101. In addition, the system 103 shown in FIGS. 1-2 can be used to fabricate the composite structure 101 in at least one of the steps of, for example but not limited to, component and subassembly manufacturing 2706, system integration 2708, and routine maintenance and servicing 2714 in the method 2700 for manufacturing and using an aircraft. In addition, at least a portion of the airframe 2802 of the aircraft 2800 shown in FIG. 28 can be fabricated using the system 103 shown in FIGS. 1-2. For example, the system 103 can be used to form the fuselage barrel of the airframe 2802.

[0274] In one illustrative example, the parts or subassemblies produced in component and subassembly manufacturing 2706 of FIG. 27 may be similarly produced or manufactured as the parts or subassemblies produced during in-service 2712 of aircraft 2800 as shown in FIG. 27. One or more of the apparatus embodiments, method embodiments, or combinations thereof may be employed during manufacturing operations such as component and subassembly manufacturing 2706 and system integration 2708 of FIG. 27. One or more of the apparatus embodiments, method embodiments, or combinations thereof may be employed during in-service 2712 and / or maintenance and service 2714 operations of aircraft 2800 as shown in FIG. 27. Using several different illustrative embodiments, the speed or cost of assembly of aircraft 2800 may be significantly increased.

[0275] The flowcharts and block diagrams in the various embodiments described above illustrate the structure, functionality, and processing of some possible implementations of the apparatus and methods in the exemplary embodiments. In this regard, each block in the flowcharts or block diagrams may represent a module, a segment, a function, and / or a portion of a process or step.

[0276] In some alternative aspects of the exemplary embodiments, the functions noted in the blocks may occur out of the order shown in the figures. For example, in some cases, two blocks shown as successive may be executed substantially concurrently or in the reverse order, depending on the functionality involved. Also, additional blocks may be added to the blocks shown in a flowchart or block diagram.

[0277] In this specification, when the expression "at least one" is used in conjunction with a list of items, it means that various combinations of one or more of the listed items may be used, and that only one of the listed items may be required. An item may be a particular object, object, step, treatment, process, or category. In other words, "at least one" means that any number of items may be used in any combination from the listed items, but not all of the listed items are required. For example, "at least one of item A, item B, or item C" or "at least one of item A, item B, and item C" includes, but is not limited to, item A, item A and item B, item B, item A, item B, and item C, item B and item C, or item A and item C. In some cases, "at least one of item A, item B, or item C" or "at least one of item A, item B, and item C" may mean, without limitation, for example, 2 item A, 1 item B, 10 item C, 4 item B and 7 item C, or any other suitable combination. The following notes are also provided herein:

[0278] 1. A method for making a composite structure (101), comprising: Assembling (2202) a stack (112) including a thermoplastic braided skin (210) and a plurality of thermoplastic braided members (206); The stack (112) is placed (2204) between an inner tool (108) and an outer tool (110); assembling (2206) the inner tool (108), the stack body (112), and the outer tool (110) together in a predetermined position using a member restraint portion (117), thereby assembling a consolidation assembly (104) including the inner tool (108), the stack body (112), the outer tool (110), and the member restraint portion (117); The method further comprises heating the consolidation mass (104) to form (2208) the composite structure (101).

[0279] 2. The method described in Appendix 1, in which, when assembling (2202) the stack body (112), the stack body (112) is assembled by combining an inner casing (202) having a plurality of recesses (216), a plurality of backing plates (204) inserted into the plurality of recesses (216), a plurality of thermoplastic braided members (206), a plurality of stringer inner casings (208), and a thermoplastic braided outer panel (210).

[0280] 3. The method of claim 1 or 2, wherein heating (2208) the consolidation mass (104) comprises inductively heating the consolidation mass (104) to press-mold the plurality of thermoplastic braided members (206) with the thermoplastic braided skin (210) to produce an integrated composite structure (101).

[0281] 4. The method of claim 3, wherein when heating (2208) the consolidation assembly (104), a first smart susceptor (114) located between the inner tool (108) and the stack body (112) and a second smart susceptor (115) located between the outer tool (110) and the stack body (112) are inductively heated to press-form the plurality of thermoplastic braided members (206) onto the thermoplastic braided outer plate (210).

[0282] 5. The method of any one of claims 1 to 4, further comprising inserting a plurality of pressurized tubes (238) through a plurality of stringer enclosures (208).

