Apparatus and method for processing composite structures

Abstract

To provide an apparatus and method for inhibiting increase in processing costs, equipment costs and cycle time in composite processing.SOLUTION: A method of processing a composite structure 102 includes positioning a first processing tool 104 of a tooling assembly 164 and a second processing tool 106 of the tooling assembly from an open position 108, in which the first processing tool and the second processing tool are disposed at a distance, to a closed position, in which the first processing tool and the second processing tool are sealed together and are sealed together with a mandrel tool 112 supporting the composite structure, so as to form a vessel that surrounds the composite structure. The method also includes processing the composite structure.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure generally relates to manufacturing composite materials, and more specifically, to an apparatus and method for processing composite structures.

Background Art

[0002] Composite components are typically processed inside an autoclave that applies heat and pressure to the components, or an oven that applies heat to the components. However, conventional autoclave and oven processing techniques have several disadvantages, particularly when processing large composite components such as aircraft structures. For example, conventional autoclaves and ovens require a significant floor area in the manufacturing facility, increasing costs. Additionally, conventional autoclaves and ovens require heating and cooling times during the processing cycle, increasing cycle time and cost. Conventional autoclaves and ovens also typically require manual attachment and removal of vacuum hoses and temperature sensors during the cycle, further increasing cycle time and cost. In addition, conventional processing techniques often require the application of consumables such as bagging, further increasing cost and cycle time. Furthermore, conventional processing techniques often require large amounts of heating gas, further increasing processing cost, equipment cost, and cycle time. Therefore, those skilled in the art continue to conduct research and development efforts in the field of composite processing, and thus, an apparatus or method that addresses the concerns identified above would be useful.

[0003] The English translation of the summary of DE 10 2017 107908 A1 states the following: "The present invention relates to a molding tool (1) for manufacturing fiber composite parts, particularly from FRP laminates, comprising a lower mold shell (2) having a molding surface (22) for inserting a semi-finished fiber product (4), and an upper mold shell (3) forming a cavity (5) with the lower mold shell (2) when the molding tool (1) is closed, wherein the molding tool (1) is adjustable in pressure (P1, P2) within the cavity for impregnating the inserted semi-finished fiber product (4) with a matrix material. Furthermore, the FRP laminate includes at least one pressure chamber (6, 7) on the lower mold shell (2) and / or the upper mold shell (3), wherein the pressure (P3, P4) within the pressure chamber (6, 7) is adjustable such that the amount of pressure difference between the pressure (P3, P4) within the pressure chamber (6, 7) and the pressure (P1, P2) within the cavity (5) is less than the pressure difference between the ambient pressure of the mold (1) and the pressure (P1, P2) within the cavity (5)."

[0004] US 2456 513 A refers to the molding of hollow articles within a mold cavity, while simultaneously heat-treating plastic material between companion rigid and flexible mold elements.

[0005] The English translation of the US 2010 / 155984 A1 abstract states: "A method for manufacturing a composite part. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool of the composite part. The inner mold line tool may be positioned inside an outer mold line tool together with the composite part. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. After the composite part and the temporary removal layer have been transferred to the outer mold line tool, the inner mold line tool and the temporary removal layer may be removed from inside the outer mold line tool." [Overview of the project]

[0006] The following are examples of subject matter permitted in this disclosure, which may or may not be claimed, and are not exhaustive.

[0007] In the embodiment, the disclosed apparatus for processing a composite structure includes a first processing tool and a second processing tool that are movable between an open position in which the first processing tool and the second processing tool are separated from each other and a closed position in which the first processing tool and the second processing tool are configured to be sealed to each other. In the closed position, the first processing tool and the second processing tool are located between the first processing tool and the second processing tool and are configured to be sealed to a mandrel tool supporting the composite structure. In the closed position, the first processing tool, the second processing tool, and the mandrel tool form a vessel configured to apply at least one of pressure and heat to the composite structure.

