Scroll for vacuum-fixing an object to a complex surface

Abstract

To provide a system and method for compacting an object onto a tool.SOLUTION: An embodiment is a method for compacting an object onto a rigid tool. The method comprises: placing an object 140 onto a surface of a rigid tool 110; arranging an end effector 120 over the object; spreading a linking mechanism 122 of the end effector; arranging a scroll 130 of a material between the linking mechanisms on a top the object while surrounding the object with the scroll 130; applying a negative pressure that offsets air leaks between the scroll and the object, to the scroll, thereby forming a suction hold that compacts the object onto the rigid tool.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to the field of manufacturing, and more particularly, to the production of composite parts.

Background Art

[0002] Composite parts such as carbon fiber parts are formed by hardening a preform of a fiber reinforcement material while maintaining a desired amount of pressure and temperature. The preform that has not yet been hardened into a composite part does not yet exhibit complete structural strength. Therefore, a "green" preform may not be able to support itself when laid up on a surface (e.g., a vertical or other non-horizontal surface) before being hardened. This complicates the layup of large preforms on complex surfaces (e.g., sagging shapes) because it increases the likelihood that a portion of the preform will peel or shift away from the forming tool before the layup is complete. Thus, accurate placement or positioning of large and / or difficult-to-handle layups remains difficult.

[0003] In the case of preforms cured via a vacuum bag curing technique, it is difficult to secure a vacuum bag around the preform before the preform peels (or shifts relative to) the corresponding complex surface. Further complicating the problem is that materials such as adhesive tapes used to secure the vacuum bag to the tool surface are not allowed to come into contact and thus cannot touch the uncured / unsolidified composite material. As a result, the entire layup must be completed before the application of the vacuum bag and its attachment to the complex surface (via a sealant). Thus, it remains desirable to quickly and efficiently secure the preform (and / or other objects) to complex surfaces, especially when the preform is placed into a complex assembly.

[0004] Therefore, it may be desirable to have a method and apparatus that take into account at least some of the problems discussed above and other possible problems.

Summary of the Invention

[0005] The embodiments described herein provide a technique in which a scroll of material is rapidly deployed onto a preform placed on a mandrel. The scroll includes a permeable layer that allows air flow, as well as an impermeable layer that extends beyond the boundaries of the permeable layer. During and after placement of the scroll, when a negative pressure is applied, the scroll presses against and consolidates the underlying preform via a consolidation process without tape. After consolidation is complete, the scroll can be rapidly removed, enabling vacuum bagging and curing of the preform.

[0006] One embodiment is a method for consolidating an object onto a rigid tool. The method includes placing the object on the surface of the rigid tool, positioning an end effector above the object, expanding the link mechanism of the end effector, placing the scroll of material between the link mechanisms around the object while placing the scroll over the object, and applying a negative pressure to the scroll that cancels out air leakage between the scroll and the object, thereby forming a suction hold that consolidates the object onto the rigid tool.

[0007] A further embodiment is a non-transitory computer-readable medium embodying programmed instructions that, when executed by a processor, are capable of implementing a method for consolidating an object onto a rigid tool. The method includes placing the object on the surface of the rigid tool, positioning an end effector above the object, expanding the link mechanism of the end effector, placing the scroll of material between the link mechanisms around the object while placing the scroll over the object, and applying a negative pressure to the scroll that cancels out air leakage between the scroll and the object, thereby forming a suction hold that consolidates the object onto the rigid tool.

[0008] A further embodiment is an apparatus for consolidating an object onto a rigid tool. The apparatus includes an end effector configured to move toward the rigid tool, a linkage mechanism coupled to the end effector and configured to pivot relative to the end effector, a spindle coupled to the linkage mechanism and rotatably mounted to the linkage mechanism, and a scroll of material stored on the spindle and configured to be placed on an object on the rigid tool.

[0009] A further embodiment is an apparatus including a spindle and a scroll of material wound around the spindle. One end of the scroll is sealed to the spindle, and the other end of the scroll is attached to an object. The material includes a permeable layer and an impermeable membrane in contact with the permeable layer.

[0010] A further embodiment is an apparatus including at least one spindle. The spindle includes an outer casing, a chamber, and a perforation coupling the chamber to the outer casing. The apparatus also includes a scroll of material wound around the spindle. One end of the scroll is sealed to the spindle. The material includes a permeable layer and an impermeable membrane in contact with the permeable layer.

[0011] A further embodiment is an apparatus for consolidating an object onto a rigid tool. The apparatus includes a plurality of spindles and a scroll of material stored on the spindles and configured to be placed on an object on the rigid tool when the spindles move away from each other.

[0012] A further embodiment is a method for consolidating an object placed on the surface of a rigid tool. The method includes unrolling a scroll of material including a permeable layer and an impermeable membrane that overlaps the object and extends beyond the boundary of the permeable layer, and applying a negative pressure to the permeable layer that counteracts air leakage between the scroll and the object, thereby forming a suction hold that consolidates the object onto the rigid tool.

[0013] Another embodiment is a non-transitory computer-readable medium embodying programmed instructions that, when executed by a processor, are executable to perform a method for consolidating an object onto a rigid tool. The method includes unrolling, over an object, a scroll of material that includes a permeable layer and an impermeable film extending beyond the boundary of the permeable layer, and applying a negative pressure to the permeable layer that counteracts air leakage between the scroll and the object, thereby forming a suction hold that consolidates the object onto the rigid tool.

[0014] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) may be described below. The features, functions, and advantages considered may be individually realizable in various embodiments or may be combined in yet other embodiments, with further details being understood with reference to the following description and drawings.

[0015] Here, some embodiments of the present disclosure will be described by way of example only, with reference to the accompanying drawings. In all the drawings, the same reference numerals represent the same elements or the same type of elements.

Brief Description of the Drawings

[0016]

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DETAILED DESCRIPTION OF THE INVENTION

[0017] Specific exemplary embodiments of the present disclosure are provided by the drawings and the following description. Accordingly, those skilled in the art can devise various configurations not explicitly described or illustrated herein to specifically implement the principles of the present disclosure, and it should be understood that they are included within the scope of the present disclosure. Furthermore, any examples described herein are intended to assist in understanding the principles of the present disclosure and should be construed as not being limited to the specifically described examples and conditions. As a result, what limits the present disclosure is not the specific embodiments or examples below, but the claims and their equivalents.