[0283] 6. The method of claim 5, further comprising securing (1722) the pressurized tubes (238) within the stringer enclosures (208) using plugs (106) disposed at the ends of the stack (112).

[0284] 7. When assembling the stack body (112), The inner tool (108) is supported by a support structure (116), and a first smart susceptor (114) is disposed (1602) around the inner tool (108); The method of any one of claims 1 to 6, further comprising disposing (1702) an inner enclosure (202) around the first smart susceptor (114).

[0285] 8. The method of claim 7, wherein the step of assembling (2202) the stack body (112) further comprises placing (1604) a plurality of backing plates (204) in the plurality of recesses (216) of the inner container (202), each of the plurality of backing plates (204) being made of an iron-nickel alloy.

[0286] 9. The method of claim 8, wherein assembling (2202) the stack (112) further comprises arranging (1606) the plurality of thermoplastic braided members (206) on the plurality of backing plates (204), wherein the shape of a given thermoplastic braided member of the plurality of thermoplastic braided members (206) is substantially the same as the shape of the backing plate of the plurality of backing plates (204) on which the given thermoplastic braided member is arranged.

[0287] 10. When assembling (2202) the stack body (112), placing (1608) a plurality of stringer envelopes (208) over the plurality of thermoplastic braided members (206); 10. The method of claim 9, further comprising completing (1610) the stack (112) by placing the thermoplastic braided skin (210) around the plurality of stringer enclosures (208) and the plurality of thermoplastic braided members (206), such that the thermoplastic braided skin (210) contacts end regions of the plurality of thermoplastic braided members (206).

[0288] 11. Further, a second smart susceptor (115) is disposed (1712) around the thermoplastic braided skin (210); 11. The method of claim 10, further comprising disposing (1714) the outer tool (110) around the second smart susceptor (115), wherein the inner tool (108), the first smart susceptor (114), the stack body (112), the second smart susceptor (115), and the outer tool (110) integrally form at least a portion of the consolidation assembly (104).

[0289] 12. The method according to any one of appendices 1 to 11, further comprising plugging (1722) a first end (126) of the stack body (112) and a second end (128) of the stack body (112) using a plurality of plugs (106), wherein a first plug (1006) among the plurality of plugs (106) used in the first end (126) of the stack body (112) and a second plug (1008) among the plurality of plugs (106) used in the second end (128) of the stack body (112) each include a plug portion (1100, 1106), a thermal insulating layer (1102, 1108), and a susceptor connection portion (1104, 1110).

[0290] 13. The method of claim 12, further comprising securing (1724) an end tool (105) to the plurality of plugs (106) in preparation for crimping and molding the plurality of thermoplastic braided members (206) to the thermoplastic braided skin (210).

[0291] 14. The method of any one of claims 1 to 13, further comprising pressurizing the casing (202) and the plurality of stringer casings (208) in the stack (112) to substantially the same pressure while crimping the plurality of thermoplastic braided members (206) to the thermoplastic braided skin (210).

[0292] 15. The method of any one of claims 1 to 14, further comprising providing mechanical strength and rigidity to the thermoplastic braided members (206) by a plurality of backing plates (204) in the stack (112) during compression molding of the thermoplastic braided members (206) to the thermoplastic braided outer plate (210).

[0293] 16. A composite aircraft barrel component (102) assembled by the method described in any one of appendixes 1 to 15.

[0294] 17. A method for making a composite fuselage structure (102), comprising: Expanding the encapsulation member (202) and the plurality of stringer encapsulation members (208) in the stack (112) to apply tension (2102) to the fibers in the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206); heating the stack (112) to melt (2104) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206); bonding (2106) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) together while the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) are in a molten state; and cooling (2108) the stack (112) to create the composite fuselage structure (102) incorporating the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206).

[0295] 18. The composite fuselage structure (102) assembled by the method of claim 17.

[0296] 19. An inner tool (108); a first smart susceptor (114) disposed around the inner tool (108); a stack (112) disposed around the first smart susceptor (114), the stack (112) including a thermoplastic braided skin (210) and a plurality of thermoplastic braided members (206); a second smart susceptor (115) disposed around the stack body (112); an outer tool (110) disposed around the second smart susceptor (115); and a member restraint portion (117) that holds the inner tool (108), the first smart susceptor (114), the stack body (112), the second smart susceptor (115), and the outer tool (110) in a predetermined position.