[0008] In another embodiment, a disclosed apparatus for processing a composite structure includes a mandrel tool configured to support the composite structure during processing. The apparatus includes a tooling assembly movable relative to the mandrel tool between an open position and a closed position. The apparatus includes an interface seal configured to seal the tooling assembly and the mandrel tool together to form a container surrounding the composite structure in the closed position.

[0009] In another embodiment, the disclosed apparatus for processing a composite structure includes a tooling assembly configured to form a container sealed with a mandrel tool and to apply at least one of pressure and heat to the composite structure supported by the mandrel tool.

[0010] In the embodiment, the disclosed method for processing a composite structure includes (1) positioning a first processing tool and a second processing tool of a tooling assembly from an open position in which the first and second processing tools are spaced apart to a closed position in which the first and second processing tools are sealed to each other and to a mandrel tool supporting the composite structure, thereby forming a container surrounding the composite structure; and (2) processing the composite structure.

[0011] In another embodiment, a disclosed method for processing a composite structure includes (1) sealing a first processing tool to a mandrel tool supporting the composite structure; (2) sealing a second processing tool to the first processing tool and the mandrel tool; and (3) forming a container surrounding the composite structure using the first processing tool, the second processing tool and the mandrel tool.

[0012] In another embodiment, a disclosed method for processing a composite structure includes (1) positioning a mandrel tool supporting the composite structure on a second processing tool; (2) sealing the first processing tool to the second processing tool and the mandrel tool; and (3) forming a container surrounding the composite structure using the first processing tool, the second processing tool and the mandrel tool.

[0013] Further examples of the systems, apparatus, and methods of this disclosure will become clearer from the following detailed description, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic perspective view of an embodiment of an apparatus for processing composite structures. [Figure 2] This is a schematic perspective view of an embodiment of the present device. [Figure 3] This is a schematic end view of an embodiment of the device. [Figure 4] This is a schematic end view of an embodiment of the device. [Figure 5] It is a schematic cross-sectional end view of an embodiment of the present device. [Figure 6] It is a schematic cross-sectional end view of an embodiment of the present device. [Figure 7] It is a schematic end view of an embodiment of the present device. [Figure 8] It is a schematic end view of an embodiment of the present device. [Figure 9] It is a schematic cross-sectional end view of an embodiment of the present device. [Figure 10] It is a schematic cross-sectional end view of an embodiment of the present device. [Figure 11] It is a schematic cross-sectional end view of an embodiment of the present device. [Figure 12] It is a schematic perspective view of an embodiment of the first processing tool of the present device. [Figure 13] It is a schematic perspective view of an embodiment of the second processing tool of the present device. [Figure 14] It is a schematic perspective view of an embodiment of the first processing tool. [Figure 15] It is a schematic perspective view of an embodiment of the sealing interface of the first processing tool in FIG. 14. [Figure 16] It is a schematic perspective view of an embodiment of the first processing tool and the second processing tool. [Figure 17] It is a schematic perspective view of an embodiment of the sealing interface of the second processing tool in FIG. 16. [Figure 18] It is a schematic cross-sectional view of an embodiment of a part of the first processing tool and the second processing tool. [Figure 19] It is a schematic perspective view of an embodiment of a part of the first processing tool. [Figure 20] It is a schematic cross-sectional perspective view of an embodiment of a part of the first processing tool. [Figure 21] It is a schematic perspective view of a part of the mandrel tool of the present device. [Figure 22] It is a schematic block diagram of an embodiment of the present device. [Figure 23] It is a schematic block diagram of an embodiment of the present device. [Figure 24] It is a schematic block diagram of an embodiment of the present device. [Figure 25] This is a flowchart illustrating an example of a method for processing composite structures. [Figure 26] This is a flowchart illustrating the manufacturing and maintenance methods for aircraft. [Figure 27] This is a schematic block diagram of an aircraft embodiment. [Modes for carrying out the invention]

[0015] The following detailed description refers to the accompanying drawings, which illustrate specific embodiments described herein. Other embodiments having different structures and processes do not depart from the scope of this disclosure. Similar reference numerals may represent the same features, elements, or components in different drawings.