[0018] Using the scroll expansion system described herein, preforms for composite parts such as preforms for sections of a fuselage can be consolidated. Composite parts such as carbon fiber reinforced polymer (CFRP) parts are first laid up in multiple layers collectively referred to as preforms. The individual fibers within each layer of the preform are aligned parallel to each other, but may exhibit various fiber orientations to enhance the strength of the resulting composite part along various dimensions. The preform contains a curable adhesive resin to solidify the preform into a composite part (e.g., for use in an aircraft). Carbon fibers impregnated with an uncured thermosetting resin or thermoplastic resin are referred to as "prepregs". Other types of carbon fibers include "dry fibers" that are not impregnated with a thermosetting resin, but may contain an adhesion promoter or binder. The dry fibers may have resin injected into them prior to solidification. With respect to thermosetting resins, solidification is a one-way process called curing, while with respect to thermoplastic resins, the resin becomes viscous when reheated and then solidifies and sets into the desired shape. As used herein, the general term for the process of transitioning a preform to its final solidified shape (i.e., transitioning the preform to a composite part) is called "hardening", and this term includes both the curing of thermosetting preforms and the forming / solidification of thermoplastic preforms into their final desired shape.

[0019] Figure 1 schematically shows a scroll deployment system 100 in an exemplary embodiment. The scroll deployment system 100 includes any system or device that can apply a negative pressure to cover an object disposed on a rigid tool (e.g., a preform for a section of an aircraft fuselage disposed on a mandrel), deploy a scroll of material, and uniformly consolidate the object onto the rigid tool. In this embodiment, the scroll deployment system 100 includes an end effector 120 configured to move towards (e.g., downwardly) the rigid tool 110. A link mechanism 122 is coupled to the end effector and configured to pivot with respect to the end effector. When the link mechanism 122 pivots, their distal ends 123 move away from each other. A spindle 124 is coupled to the link mechanism and rotatably attached to the link mechanism 122. Further, the spindle 124 stores a portion of a continuous material scroll 130 configured to be placed on an object 140 on the rigid tool 110, respectively. Thus, the spindle 124 carries the material scroll 130. In one embodiment, the scroll 130 includes a permeable layer and an impermeable film, and the impermeable film extends beyond the outer periphery of the permeable layer. In a further embodiment, the scroll 130 also includes one or more layers of fiber-reinforced material for consolidation onto the object 140.

[0020] As the link mechanism 122 pivots, the spindle 124 rotates, which unfurls the material scroll 130 from the spindle 124. After deployment, the scroll 130 covers the object 140 and extends beyond the boundaries of the object 140 (e.g., circumferentially and into and out of the page). Thus, Figure 1 depicts the scroll 130 in a deployed configuration with respect to the object 140. In this embodiment, the object 140 is a preform that includes a plurality of layers of fiber-reinforced material (e.g., CFRP), is disposed on the surface 112 of the rigid tool 110, and is a preform waiting to be cured into a composite part.

[0021] During and / or after the deployment of the scroll 130, the pump 150 is activated to draw air from under the scroll 130. Specifically, the pump 150 draws air from under the impermeable membrane 132 (e.g., a latex sheet or other material that exhibits a high level of stretch while maintaining impermeability) of the scroll 130 that covers the object 140. The pump 150 draws air through a port 152 that penetrates into the scroll 130 at an aperture 133 by applying a negative pressure through the port 152. In this embodiment, the port 152 is positioned at the upper end portion 182 of the scroll 130. However, the port 152 may be positioned at other portions of the scroll as desired. The port 152 may penetrate the impermeable membrane 132 and be in direct contact with or be disposed directly on the permeable layer 134 of the scroll 130.

[0022] The permeable layer 134 is permeable to air in both the lateral and vertical directions. This enables the negative pressure to be distributed uniformly across the entire scroll 130. This means that the negative pressure drawn through the port 152 is not limited to the port 152 but is applied uniformly across the entire object 140. The negative pressure secures the end flap 136 of the scroll to the rigid tool 110 and forms a loose seal between the end flap 136 and the rigid tool 110. That is, even when the end flap 136 does not include an adhesive or other chemical bonding means, as long as the amount of air drawn by the pump 150 is at least equal to the amount of air leakage between the end flap 136 and the rigid tool 110, the applied negative pressure loosely seals the end flap to the rigid tool 110 through suction. The negative pressure also consolidates the scroll 130 onto the object 140. This ensures that the object 140 remains in place on the rigid tool 110.

[0023] The pump 150 is a high-volume flow pump, which means that the pump 150 can draw a large amount of air through the port 152, but it does not necessarily have to be at a high pressure. In one embodiment, the pump 150 applies a negative pressure between 22 and 29 inches of mercury (in.Hg) to generate a vacuum, and the flow rate is in the tens of cubic feet per minute (CFM) (e.g., between 50 and 200 CFM). Thus, the pump 150 and the port 152 will be able to maintain a pressure of at least 1 inch of mercury across the impermeable membrane (e.g., the covered area). This can be accomplished by the pump 150 alone or in combination with other desired pumps. The amount of pressure applied by the pump 150 and the amount of CFM drawn can vary depending on the overall boundary length of the scroll 130.

[0024] To overcome leakage along the outer periphery of the scroll 130 and ensure that the negative pressure is constantly within the desired range, the controller 160 manages the operation of the pump 150 based on inputs from sensors (not shown) such as pressure sensors and flow sensors. The sensors may be positioned at any suitable location, such as the permeable layer 134, the scroll 130, the port 152, the pump 150, etc. In one embodiment, the controller 160 increases or decreases the speed or intensity of the pumping operation in the pump 150 to maintain a constant volume flow rate of air or to maintain a constant negative pressure. The controller 160 may be implemented, for example, as a custom circuit, as a hardware processor that executes programmed instructions, or as some combination of these.