[0297] 20. The apparatus of claim 19, wherein the stack (112) further includes a plurality of backing plates (204), each of which imparts a predetermined contoured surface and stiffness to a corresponding one of the plurality of thermoplastic braided members (206).

[0298] 21. A plurality of pressurizing tubes (238) passing through a plurality of stringer enclosures (208) in the stack (112); 21. The apparatus of claim 19 or 20, further comprising a pressurized tube (240) passing through the inner container (202) in the stack (112).

[0299] 22. Fabrication of a composite aircraft fuselage barrel (102) using an apparatus according to any one of appendices 19 to 21.

[0300] 23. A method for making a composite fuselage structure (101), comprising: The inner tool (108), the stack body (112), and the outer tool (110) are held together in a predetermined position using a member restraint portion (117) (2002); pressurizing the inner casing (202) and the plurality of stringer inner casings (208) in the stack (112) to expand the inner casing (202) and the plurality of stringer inner casings (208), thereby pressing (2004) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) in the stack (112) against one another; and co-molding (2006) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) together while the inner casing (202) and the plurality of stringer inner casings (208) are under pressure to form the composite structure (101).

[0301] 24. When integrally molding (2006) the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206), 24. The method of claim 23, further comprising inductively heating a first smart susceptor (114) and a second smart susceptor (115) in the stack (112) to melt the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206), thereby bonding the thermoplastic braided outer panel (210) and the plurality of thermoplastic braided members (206).

[0302] 25. When the first smart susceptor (114) and the second smart susceptor (115) are induction heated, generating magnetic energy using a first induction coil (118) embedded in the inner tool (108) and a second induction coil (120) embedded in the outer tool (110); 25. The method of claim 24, wherein the first smart susceptor (114) and the second smart susceptor (115) are used to convert the magnetic energy into thermal energy.

[0303] 26. When compressing (2004) the inner container (202) and the plurality of stringer inner containers (208) in the stack (112), 26. The method of any one of claims 23 to 25, wherein the plurality of stringer enclosures (208) are pressurized using inert gas flowing through a plurality of pressurization tubes (238) passing through the plurality of stringer enclosures (208).

[0304] 27. When compressing (2004) the inner container (202) and the plurality of stringer inner containers (208) in the stack (112), 27. The method of any one of claims 23 to 26, wherein the inner envelope (202) is pressurized using an inert gas flowing through a pressurization tube passing through the inner envelope (202).

[0305] 28. The method of any one of claims 23 to 27, further comprising supporting each of the plurality of thermoplastic braided members (206) by a predetermined contoured surface defined by a corresponding one of the plurality of backing plates (204) in the stack (112) during induction heating.

[0306] 29. The method of any one of appendices 23 to 28, further comprising cooling the stack (112) to bond (2108) the thermoplastic braided skin (210) and the plurality of thermoplastic braided members (206) to form an integrated composite structure (101).

[0307] 30. The method of any one of appendices 23 to 29, further comprising fixing (1722) a first end (126) and a second end (128) of the stack body (112) with a plurality of plugs to prevent the encapsulation body (202) or the plurality of stringer encapsulation bodies (208) from expanding longitudinally during induction heating.

[0308] 31. Further, the stack body (112) is assembled (2202, 2204) on the inner tool (108); Fixing (2204) the outer tool (110) around the stack (112); 31. The method of any one of claims 23 to 30, further comprising applying a compressive load (2206) to the inner tool (108) while assembling the stack (112) on the inner tool (108) and fastening the outer tool (110) around the stack (112).

[0309] 32. A composite aircraft barrel (102) component assembled by the method described in any one of appendixes 23 to 31.

[0310] 33. An inner container (202) having a plurality of recesses (212); A plurality of backing plates (204) disposed in the plurality of recesses (212); a plurality of thermoplastic braided members (206) disposed on the plurality of backing plates (204); a plurality of stringer envelopes (208) disposed on the plurality of thermoplastic braided members (206); a thermoplastic braided skin (210) disposed over the plurality of stringer envelopes (208) and the plurality of thermoplastic braided members (206).

[0311] 34. The apparatus of claim 33, wherein a given one of the plurality of backing plates (204) is made of an iron-nickel alloy.

[0312] 35. The apparatus of claim 34, wherein the iron-nickel alloy is an Invar alloy containing about 40% to about 43% nickel.

[0313] 36. The device of any one of appendices 33 to 35, wherein a first coefficient of thermal expansion (227) of the plurality of backing plates (204) is sufficiently close to a second coefficient of thermal expansion (237) of the plurality of thermoplastic braided members (206).