[0016] Exemplary and non-exclusive examples of the subject matter relating to this disclosure are provided below. These may be claimed, but are not necessarily claimed. Where the “Example” is referred to herein, it means that one or more features, structures, elements, components, properties, and / or operating steps described in relation to that example are included in at least one aspect, embodiment, form, and / or embodiment of the subject matter relating to this disclosure. Thus, expressions such as “one example” and “another example,” and similar wording used throughout this disclosure, may, but are not necessarily, refer to the same example. Furthermore, the subject matter characterizing any one example may, but are not necessarily, include the subject matter characterizing any other example. Furthermore, the subject matter characterizing any one example may, but are not necessarily, be combined with the subject matter characterizing any other example.

[0017] This disclosure recognizes that current technologies employed to manufacture large composite structures primarily impose a continuous flow on the processing of composite structures. For example, current autoclave processing typically involves a series of steps performed along the following processing flow path: (1) a bagging step, (2) transferring the mandrel supporting the composite structure from a transfer cart to an autoclave-compatible cart for curing, (3) installing a vacuum hose between the autoclave and the mandrel, (4) performing a system leak check that takes at least one time, (5) heating and cooling the autoclave, (6) removing the mandrel from the autoclave, (7) removing the vacuum hose, (8) returning the mandrel to the transfer cart, and (9) a bagging release step. Conventional processing technologies often require large amounts of heated gas (e.g., air), which increases processing costs and the costs of the equipment required for the autoclave, such as the internal pressure and the structure for reacting large amounts of gas. This disclosure also recognizes that this method imposes limitations on reducing the cycle time and costs associated with composite processing.

[0018] Generally referring to Figure 1-24, as an example, the present disclosure relates to an apparatus 100 for processing a composite structure 102. The apparatus 100 is configured to perform any one of a variety of composite processing operations. In one or more embodiments, the apparatus 100 is located inside a sealed container 114 Applying compacting pressure Through this, the composite structure 102 to compact It is configured as follows. In one or more embodiments, the apparatus 100 is configured to perform low to medium debulking in a sealed container 114. (debulking) heat Add and low to moderate debulking pressure Adding and Debulk the composite structure 102 through the combination ( debulk, It is configured to reduce volume. In one or more embodiments, the device 100 is configured to reduce volume to a medium to high degree within a sealed container 114. of hardening Applying heat And, medium to high level of hardening Applying pressureThe apparatus is configured to cure the composite structure 102 through a combination of the above. Thus, the apparatus 100 performs the function of an autoclave or an oven without the disadvantages associated with the use of conventional autoclave and oven processing techniques.

[0019] Referring to Figures 1 and 2, in one or more embodiments, the apparatus 100 includes a tooling assembly 164. In one or more embodiments, the tooling assembly 164 includes a first processing tool 104. In one or more embodiments, the assembly 164 also includes two processing tools 106.

[0020] In one or more embodiments, the apparatus 100 also includes a mandrel tool 112. The mandrel tool 112 is configured to support the composite structure 102 during layup and processing, etc. The mandrel tool 112 is sometimes commonly referred to as a layup mandrel.

[0021] In one or more embodiments, the mandrel tool 112 is movable relative to the tooling assembly 164. In one or more embodiments, the tooling assembly 164 is movable relative to the mandrel tool 112. In one or more embodiments, the tooling assembly 164 is movable relative to the mandrel tool 112, and the mandrel tool 112 is movable relative to the tooling assembly 164.