[0025] The amount of the holding force (FH) applied to the object 140 by the scroll 130 is based on the difference between the volume per unit time (VP) drawn by the pump 150 and the volume per unit time (VL) of air leakage through the end flap 136 of the scroll 130, and the total area covered by the scroll 130. FH can also be modeled as a function of the pressure applied by the pump 150. VL is overcome by VP. Therefore, VP should be greater than or equal to VL. The scroll 130 is not attached to the rigid tool 110 by a sealant, an adhesive, a fastener, a magnetic force, etc. However, the vacuum under the scroll 130 is maintained by the pump 150 while air leaks into the system through the outer periphery. Therefore, in this configuration, a slight leakage may still exist. This is because the negative pressure is the main (e.g., sole) force that fixes the scroll 130 to the rigid tool 110. The air leakage can be caused by wrinkles in the scroll 130 that provide a passage for the air flow. However, the wrinkles are only one cause of the air leakage. This is because when the scroll 130 is not sealed to the rigid tool 110, air leaks from the edge of the scroll 130. Even so, VL remains small. Therefore, the negative pressure is maintained by exhausting an amount of air greater than the loss through the leakage between the end flap 136 of the impermeable membrane 132 and the rigid tool 110.

[0026] The permeable layer 134 includes a material that deforms when the impermeable membrane 132 applies force, allowing air to be drawn freely across the object 140 while fitting snugly around the entire object 140. That is, the permeable layer 134 allows air to be drawn across the entire object 140 without partitioning the object 140. For example, the permeable layer 134 may include a conforming biplanar mesh of a material that facilitates air flow. The permeable layer 134 is a high-flow material. That is, the permeable layer 134 does not substantially limit the rate at which the pump 150 draws air. Thus, the resistance of the permeable layer 134 to air flow has little effect on the flow rate of the pump 150. In some embodiments, the permeable layer 134 includes an open celled foam material. However, in such embodiments, the selected open celled foam material is sufficiently rigid so as not to collapse under the impermeable membrane 132 and is sufficiently open so as not to inhibit air flow. Collapse of the impermeable membrane 132 can block or limit air flow. That is undesirable because then air flow from such an area under the impermeable membrane 132 is restricted.

[0027] The impermeable membrane 132 may include any suitable flexible gas-impermeable material. For example, the impermeable membrane 132 may include a plastic sheet that prevents air from escaping directly through it. In further embodiments, the impermeable membrane 132 and the permeable layer 134 may be structurally integrated or joined for convenience. In one embodiment, the permeable layer 134 and the impermeable membrane 132 include materials that are allowed to be used with carbon fiber composites and have a contact that is recognized not to chemically interact with the resin.

[0028] Exemplary details of the operation of the scroll deployment system 100 are described with respect to one embodiment of the method shown in method 200 of FIG. 2. In this embodiment, it is assumed that the rigid tool 110 is waiting for the placement of the preform for consolidation and curing into the composite part.

[0029] Figure 2 is a flowchart showing a method 200 for operating a scroll deployment system in an exemplary embodiment. The steps of method 200 are described with reference to the scroll deployment system 100 of FIG. 1, but it will be understood by those skilled in the art that method 200 may be executed within other systems. The steps of the flowchart described herein are not exhaustive and may include other steps not shown. The steps described herein may also be executed in an alternative order.

[0030] In step 202, the object 140 is placed on the surface 112 of the rigid tool 110. In one embodiment, this includes laying up the preform on the surface 112 via an automated fiber placement (AFP) machine or other tool. In a further embodiment, this includes lifting the preform from another location and placing it on the surface 112.

[0031] Step 204 includes positioning the end effector 120 above the object 140. In one embodiment, this includes moving the end effector 120 on a rail, stand, or track (not shown) to align the end effector with the object 140.

[0032] Step 206 expands the link mechanism 122 of the end effector 120 and places the scroll 130 over the object 140 while enclosing the object with the scroll 130 of the material between the link mechanisms 122. In one embodiment, when the end effector 120 is lowered, the link mechanism 122 is expanded by gravity as the spindle 124 follows the contour of the rigid tool. While expanding, the link mechanism pivots with respect to the end effector 120. This is because the link mechanism 122 contacts the rigid tool 110 (and / or the object 140), is deflected therefrom, and swings outwardly. In a further embodiment, the link mechanism is electrified and actively driven to move away from each other. When the link mechanism 122 is expanded, the spindle 124 coupled to the link mechanism is rotated. Since the scroll 130 is wound around the spindle 124, the rotation of the spindle distributes the scroll 130 or spreads / positions the material of the scroll in place. This means that when the link mechanism 122 is expanded, the two spindles 124 advance such that they roll in opposite directions to each other, which unfolds the scroll 130. That is, a portion of the scroll 130 is held by the spindle 124 for one of the link mechanisms 122, another portion of the scroll is held by the spindle for the other of the link mechanisms, and the act of expanding the link mechanism unrolls the scroll 130 from the spindle.

[0033] In step 208, the scroll 130, which includes an impermeable layer overlapping the permeable layer and extending beyond the boundary of the permeable layer, is unrolled over the object 140. In one embodiment, this occurs in response to the link mechanism spreading. On the other hand, in a further embodiment where the link mechanism is not utilized, this includes unrolling the scroll 130 via any other suitable means.

[0034] In step 210, port 152 applies a negative pressure to scroll 130 that counteracts the leakage of air between scroll 130 and object 140, thereby forming a suction hold that consolidates object 140 onto rigid tool 110. By applying the negative pressure, end flap 136 of the impermeable membrane 132 of scroll 130 is attracted to contact rigid tool 110. Applying the negative pressure can be performed by drawing a desired volumetric flow rate through pump 150, or by applying a certain amount of pressure through pump 150, as described above. Since air is drawn through port 152, applying the negative pressure evacuates air from beneath scroll 130. The negative pressure is applied for a desired amount of time with a desired amount of force to fully consolidate object 140.