[0314] 37. The apparatus of any one of claims 33 to 36, wherein the inner casing (202), the plurality of backing plates (204), the plurality of thermoplastic braided members (206), the plurality of stringer inner casings (208), and the thermoplastic braided outer plate (210) form a stack (112).

[0315] 38. The apparatus described in Appendix 37, wherein the stack body (112) is positioned between a first smart susceptor (114) attached to an inner tool (108) and a second smart susceptor (115) attached to an outer tool (110), and the thermoplastic braided outer plate (210) is crimped and molded with the multiple thermoplastic braided members (206) by induction heating via the first smart susceptor (114) and the second smart susceptor (115).

[0316] 39. The apparatus of claim 38, wherein the inner tool (108) has a first induction coil (118) embedded therein and the outer tool (110) has a second induction coil (120) embedded therein.

[0317] 40. The apparatus of any one of appendices 37 to 39, further comprising a plurality of plugs (106) sealing a first end (126) of the stack body (112) and a second end (128) of the stack body (112).

[0318] 41. Each of a first plug (1006) of the plurality of plugs (106) and a second plug (1008) of the plurality of plugs (106) comprises: a plug portion (1100, 1106) through which a pressurizing tube (1112) passing through the plurality of stringer enclosures (208) is inserted; A heat insulating layer (1102, 1108); 41. The apparatus of claim 40, further comprising a susceptor connection (1104, 1110).

[0319] 42. The apparatus of claim 41, wherein the susceptor connections (1104, 1110) are water-cooled.

[0320] 43. The apparatus of any one of claims 37 to 42, further comprising a plurality of pressurized tubes (238) passing through the plurality of stringer enclosures (208).

[0321] 44. A method of forming a composite aircraft fuselage barrel (102) using the apparatus of claim 33.

[0322] 45. An inner tool (108) made of a dielectric material, the inner tool (108) having a first induction coil (118) embedded therein; an outer tool (110) made of the dielectric material, the outer tool (110) having a second induction coil (120) embedded therein and shaped and sized to surround the inner tool (108); a first smart susceptor (114) affixed to the inner tool (108); a second smart susceptor (115) affixed to the outer tool (110), A system (103) in which when a stack (112) disposed between the inner tool (108) and the outer tool (110) is inductively heated using the first induction coil (118) and the second induction coil (120), heat dispersion and heat uniformity are promoted by both the first smart susceptor (114) and the second smart susceptor (115).

[0323] 46. ​​A method for producing a composite fuselage structure (102) using the system (103) of appended note 45.

[0324] 47. Inner tool (108); a first smart susceptor (114) disposed around the inner tool (108); a stack body (112) disposed around the first smart susceptor (114), the stack body (112) comprising: an inner container (202) having a plurality of recesses (212); A plurality of backing plates (204) disposed in the plurality of recesses (212); a plurality of thermoplastic braided members (206) disposed on the plurality of backing plates (204); a plurality of stringer envelopes (208) disposed in contact with the plurality of thermoplastic braided members (206); a thermoplastic braided skin (210) disposed on the plurality of stringer encapsulations (208) and the plurality of thermoplastic braided members (206), the thermoplastic braided skin (210) being disposed to sandwich each of the plurality of stringer encapsulations (208) between a corresponding one of the plurality of thermoplastic braided members (206); a second smart susceptor (115) disposed around the stack body (112); an outer tool (110) disposed about the second smart susceptor (115).

[0325] 48. The system (103) of claim 47, further comprising a plurality of plugs (106) sealing the first end (126) and the second end (128) of the stack body (112).

[0326] 49. A first induction coil (118) is embedded in the inner tool (108), and a second induction coil (120) is embedded in the outer tool (110); 49. The system (103) of claim 48, further comprising a plurality of connecting devices (107) for connecting the first induction coil (118) and the second induction coil (120).

[0327] 50. The system (103) of any one of claims 48 to 49, further comprising an end tool (105) for positioning and securing the plurality of plugs (106).

[0328] 51. A method of forming a composite fuselage barrel (102) for an aircraft using the system (103) described in Appendix 47.

[0329] 52. A method for making a composite fuselage structure (101), comprising: expanding a plurality of stringer enclosures (208) in the stack (112) to apply a force to the plurality of thermoplastic braided members (206) and the thermoplastic braided skin (210); constraining the stack (112) by a dielectric material having a non-dielectric material embedded therein during expansion of the plurality of stringer encapsulants (208); The method further comprising: constraining the non-dielectric material by the dielectric material during expansion of the plurality of stringer enclosures (208).