[0022] In one or more embodiments, the tooling assembly 164 and the mandrel tool 112 are configured to form a sealed container 114 (Figure 2). In one or more embodiments, as shown in Figure 1-2, the container 114 (Figure 2) is formed by sealing the first processing tool 104 and the second processing tool 106 together along a first interface 124 (Figure 2) through a portion of the interface seal 180 (Figure 1), sealing the end of the first processing tool 104 around a portion of the outer circumference of the opposite end of the mandrel tool 112 along a second interface 126 (Figure 1) through another portion of the interface seal 180, and sealing the end of the second processing tool 106 around another portion of the outer circumference of the opposite end of the mandrel tool 112 along a third interface 132 (Figure 1) through another portion of the interface seal 180.

[0023] Accordingly, the disclosed apparatus 100 allows the end 214 of the mandrel tool 112 to extend beyond the tooling assembly 164 and be located outside the container 114. The disclosed apparatus 100 also allows the processing cart 184 supporting the mandrel tool 112 during processing to be located outside the container 114 during processing. The placement of part of the mandrel tool 112 and the processing cart 184 outside the container 114 advantageously reduces the required size of the container 114, reduces the internal space of the container 114, and reduces the time and energy required to process the composite structure 102.

[0024] In one or more embodiments, the tooling assembly 164 is movable between an open position 108 (Figure 1) and a closed position 110 (Figure 2). In the open position 108, the first processing tool 104 and the second processing tool 106 of the tooling assembly 164 are positioned such that the mandrel tool 112 supporting the composite structure 102 can be appropriately positioned between the first processing tool 104 and the second processing tool 106 for processing. In the closed position 110, the first processing tool 104 and the second processing tool 106 of the tooling assembly 164 are positioned such that the tooling assembly 164 and the mandrel tool 112 are sealed together to form a container 114.

[0025] The container 114 surrounds the composite structure 102 during processing. The container 114 is formed by the outer surface 210 (Figure 1) of the mandrel tool 112, the first processing tool 104, and the second processing tool 106. When the tooling assembly 164 is in the closed position 110 (Figure 2), the container 114 is sealed via an interface seal 180 (Figure 1) that is in direct contact with the outer surface 210 of the opposite end 214 of the mandrel tool 112, the first processing tool 104, and the second processing tool 106. In short, the mandrel tool 112, the first processing tool 104, and the second processing tool 106 form the outer periphery of the container 114 along the interface seal 180. With the container 114 formed and sealed around the composite structure 102, the tooling assembly 164 is configured to apply at least one of pressure and heat to the composite structure 102 supported by the mandrel tool 112.

[0026] Accordingly, the disclosed apparatus 100 advantageously reduces the volume of gas 118 (Figures 5-6 and 9-11), such as heated and / or pressurized gas, located within and surrounded by the vessel 114, compared to conventional autoclaves, thereby reducing processing costs and cycle times for processing the composite, as well as the structural costs of the tooling assembly 164 required to react to the internal pressure. For example, in conventional autoclaves, the outer walls and door of the autoclave form the pressure vessel, but must be large enough to accommodate the mandrel supporting the composite and the entire processing cart used to support the mandrel during processing of the composite. In contrast, the disclosed apparatus 100 utilizes a mandrel tool 112 to form the structural components of the vessel 114. Thus, the mandrel tool 112 performs a dual function: supporting the composite structure 102 (Figure 1) (e.g., composite preform) and forming part of the vessel 114 used for processing the composite structure 102.

[0027] In one or more embodiments, the apparatus 100 includes a heating system ("HS") 116. The heating system 116 is configured to generate heat used during the processing of the composite structure 102. In one or more embodiments, the heating system 116 heats a gas 118 located in the vessel 114 (Figures 5-6 and 9-11). In one or more embodiments, the heating system 116 heats at least one of the first processing tool 104 and the second processing tool 106 of the tooling assembly 164. In one or more embodiments, the heating system 116 heats the mandrel tool 112.

[0028] In one or more embodiments, the apparatus 100 includes a pressurization system ("PS") 140. The pressurization system 140 is used to generate positive pressure used during the processing of the composite structure 102. The positive pressure acts on the composite structure 102 (Figure 1) during processing, applying a compressive force to consolidate the composite structure 102. consolidate In one or more embodiments, the pressurizing system 140 pressurizes the gas 118 located inside the container 114 (Figures 5-6 and 9-11).