[0035] After consolidation is complete, link mechanism 122 retracts, lifting scroll 130 from the preform. In embodiments where scroll 130 includes one or more layers of fiber-reinforced material, the consolidation process secures the fiber-reinforced material to object 140. Thus, when scroll 130 retracts, these layers of fiber-reinforced material remain on object 140 while permeable layer 134 and impermeable membrane 132 are retracted. After scroll 130 is removed, scroll 130 can be cleaned, refilled with additional layers of fiber-reinforced material, and / or exchanged with another spindle that has already been cleaned and filled with the desired material.

[0036] Method 200 provides technical advantages over the prior art. This is because it enables the rapid deployment of a tape-free consolidation system through an end effector that occupies a relatively small space. It also enables the deployment of layers of fiber-reinforced material as part of the consolidation process. This increases the production speed and reduces the labor force.

[0037] Figure 3 depicts an end effector 300 having an unrolled scroll in an exemplary embodiment. In this embodiment, the end effector 300 includes a frame 330 and a base 332. A link mechanism 334 extends from the base 332. An actuator 336 is disposed on the link mechanism 334 and promotes the retraction of the link mechanism 334 after consolidation by rolling a spindle 338 upward along the mandrel 310. In one embodiment, the actuator 336 comprises a motor having a slip clutch that moves the spindle 338 upward and back after consolidation is complete. In this embodiment, the end effector 300 unfolds a scroll of material onto the preform 320 placed on the mandrel 310 from the spindle 338.

[0038] Figure 4 depicts the end effector 300 of FIG. 3 having an unfolded scroll 400 in an exemplary embodiment. As shown in FIG. 4, the spindle 338 is moved to unfold the scroll 400 such that the scroll 400 covers the entire preform 320. A vacuum port 410 is utilized by a pump 420 to apply a negative pressure during the unfolding of the scroll 400 and to consolidate the preform 320 in place even after unfolding.

[0039] Figure 5 is a cross-sectional cutaway view of the scroll 400 in an exemplary embodiment and corresponds to the view arrow 5 of FIG. 3. The scroll 400 is wound around the spindle 338. The spindle 338 rolls away from each other as the link mechanism 334 spreads outward. Thereby, the web 500 of the scroll 400 is unfolded.

[0040] FIG. 6 is an enlarged view of a portion of the scroll including layers of fiber reinforced material in an exemplary embodiment and corresponds to region 6 of FIG. 5. FIG. 6 shows that the scroll 400 includes a plurality of layers. In this embodiment, the scroll 400 includes one or more layers 612 of fiber reinforced material. The layer 612 can directly contact the underlying object when the scroll 400 is deployed and form an outer mold line (OML) or inner mold line (IML) ply for the composite part. The permeable layer 614 follows the layer 612 and, as described above, enables the negative pressure to be evenly distributed along the underside of the scroll 400 when the scroll 400 is deployed. In embodiments where the scroll 400 does not include layers of fiber reinforced material, the permeable layer 614 is positioned to directly contact the underlying object. The permeable layer 614 is followed by an impermeable layer 616. The impermeable layer 616 prevents airflow from crossing the impermeable layer 616 when the scroll is deployed. When laid flat, the scroll 400 includes only one bundle 610 of the layer 612, the permeable layer 614, and the impermeable layer 616. However, the scroll 400 is wound around the spindle such that the bundle 610 is visible multiple times along the diameter of the spindle.

[0041] Figure 7 depicts a permeable layer that is air permeable in both the vertical and lateral directions in an exemplary embodiment. That is, air 710 can flow freely through the gaps 720 within the permeable layer 700 and across the gaps 720 within the permeable layer 700. This is possible because the permeable layer 700 is a two-plane mesh. The first layer 730 of the two-plane mesh includes structural elements 732 arranged parallel to each other, and the second layer 740 of the two-plane mesh includes structural elements 742 arranged parallel to each other but in a direction different from the first layer 730. The first layer 730 allows air to flow horizontally in a first direction, and the second layer 740 allows air to flow horizontally in a second direction. On the other hand, both layers allow air to flow freely in the vertical direction. Thus, when a negative pressure is applied to a portion of the permeable layer 700, the negative pressure can draw air uniformly across the entire permeable layer 700. The permeable layer 700 allows for free air flow and does not interfere with the pumping of air. That is, the permeable layer 700 does not limit the CFM speed of the pump. The permeable layer 700 may include polyethylene, polypropylene, nylon, etc. In one embodiment, the permeable layer 700 is selected as a "contact approved" material that does not chemically interfere with the adhesion of curable resins in the object being fixed. For example, the permeable layer 700 can be made from a silicon-free material that does not leave a mark on the underlying object 140.

[0042] The apparatus and method described above relate to the use of a pair of opposing rollers and a vacuum port configured to apply a vacuum through an aperture in the material. However, in other embodiments, further configurations are possible. By way of example, in a further embodiment, the material is scrolled onto a single roller rather than a pair of opposing rollers and / or the vacuum is applied through an end of the roller spindle via a chamber within the spindle and a perforation through the spindle. To illustrate these configurations, an embodiment of a vacuum system including both of these configurations, as well as a method for utilizing such a system, are shown in FIGS. 8 - 11 and described next.

[0043] FIG. 8 is a diagram 800 depicting a vacuum system 870 coupled to a spindle 840 in an exemplary embodiment. As shown in FIG. 8, the spindle 840 includes a chamber 842 having a plurality of perforations 844 that lead to an exterior 846. The chamber 842 communicates with a vacuum port 850. This means that when the vacuum system 870 evacuates air from the vacuum port 850, the air inside the chamber 842 is removed.

[0044] A scroll 838 of material 830 is wound around the spindle 840 and covers a lower preform 860 for a composite part, or any other suitable object. The ends of the scroll 838 are sealed to the spindle 840 around the perforations 844, thereby causing suction applied through the vacuum port 850 to distribute negative pressure through the scroll 838. Further details of this configuration are provided in FIG. 9 below.

[0045] Another end 836 of the scroll 838 of material 830 is attached to the surface 812 of the mandrel 810 via a tape 820. In a further embodiment, the end 836 is attached to the mandrel 810 via the application of negative pressure to the scroll 838. The material 830 includes a plurality of layers. The plurality of layers includes at least one impermeable film 832 and a permeable layer 834 (e.g., a two-plane mesh) disposed beneath the impermeable film 832. The permeable layer 834 is in fluid communication with the chamber 842 inside the spindle 840. Further details of the layer arrangement for the material 830 are described below in connection with FIG. 9.