[0330] 53. Assembling the stack (112) including the casing (202), the plurality of stringer casings (208), the plurality of thermoplastic braided members (206), and the thermoplastic braided skin (210); 53. The method of claim 52, further comprising disposing the stack between an inner tool and an outer tool, each of which includes the dielectric material and the non-dielectric material.

[0331] 54. The method of claim 52 or 53, wherein the expanding the plurality of stringer encapsulations (208) in the stack (112) comprises heating the plurality of stringer encapsulations (208).

[0332] 55. A method according to any one of appendices 52 to 54, wherein when expanding the plurality of stringer internal bodies (208) in the stack body (112), the plurality of stringer internal bodies (208) are pressurized by inert gas flowing through a plurality of pressure tubes into the plurality of stringer internal bodies (208).

[0333] 56. A method according to any one of appendices 52 to 55, wherein when restraining the stack body (112), the stack body (112) is pressed against an outer tool (110) including the dielectric material, wherein the dielectric material is a ceramic material and the non-dielectric material embedded in the dielectric material is a plurality of induction coils.

[0334] 57. A method according to any one of appendices 52 to 56, wherein when expanding the plurality of stringer encapsulants (208) in the stack (112), the plurality of stringer encapsulants (208) are expanded, and the expansion applies tension to the plurality of thermoplastic braided members (206).

[0335] 58. A method according to any one of claims 52 to 57, wherein when expanding the plurality of stringer encapsulants (208) in the stack (112), expanding the plurality of stringer encapsulants (208) resists a compressive load on the plurality of thermoplastic braided members (206).

[0336] 59. A composite aircraft barrel (102) component assembled by the method described in any one of appendixes 52 to 58.

[0337] 60. A method for making a composite fuselage structure (101), comprising: A plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded (2304) into a circumferentially restrained arc-shaped stack (112); The method further comprises tensioning (2306) the fibers of the plurality of crimp-molded thermoplastic braided preforms (206, 210) during co-molding.

[0338] 61. The method of claim 60, wherein when integrally molding (2304) the plurality of crimped thermoplastic braided preforms (206, 210), the plurality of crimped thermoplastic braided preforms (206, 210) are integrally molded by heating the arc-shaped stack (112).

[0339] 62. The method of claim 61, wherein when the arc-shaped stack body (112) is heated, the arc-shaped stack body (112) is inductively heated to integrally mold the multiple crimped thermoplastic braided preforms (206, 210).

[0340] 63. A method according to any one of appendices 60 to 62, wherein when integrally molding (2304) the multiple crimped thermoplastic braided preforms (206, 210), the multiple crimped thermoplastic braided preforms (206, 210) are integrally molded by heating the arc-shaped stack body (112) using multiple induction coils and multiple smart susceptors.

[0341] 64. A method according to any one of appendices 60 to 63, wherein when integrally molding (2304) the multiple crimped thermoplastic braided preforms (206, 210), a force is applied to the multiple crimped thermoplastic braided preforms (206, 210) by expanding the multiple stringer encapsulants (208) and encapsulants (202) in the arc-shaped stack (112).

[0342] 65. The method of claim 64, wherein when expanding the plurality of stringer encapsulants (208) and the encapsulant (202), the plurality of stringer encapsulants (208) and the encapsulant (202) in the arc-shaped stack (112) are pressurized using an inert gas.

[0343] 66. A component of a composite aircraft barrel (102) assembled by the method described in any one of appendixes 60 to 65.

[0344] 67. A tucking and trimming system (1301) used to tuck and trim a thermoplastic tow (1404) to a braid (1306); and a support system (1302) to which the tucking and trimming system (1301) is attached, the support system (1302) having a shape and size suitable for operatively positioning the tucking and trimming system (1301) relative to a cylindrical thermoplastic stack body (306).

[0345] 68. A tucking and trimming device for tow as described in Appendix 67, wherein the support system (1302) includes a support ring (1303) having a size and shape to surround the entire circumference of an arc-shaped mounting surface (1304), and the tucking and trimming system (1301) is attached to the support ring (1303).

[0346] 69. A tucking and trimming apparatus for tow as described in any one of claims 67 to 68, wherein the tacking and trimming system (1301) includes a tack weld (1400) fixed to a portion of the support system (1302), and the tack weld (1400) is heated by resistive heat.

[0347] 70. A tucking and trimming device for tows described in any one of Appendices 67 to 69, wherein the tucking and trimming system (1301) includes a trimming portion (1402) fixed to a portion of the support system (1302), and the trimming portion (1402) trims the thermoplastic tow (1404) using laser energy.

[0348] 71. The tow tucking and trimming device of claim 70, further comprising a conductive member (1308) disposed between the braid (1306) and the thermoplastic tow (1404).

[0349] 72. The tow tucking and trimming device of claim 71, wherein the conductive member (1308) has a wedge-shaped cross-sectional shape.

[0350] 73. A tacking and trimming device for tows as described in appendix 71 or 72, wherein the conductive member (1308) has thermal conductivity and is used to absorb the laser energy emitted from the trimming portion (1402) and protect the braided body (1306).

[0351] 74. The tow tucking and trimming device of any one of notes 71-73, configured to receive the thermoplastic tow (1404) from a braiding ring and pass it over the conductive member (1308).

[0352] 75. A tow tucking and trimming device according to any one of claims 67 to 74, wherein the support system (1302) moves with a braided ring that feeds the thermoplastic tow (1404).

[0353] 76. A tucking and trimming device for tow described in any one of appendices 67 to 76, wherein the tucking and trimming system (1301) is one of a plurality of tucking and trimming systems distributed across the support system (1302).

[0354] 77. The tucking and trimming device for tows of any one of appendices 67 to 76, wherein the braid (1306) includes a plurality of thermoplastic plies formed by braiding continuous fibers of a thermoplastic composite material.

[0355] 78. A method for tucking and trimming a thermoplastic tow (1404), comprising: Laminating (2502) the thermoplastic tows (1404) received from the braiding system above the braid (1306) on the mounting surface (1304); tack welding (2504) the thermoplastic tow (1404) to the braid (1306); The method further comprises trimming (2506) the thermoplastic tow (1404) received above the braid (1306) by trimming a portion of the thermoplastic tow (1404).

[0356] 79. The method of claim 78, further comprising receiving a portion of the thermoplastic tow (1404) above a conductive member (1308) disposed between the braid (1306) and the thermoplastic tow (1404).

[0357] 80. The method of claim 78 or 79, wherein when tack welding (2504) the thermoplastic tow (1404) is performed, the thermoplastic tow (1404) is tack welded to the braid (1306) using a tack welding portion (1400) fixed to a support ring (1303).

[0358] 81. The method of any one of appendices 78 to 80, wherein when tack welding (2504) the thermoplastic tow (1404) is performed, the thermoplastic tow (1404) is tack welded to the braid (1306) using a tack weld portion (1400) fixed to a support ring (1303) surrounding the mounting surface (1304), and the tack weld portion (1400) is heated by resistance heat.

[0359] 82. The method of any one of claims 78 to 81, further comprising supporting the portion of the thermoplastic tow (1404) by a conductive member (1308).

[0360] 83. The method of claim 82, wherein trimming (2506) the portion of the thermoplastic tow (1404) comprises irradiating the portion of the thermoplastic tow (1404) supported by the conductive member (1308) with laser energy.

[0361] 84. The method of claim 83, comprising protecting the braided body (1306) by absorbing the laser energy with the conductive member (1308) as the thermoplastic tow (1404) is trimmed when the laser energy is irradiated.

[0362] 85. The method of any one of appendices 78 to 84, wherein when laying (2502) the thermoplastic tow (1404) is performed, the thermoplastic tow (1404) is laid onto the mounting surface (1304), and wherein the mounting surface (1304) is formed by at least one of a tool face (1304), a backing plate (502), an encapsulation body (400), a stringer encapsulation body (702), a partially formed braided layup (1306), a preform (800, 600), or an integrated composite structure (101).

[0363] 86. The method according to any one of appendices 78 to 85, wherein when stacking (2502) the thermoplastic tow (1404), a unique portion is added to a portion of the braided body (1306) by stacking the thermoplastic tow (1404).

[0364] 87. A component of a composite aircraft barrel (102) assembled by the method described in any one of appendixes 78 to 86.

[0365] 88. A method for tucking and trimming a thermoplastic tow (1404), comprising: Laminating (2602) the thermoplastic tows (1404) received from the braiding system above the braid (1306) on the mounting surface (1304); tack welding (2604) the thermoplastic tow (1404) received from the braiding system to the braid (1306); The method further comprises: trimming (2606) the thermoplastic tow (1404) by applying laser energy to a portion of the thermoplastic tow (1404).