[0046] Implementing a hollow spindle 840 and / or coupling a vacuum port 850 to the hollow portion of the spindle 840 provides numerous benefits by enabling a single component (i.e., the spindle) to perform multiple functions that not only unroll the material but also facilitate consolidation of the underlying preform 860. In further embodiments, multiple spindles (such as the spindles depicted in FIGS. 3-4) are implemented as hollow spindles having a chamber and a vacuum port for applying a negative pressure. In such embodiments, the vacuum ports for the various spindles may be located on the same side, different sides, or both sides of each spindle as desired.

[0047] FIG. 9 is a cut-through view 900 of the spindle 840 of FIG. 8 in an exemplary embodiment. The dimensions of FIG. 9 have been adjusted to better illustrate the spindle 840 with respect to the other components depicted in FIG. 8, and thus the dimensions of these figures do not match. FIG. 9 shows how the airflow moves from the material 830 to the spindle 840 when suction is applied, as indicated by the arrows. As shown in FIG. 9, the permeable layer 834 extends to contact the perforations 844 and thus is in fluid communication with the perforations 844. Further, the perforations 844 are disposed between a plurality of locations 938 where the end 936 of the scroll is sealed to the spindle 840. The permeable layer 834 is bounded by a first impermeable membrane 832 that forms an upper boundary above the preform 860 and is further bounded by a second impermeable membrane 910 that forms a lower boundary. The impermeable membranes contact the permeable layer and thus confine the airflow within the extent of the permeable layer 834.

[0048] The first impermeable membrane 832 terminates behind the permeation layer 834, and the second impermeable membrane 910 terminates before reaching the preform 860. The second impermeable membrane 910 prevents pressure loss from the permeation layer 834 during and after the unrolling process by providing a direct flow path to the chamber 842 of the spindle 840. In further embodiments, such as those described above, the scroll 838 is wound around a second spindle, and the end 836 of the scroll is sealed to the second spindle in a manner similar to that described for the end 936.

[0049] Figure 10 is a flowchart depicting a method 1000 for applying a negative pressure via a spindle in an exemplary embodiment. Step 1002 includes placing the spindle 840 on an object such as a preform for a composite part. This may include physically placing the spindle 840 on the object or on a mandrel 810 on which the object is laid up. Step 1004 includes unrolling the scroll 838 of the material 830 from the spindle 840 onto the object, thereby covering the object with the material. In some embodiments, the unrolling action places the permeation layer in direct contact with the object.

[0050] Step 1006 includes applying a negative pressure to the permeable layer 834 in the material 830 that is in fluid communication with the chamber 842 inside the spindle 840. In one embodiment, applying the negative pressure is performed via a vacuum port 850 that is in fluid communication with the chamber 842 and via a plurality of perforations 844 in the spindle 840 that connects the chamber 842 to the permeable layer 834. The negative pressure is distributed across the entire impermeable membrane via the permeable layer. This ensures that the impermeable membrane does not pinch off or self-seal in undesirable locations in response to the negative pressure. Step 1008 forms a suction hold that draws the impermeable membrane of the material into contact with the object in response to the negative pressure. The suction hold is formed naturally as the negative pressure is distributed across the impermeable membrane. At the location where the permeable layer 834 terminates and the impermeable membrane 832 is continuous, the negative pressure causes the impermeable membrane to seal itself to the underlying mandrel 810.

[0051] Figure 11 is a flowchart depicting a method 1100 for unrolling a scroll from a single spindle in an exemplary embodiment. Method 1100 places the spindle 840 on top of an object positioned on the mandrel 810 in step 1102. Step 1104 includes attaching an end 836 of a scroll 838 of material on the spindle 840 to the mandrel 810. In one embodiment, attaching the end 836 of the scroll includes taping the end 836 of the scroll 838 to the mandrel 810. In a further embodiment, attaching the end of the scroll includes forming a suction hold between the impermeable membrane of the material and the mandrel as described above for method 1000. Thus, activating the vacuum system 870 can help attach the end 836 as long as there is not a significant air leak.

[0052] Step 1106 applies a negative pressure to the permeable layer within the material, thereby forming a suction hold that places the material in contact with the object. This can be performed in a manner similar to step 1008 of method 1000 described above. In one embodiment, applying the negative pressure is performed through a plurality of perforations 844 in a spindle that connects the spindle chamber to the permeable layer. The permeable layer 834 distributes the negative pressure across the entire impermeable membrane of the material.

[0053] Step 1108 includes unrolling the scroll while the negative pressure is being applied. In one embodiment, unrolling the scroll includes covering a preform for a composite part. By unrolling the scroll, the permeable layer is placed in direct contact with the object. Further, since the ends 836 of the scroll 838 are attached in place, the scroll does not veer off course or change its orientation while the unrolling process is ongoing. This enables the entire scroll to be spread as desired (or the entire object to be covered). In a further embodiment, the method further includes consolidating the object via the suction hold. This can include increasing the negative pressure until the object is firmly pressed against the mandrel at a desired level of pressure.

[0054] Figures 8 - 11 depict a single roller, tube - type vacuum device, and related methods. However, in further embodiments, the various aspects and features described herein are applicable to various systems. For example, the chamber and vacuum system arrangements depicted in these Figures 8 - 11 can be applied to the two - roller embodiments depicted in Figures 1 and 3 - 5, except that the vacuum is applied through one or more ends of one or both of the spindles. In a further embodiment, a single - roller embodiment as depicted in these Figures 8 - 11 may apply the vacuum through apertures within the material, as described with respect to Figures 1 and 3 - 5.

[0055] Example In the following examples, further processes, systems, and methods are described in the context of a scroll deployment system for consolidating a preform onto a rigid tooling (e.g., a mandrel).