[0366] 89. The method of claim 88, further comprising supporting the portion of the thermoplastic tow (1404) by a conductive member (1308).

[0367] 90. The method of claim 88 or 89, wherein when trimming (2606) the portion of the thermoplastic tow (1404), the portion of the thermoplastic tow (1404) is supported by a conductive member (1308) and the portion is irradiated with laser energy.

[0368] 91. A composite aircraft barrel (102) component assembled by the method described in Appendix 88.

[0369] 92. A support ring (1303) having a size and shape that surrounds the entire circumference of the arc-shaped installation surface (1304); and a tucking and trimming system (1301) fixed to the support ring (1303) and used to tuck a thermoplastic tow (1404) to a braid (1306), the tucking and trimming assembly including: a tack weld (1400) secured to a portion of the support system (1303), the tack weld (1400) being heated by resistive heat; a trimming portion (1402) secured to a portion of the support ring (1303), the trimming portion (1402) trimming the thermoplastic tow (1404) using laser energy; a conductive member (1308) disposed between the braid (1306) and the thermoplastic tow (1404).

[0370] 93. A tacking and trimming assembly as described in Appendix 92, wherein the conductive member (1308) has a wedge-shaped cross-sectional shape and is thermally conductive, and absorbs the laser energy emitted from the trimming portion (1402) during trimming of the thermoplastic tow (1404) to protect the braided body (1306).

[0371] 94. The tacking and trimming assembly of claim 93, wherein the tacking and trimming system (1301) is one of a plurality of tacking and trimming systems (1301) distributed across the support ring (1303).

[0372] 95. A tacking and trimming assembly as described in any one of Appendices 92 to 94, wherein the braided body (1306) includes a plurality of thermoplastic plies formed by braiding continuous fibers of a thermoplastic composite material.

[0373] 96. A tacking and trimming assembly as described in any one of Appendices 92 to 95, wherein the installation surface (1304) is a surface formed by at least one of a tool face (1304), a backing plate (502), an encapsulation body (400), a stringer encapsulation body (702), a braided layup in the process of being formed (1306), a preform (800, 600), or an integrated composite structure (101).

[0374] The above description of various exemplary embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the present invention to the disclosed form. Many modifications and variations will be apparent to those skilled in the art. Furthermore, some exemplary embodiments may provide different features than other preferred embodiments. The selected embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments, and to enable those skilled in the art to understand the disclosure for the various embodiments with various modifications suitable for the specific applications envisioned.

Claims

1. 1. A method for making a composite structure, comprising: Assembling a stack including the thermoplastic braided outer panel and a plurality of thermoplastic braided members; placing the stack between an inner tool and an outer tool; The inner tool, the stack body, and the outer tool are integrally held in a predetermined position using a member restraint portion, thereby assembling a consolidation assembly including the inner tool, the stack body, the outer tool, and the member restraint portion; forming the composite structure by heating the consolidation mass; The method further comprises pressing an inner casing and a plurality of inner stringer casings in the stack to substantially the same pressure while crimping the plurality of thermoplastic braided members to the thermoplastic braided skin.

2. A method for making a composite structure, comprising: Assembling a stack including the thermoplastic braided outer panel and a plurality of thermoplastic braided members; placing the stack between an inner tool and an outer tool; The inner tool, the stack body, and the outer tool are integrally held in a predetermined position using a member restraint portion, thereby assembling a consolidation assembly including the inner tool, the stack body, the outer tool, and the member restraint portion; forming the composite structure by heating the consolidation mass; To assemble the stack, the method includes assembling the stack including an inner casing having a plurality of recesses, a plurality of backing plates fitted into the plurality of recesses, a plurality of thermoplastic braided members, a plurality of stringer inner casings, and a thermoplastic braided outer panel.

3. 3. The method of claim 1 or 2, wherein heating the consolidation mass comprises inductively heating the consolidation mass to crimp the plurality of thermoplastic braided members with the thermoplastic braided skin to create an integrated composite structure.