[0056] Referring to the drawings in more detail, embodiments of the present disclosure may be described from the perspective of aircraft manufacturing and maintenance in method 1200 shown in FIG. 12, and from the perspective of aircraft 1202 shown in FIG. 9. In the pre-manufacturing stage, method 1200 may include aircraft 1202 specifications and design 1204 and material procurement 1206. In the manufacturing stage, manufacturing 1208 of aircraft 1202 components and sub-assemblies and system integration 1210 are performed. Thereafter, aircraft 1202 may be subjected to operation 1214 through approval and delivery 1212. During the period of operation by the customer, aircraft 1202 is scheduled for regular work of maintenance and repair 1216 (which may also include modifications, reconfigurations, overhauls, etc.). The apparatus and methods embodied herein may be employed at any suitable stage or stages of manufacturing and maintenance described in method 1200 (e.g., specifications and design 1204, material procurement 1206, manufacturing 1208 of components and sub-assemblies, system integration 1210, approval and delivery 1212, operation 1214, maintenance and repair 1216), and / or any suitable component of aircraft 1202 (e.g., airframe 1218, systems 1220, interiors 1222, propulsion systems 1224, electrical systems 1226, hydraulic systems 1228, environmental systems 1230).

[0057] Each step of method 1200 may be implemented or executed by a system integrator, third party, and / or operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and subcontractors of major systems, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military organization, a service agency, etc.

[0058] As shown in FIG. 13, the aircraft 1202 manufactured by method 1200 may include a fuselage 1218 having a plurality of systems 1220 and an interior 1222. Examples of systems 1220 may include one or more of a propulsion system 1224, an electrical system 1226, a hydraulic system 1228, and an environmental system 1230. Any number of other systems may also be included. Although examples in the aerospace are shown, the principles of the present invention may also be applied to other industries such as the automotive industry.

[0059] As already described above, the devices and methods embodied herein may be used at any one or more stages of the manufacturing and maintenance described in method 1200. For example, a component or subassembly corresponding to the manufacture 1208 of components and subassemblies may be fabricated or manufactured in a similar manner as the components or subassemblies manufactured during the operation of the aircraft 1202. Also, one or more device embodiments, method embodiments, or combinations thereof may be utilized in the manufacture 1208 of subassemblies and system integration 1210, for example, by significantly streamlining the assembly of the aircraft 1202 or by significantly reducing the cost of the aircraft 1202. Similarly, one or more of the device embodiments, method embodiments, or combinations thereof may be utilized during the operation of the aircraft 1202 (by way of example and not limitation, in servicing and maintenance 1216). Accordingly, the present invention is used at any stage described herein, or combinations thereof. For example, specification and design 1204, procurement of materials 1206, manufacture of components and subassemblies 1208, system integration 1210, approval and delivery 1212, operation 1214, servicing and maintenance 1216, and / or any suitable component of the aircraft 1202 (e.g., fuselage 1218, systems 1220, interior 1222, propulsion system 1224, electrical system 1226, hydraulic system 1228, and / or environmental system 1230).

[0060] In one embodiment, a component includes a portion of the airframe 1218 and is manufactured during the manufacture 1208 of components and subassemblies. This component may then be assembled to the aircraft in system integration 1210 and subsequently utilized in operation 1214 until the component becomes inoperable due to wear. Thereafter, the component may be discarded and replaced with a newly manufactured component in servicing and maintenance 1216. The components and methods of the present invention may be utilized over the period of manufacture 1208 of components and subassemblies to manufacture new components.

[0061] Any of the various control elements (e.g., electrical components or electronic parts) shown in the figures or described in this specification can be implemented as hardware, processor-implemented software, processor-implemented firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. Dedicated hardware elements can be referred to as "processors", "controllers", or some similar term. When functions are provided by a processor, they can be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which can be shared. Further, the explicit use of the term "processor" or "controller" should not be construed to represent only hardware capable of executing software, and without limitation, digital signal processor (DSP) hardware, network processors, application specific integrated circuits (ASICs) or other circuits, field programmable gate arrays (FPGAs), read only memory (ROM) for storing software, random access memory (RAM), non-volatile storage devices, logic units, or some other physical hardware component or module may be implicitly included.