4. A method for making a composite structure, comprising: Assembling a stack including the thermoplastic braided outer panel and a plurality of thermoplastic braided members; placing the stack between an inner tool and an outer tool; The inner tool, the stack body, and the outer tool are integrally held in a predetermined position using a member restraint portion, thereby assembling a consolidation assembly including the inner tool, the stack body, the outer tool, and the member restraint portion; forming the composite structure by heating the consolidation mass; The method further comprises passing a plurality of pressurized tubes through the plurality of stringer enclosures.

5. When assembling the stack body, the inner tool is supported by a support structure, and a first smart susceptor is disposed around the inner tool; The method of any one of claims 1 to 4, further comprising disposing an inner envelope around the first smart susceptor.

6. A method for making a composite structure, comprising: Assembling a stack including the thermoplastic braided outer panel and a plurality of thermoplastic braided members; placing the stack between an inner tool and an outer tool; The inner tool, the stack body, and the outer tool are integrally held in a predetermined position using a member restraint portion, thereby assembling a consolidation assembly including the inner tool, the stack body, the outer tool, and the member restraint portion; forming the composite structure by heating the consolidation mass; The method further includes plugging a first end of the stack body and a second end of the stack body using a plurality of plugs, wherein a first plug among the plurality of plugs used at the first end of the stack body and a second plug among the plurality of plugs used at the second end of the stack body each include a plug portion, an insulating layer, and a susceptor connection portion.

7. 7. The method of claim 2, further comprising pressing an inner casing and a plurality of inner stringer casings in the stack to substantially the same pressure while crimping the plurality of thermoplastic braided members to the thermoplastic braided skin.

8. A method for making a composite structure, comprising: Assembling a stack including the thermoplastic braided outer panel and a plurality of thermoplastic braided members; placing the stack between an inner tool and an outer tool; The inner tool, the stack body, and the outer tool are integrally held in a predetermined position using a member restraint portion, thereby assembling a consolidation assembly including the inner tool, the stack body, the outer tool, and the member restraint portion; forming the composite structure by heating the consolidation mass; The method further comprises providing mechanical strength and stiffness to the thermoplastic braided members by a plurality of backing plates in the stack during compression molding of the thermoplastic braided members to the thermoplastic braided skin.

9. Inner tools and a first smart susceptor disposed around the inner tool; a stack disposed about the first smart susceptor, the stack including a thermoplastic braided skin and a plurality of thermoplastic braided members; a second smart susceptor disposed around the stack; an outer tool disposed around the second smart susceptor; a member restraint portion that holds the inner tool, the first smart susceptor, the stack, the second smart susceptor, and the outer tool in predetermined positions; a plurality of pressurizing tubes passing through a plurality of stringer enclosures in the stack; and a pressure tube passing through an inner envelope in the stack.

10. An inner tool; a first smart susceptor disposed around the inner tool; a stack disposed about the first smart susceptor, the stack including a thermoplastic braided skin and a plurality of thermoplastic braided members; a second smart susceptor disposed around the stack; an outer tool disposed around the second smart susceptor; a member restraint portion for holding the inner tool, the first smart susceptor, the stack, the second smart susceptor, and the outer tool in a predetermined position, The stack further includes a plurality of backing plates, each of the plurality of backing plates providing a predetermined contoured surface and stiffness to a corresponding one of the plurality of thermoplastic braided members.

11. a plurality of pressurizing tubes passing through a plurality of stringer enclosures in the stack; The apparatus of claim 10 further comprising a pressurized tube passing through an inner envelope in the stack.

12. Inner tools and a first smart susceptor disposed around the inner tool; a stack disposed about the first smart susceptor, The stack body is An inner shell having a plurality of recesses; A plurality of backing plates disposed in the plurality of recesses; a plurality of thermoplastic braided members disposed on the plurality of backing plates; a plurality of stringer envelopes disposed in contact with the plurality of thermoplastic braided members; a thermoplastic braided skin disposed over the plurality of stringer envelopes and the plurality of thermoplastic braided members, the thermoplastic braided skin being disposed to sandwich each of the plurality of stringer envelopes between a corresponding one of the plurality of thermoplastic braided members; a second smart susceptor disposed around the stack; an outer tool disposed about the second smart susceptor.

13. The system of claim 12 further comprising a plurality of plugs plugging the first and second ends of the stack.

14. a first induction coil is embedded in the inner tool and a second induction coil is embedded in the outer tool; 14. The system of claim 13, further comprising a plurality of connecting devices for connecting the first induction coil and the second induction coil.

15. 15. The system of claim 13 or 14, further comprising an end tool for positioning and securing the plurality of plugs.

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