[0062] Further, the control element is implemented as an instruction executable by a processor or computer to perform the functions of that element. Some examples of instructions are software, program code, and firmware. The instructions are operable to direct the processor to perform the functions of that element when executed by the processor. The instructions can be stored in a storage device readable by the processor. Some examples of storage devices are digital or solid state memories, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0063] This disclosure includes exemplary embodiments according to the following clauses. Clause 1. A method for compacting an object placed on the surface of a rigid tool, comprising: unrolling (208) a scroll of material that overlaps a permeable layer and includes an impermeable film extending beyond the boundary of the permeable layer, over the object; and applying (210) a negative pressure to the permeable layer to counteract air leakage between the scroll and the object, thereby forming a suction hold that compacts the object onto the rigid tool. Clause 2. placing (204) an end effector above the object; and further comprising spreading the linkage of the end effector and placing (206) the scroll of material over the object while surrounding the object with the scroll of material. The method according to Clause 1. Clause 3. Applying the negative pressure includes applying the negative pressure through apertures in the material. The method according to Clause 2. Clause 4. Applying the negative pressure includes applying the negative pressure to a permeable layer within the material, the permeable layer being in fluid communication with a chamber inside a spindle carrying the scroll. The method according to Clause 2 or 3. Clause 5. The method according to any one of clauses 2 to 4, wherein by expanding the link mechanism of the end effector, a spindle coupled to the link mechanism and storing a scroll is rotated to distribute the scroll. Clause 6. The method according to any one of clauses 2 to 5, further comprising contracting the link mechanism after consolidation to lift the scroll from the object. Clause 7. The method according to any one of clauses 2 to 6, wherein expanding the link mechanism is performed by driving the end effector towards the rigid tool. Clause 8. The method according to any one of clauses 2 to 7, wherein expanding the link mechanism of the end effector includes pivoting the link mechanism relative to the end effector. Clause 9. The method according to any one of clauses 1 to 8, wherein applying negative pressure includes exhausting air from under the scroll. Clause 10. The method according to any one of clauses 1 to 9, wherein by applying negative pressure, the flap of the impermeable film of the scroll of the material is attracted into contact with the rigid tool. Clause 11. Further comprising placing the spindle around which the scroll of the material is wound on the object before unwinding, The method according to any one of clauses 1 to 10, wherein applying negative pressure includes applying negative pressure to the permeable layer in the material in fluid communication with the chamber inside the spindle. Clause 12. The method according to any one of clauses 1 to 11, wherein applying negative pressure is performed through a plurality of perforations in the spindle connecting the chamber of the spindle to the permeable layer. Clause 13. The method according to clause 12, wherein applying negative pressure is performed through a vacuum port in fluid communication with the chamber. Clause 14. The method according to any one of clauses 1 to 13, further comprising distributing negative pressure across the impermeable film through the permeable layer. Clause 15. Unrolling a scroll of material, the method according to any one of Clauses 1 to 14, including covering a preform for a composite part. Clause 16. The method according to any one of Clauses 1 to 15, further including densifying an object through suction holding. Clause 17. The method according to any one of Clauses 1 to 16, further including placing a permeable layer in direct contact with the object during unrolling. Clause 18. The method according to any one of Clauses 1 to 17, further including attaching an end of a scroll of material to a rigid tool. Clause 19. Attaching the end of the scroll, the method according to Clause 18, including taping the end of the scroll to a rigid tool. Clause 20. A non-transitory computer-readable medium embodying programmed instructions, the instructions being executable to perform a method for densifying an object placed on the surface of a rigid tool when executed by a processor, the method including unrolling (208) a scroll of material, including an impermeable film overlapping a permeable layer and extending beyond the boundary of the permeable layer, over the object, and applying a negative pressure to the permeable layer to counteract air leakage between the scroll and the object, thereby forming a suction hold for densifying the object on the rigid tool (210). Clause 21. The method includes placing (204) an end effector above the object, and spreading the linkage mechanism of the end effector and placing the scroll of material over the object while surrounding the object with the scroll of material (206). The medium according to Clause 20. Clause 22. Applying the negative pressure, the medium according to Clause 21, including applying the negative pressure through apertures in the material. Clause 23. Applying a negative pressure includes applying a negative pressure to a permeable layer within the material, the permeable layer being in fluid communication with a chamber inside a spindle that carries the scroll, the medium according to clause 21 or 22. Clause 24. Spreading the link mechanism of the end effector rotates a spindle coupled to the link mechanism and storing the scroll, and distributes the scroll, the medium according to any one of clauses 21 to 23. Clause 25. The method is further comprising contracting the link mechanism after consolidation and pulling the scroll away from the object, the medium according to any one of clauses 21 to 24. Clause 26. Spreading the link mechanism is performed by driving the end effector towards a rigid tool, the medium according to any one of clauses 21 to 25. Clause 27. Spreading the link mechanism of the end effector includes pivoting the link mechanism relative to the end effector, the medium according to any one of clauses 21 to 26. Clause 28. Applying a negative pressure includes exhausting air from under the scroll, the medium according to any one of clauses 20 to 27. Clause 29. By applying a negative pressure, a flap of the impermeable film of the scroll of the material is attracted into contact with the rigid tool, the medium according to any one of clauses 20 to 28. Clause 30. The method is further comprising placing the spindle on which the scroll of the material is rolled on top of the object before unrolling, Applying a negative pressure includes applying a negative pressure to a permeable layer within the material in fluid communication with a chamber inside the spindle, the medium according to any one of clauses 20 to 29. Clause 31. The application of negative pressure is effected through a plurality of perforations in the spindle that connects the spindle chamber to the permeable layer, the medium according to any one of clauses 20 to 30. Clause 32. The application of negative pressure is effected through a vacuum port in fluid communication with the chamber, the medium according to any one of clauses 20 to 31. Clause 33. The method further includes distributing negative pressure across the impermeable membrane through the permeable layer, the medium according to any one of clauses 20 to 32. Clause 34. Unrolling the scroll of material includes covering a preform for a composite part, the medium according to any one of clauses 20 to 33. Clause 35. The method further includes consolidating the object through suction holding, the medium according to any one of clauses 20 to 34. Clause 36. The method further includes placing the permeable layer in direct contact with the object during unrolling, the medium according to any one of clauses 20 to 35. Clause 37. An apparatus for consolidating an object on a rigid tool, a plurality of spindles (124), and a scroll (130) of material (830) stored on the spindles and configured to be placed on an object (140) on the rigid tool (110) when the spindles move away from each other. Clause 38. an end effector (120) configured to move towards the rigid tool, and further comprising a link mechanism (122) coupled to the end effector and configured to pivot with respect to the end effector, wherein the spindles are coupled to the link mechanism and rotatably attached to the link mechanism, the apparatus according to clause 37. Clause 39. The scroll includes a permeable layer (134) and an impermeable membrane (132), The impermeable membrane extends beyond the outer periphery of the permeable layer, the device according to clause 37 or 38. Clause 40. The rigid tool includes a mandrel (310) for a section of the fuselage of an aircraft, the device according to any one of clauses 37 to 39. Clause 41. A port (850) penetrating into the scroll, and The device according to any one of clauses 37 to 40, further comprising a pump (150) for applying a negative pressure through the port. Clause 42. The scroll extends beyond an object, the device according to any one of clauses 37 to 41. Clause 43. The scroll includes at least one layer of a fiber-reinforced material, the device according to any one of clauses 37 to 42. Clause 44. An exterior (846), A chamber (842), and At least one spindle (124) provided with a perforation (844) for coupling the chamber to the exterior, A scroll (838) of a material (830) wound around the spindle, one end (836) of the scroll being sealed to the spindle, the material Including a permeable layer (834), and An impermeable membrane (832) in contact with the permeable layer, the scroll (838), a device. Clause 45. The chamber is coupled to a vacuum system (870), the device according to clause 44. Clause 46. The device according to clause 45, further comprising a vacuum port (850) in fluid communication with the chamber in the spindle for coupling the spindle to the vacuum system. Clause 47. The permeable layer includes a two-plane mesh, the device according to any one of clauses 44 to 46. Clause 48. The apparatus according to any one of clauses 44 to 47, wherein the material further comprises a second impermeable film (910) that contacts the permeable layer. Clause 49. The apparatus according to any one of clauses 44 to 48, wherein at least one spindle comprises two spindles, the scroll is wound around each of the two spindles, and the ends (836) of the scroll are sealed to the two spindles. Clause 50. The apparatus according to any one of clauses 44 to 49, wherein the perforations are arranged between a plurality of locations where the ends of the scroll are sealed to the spindles. Clause 51. Placing the spindle on an object positioned on a mandrel (1102), Attaching the end of the scroll of material on the spindle to the mandrel (1104), Applying a negative pressure to the permeable layer within the material, thereby forming a suction hold that places the material in contact with the object (1106), and Unrolling the scroll while the negative pressure is applied (1108). A method comprising. Clause 52. The method according to clause 51, wherein attaching the end of the scroll comprises taping the end of the scroll to the mandrel. Clause 53. The method according to clause 51 or 52, wherein attaching the end of the scroll comprises forming a suction hold between the impermeable film of the material and the mandrel. Clause 54. The method according to any one of clauses 51 to 53, wherein applying the negative pressure is performed through a plurality of perforations in the spindle that connect the chamber of the spindle to the permeable layer. Clause 55. The method according to any one of clauses 51 to 54, wherein unrolling the scroll comprises covering a preform for a composite part. Clause 56. The method according to any one of clauses 51 to 55, further comprising consolidating the object through the suction hold. Article 57. The method according to any one of Articles 51 to 56, further comprising distributing a negative pressure across the impermeable membrane through a permeable layer. Article 58. The method according to any one of Articles 51 to 57, further comprising placing the permeable layer in direct contact with the object during unrolling.

[0064] Although specific embodiments are described herein, the scope of the present disclosure is not limited to these specific embodiments. The scope of the present disclosure is defined by the following claims and any equivalents thereof.

Claims

1. A method for consolidating an object placed on the surface of a rigid tool, comprising: unrolling a scroll of a material including a permeable layer and an impermeable film overlapping the permeable layer and extending beyond the boundary of the permeable layer over the object (208), and applying a negative pressure that cancels air leakage between the scroll and the object through an aperture penetrating the impermeable film or through a perforation provided at a portion of a spindle carrying the scroll in contact with the permeable layer, thereby forming a suction hold for bringing the material into contact with the object (210).

2. placing an end effector above the object (204), and further comprising spreading a link mechanism of the end effector and placing the scroll of the material over the object while surrounding the object with the scroll of the material (206), the method according to claim 1.

3. The method according to claim 1, wherein applying the negative pressure includes applying the negative pressure through the aperture.

4. The method according to claim 1, wherein applying the negative pressure includes applying the negative pressure through the perforation of the spindle, and the perforation is in fluid communication with a chamber inside the spindle.

5. The method according to claim 2, wherein by spreading the link mechanism of the end effector, a spindle coupled to the link mechanism and storing the scroll is rotated to distribute the scroll.

6. The method according to any one of claims 1 to 5, wherein applying the negative pressure includes exhausting air from under the scroll.

7. further comprising placing, above the object, a spindle around which the scroll of the material is rolled before unrolling, The method according to claim 1, wherein applying the negative pressure includes applying a negative pressure to the permeable layer in fluid communication with a chamber inside the spindle through the perforation.

8. The method according to any one of claims 1 to 7, wherein unrolling the scroll of the material includes covering a preform for a composite part.

9. The method according to any one of claims 1 to 8, further comprising consolidating the object through the suction hold.

10. The method according to any one of claims 1 to 9, further comprising attaching an end portion of a scroll of the material to the rigid tool.

11. A non-transitory computer-readable medium embodying programmed instructions, which, when executed by a processor, are executable to perform a method for consolidating an object placed on a surface of a rigid tool, the method comprising: unrolling (208) a scroll of a material including a permeable layer and an impermeable film overlapping the permeable layer and extending beyond a boundary of the permeable layer, over an object; and applying a negative pressure to the permeable layer, which cancels air leakage between the scroll and the object, through an aperture penetrating the impermeable film or through a perforation provided at a portion of the spindle carrying the scroll in contact with the permeable layer, thereby forming a suction hold for bringing the material into contact with the object (210).

12. An apparatus for consolidating an object on a rigid tool, comprising: a plurality of spindles (124); and a scroll (130) of a material (830) stored on the spindles and configured to be placed on an object (140) on the rigid tool (110) when the spindles move away from each other.

13. an end effector (120) configured to move towards the rigid tool; and a linkage mechanism (122) coupled to the end effector and configured to pivot with respect to the end effector, wherein the spindles are coupled to the linkage mechanism and rotatably attached to the linkage mechanism, according to claim 12.

14. wherein the scroll includes a permeable layer (134) and an impermeable film (132), and the impermeable film extends beyond an outer periphery of the permeable layer, according to claim 12 or 13.

15. wherein the rigid tool includes a mandrel (310) for a section of an aircraft fuselage, according to any one of claims 12 to 14.

16. The scroll includes a permeable layer (134) and an impermeable film (132), and the apparatus further comprises: a port (850) attached to an aperture penetrating the impermeable film; and a pump (150) for applying a negative pressure through the port, according to any one of claims 12 to 15.

17. The device according to any one of claims 12 to 16, wherein the scroll extends beyond the object.

18. The device according to any one of claims 12 to 17, wherein the scroll comprises at least one layer of fiber-reinforced material.

19. At least one spindle (124), a housing (846), a chamber (842), and at least one spindle (124) comprising a perforation (844) coupling the chamber to the housing; a scroll (838) of a material (830) wound around the spindle, one end (836) of the scroll being sealed to the spindle, the material comprising a permeable layer (834), and an impermeable membrane (832) contacting the permeable layer, the device comprising the scroll (838).

20. positioning a spindle on an object positioned on a mandrel (1102), a scroll of a material comprising a permeable layer and an impermeable membrane, attaching an end of the scroll at the spindle to the mandrel (1104), applying a negative pressure to the permeable layer within the material through an aperture penetrating the impermeable membrane or through a perforation provided in a portion of the spindle contacting the permeable layer, thereby forming a suction hold placing the material in contact with the object (1106), and unrolling the scroll while the negative pressure is applied (1108).

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