[0029] In one or more embodiments, the apparatus 100 includes a vacuum system ("VS") 138. The vacuum system 138 is used to generate negative pressure used during processing of the composite structure 102. As described in more detail herein, the vacuum system 138 is configured to evacuate gas located between the outer surface 210 of the mandrel tool 112 and one of the fitting membranes (e.g., a first fitting membrane 136 (Figures 6, 10-11) and / or a second fitting membrane 146 (Figure 6) or compression bagging (e.g., compression bagging 162 (Figures 5 and 9)) surrounding the outer surface 212 of the composite structure 102 (Figure 1).

[0030] In one or more embodiments, the apparatus 100 includes two or more combinations of a heating system 116, a pressurizing system 140, and a vacuum system 138 to generate heat, positive pressure, and negative pressure used during processing of the composite structure 102.

[0031] Therefore, in the various embodiments described herein, the tooling assembly 164 is opened to position the mandrel tool 112 and closed to form a container 114 surrounding the composite structure 102 for processing the composite structure 102 in place of conventional autoclave or oven processing techniques. Apparatus 100 advantageously reduces the size of the processing apparatus and improves the cycle time and cost associated with processing the composite structure 102 compared to conventional autoclave and oven processing techniques. Apparatus 100 also advantageously provides increased throughput, reduced operating costs, and flexibility in facility layout.

[0032] Generally referring to Figure 1-11, in one or more embodiments, the first processing tool 104 and the second processing tool 106 are movable between an open position 108 (Figures 1, 3, and 7) and a closed position 110 (Figures 2, 4-6, and 7-11). In the open position 108, the first processing tool 104 and the second processing tool 106 are separated from each other so that the mandrel tool 112 supporting the composite structure 102 can be appropriately positioned for processing, for example, between the first processing tool 104 and the second processing tool 106. In the closed position 110, at least two of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 are sealed from each other and configured to form a container 114 around the composite structure 102.

[0033] In one or more embodiments, the container 114 is a sealed chamber that surrounds and confines the composite structure 102 for processing. The container 114 is configured to apply at least one of pressure and heat to the composite structure 102.

[0034] In one or more embodiments, the first processing tool 104 is movable relative to the second processing tool 106. In one or more embodiments, the second processing tool 106 is movable relative to the first processing tool 104. In one or more embodiments, the first processing tool 104 and the second processing tool 106 are movable relative to each other.

[0035] In one or more embodiments, the movement of the first processing tool 104 and / or the second processing tool 106 relative to each other and / or relative to the mandrel tool 112 is performed automatically by computer control, such as by using a drive mechanism configured to move at least one of the first processing tool 104 and the second processing tool 106 in one or more directions between an open position 108 and a closed position 110.

[0036] As best shown in Figures 3-4, in one or more embodiments, with the mandrel tool 112 properly positioned relative to the tooling assembly 164, at least one of the first processing tool 104 and the second processing tool 106 moves linearly (e.g., approximately horizontally) relative to each other and to the mandrel tool 112 between an open position 108 (Figure 3) and a closed position 110 (Figure 4).

[0037] In one or more embodiments, as shown in Figures 1-6, the mandrel tool 112 and composite structure 102 have a closed cross-sectional shape (e.g., circular) used to form a barrel-shaped composite product. The first processing tool 104 and the second processing tool 106 are appropriately designed to accommodate the closed cross-sectional shape of the mandrel tool 112 and composite structure 102 for processing.

[0038] As best shown in Figures 7-8, in one or more embodiments, with the mandrel tool 112 properly positioned relative to the tooling assembly 164, the first processing tool 104 pivotally moves between an open position 108 (Figure 7) and a closed position 110 (Figure 8) relative to the second processing tool 106 and the mandrel tool 112.

[0039] In one or more embodiments (not expressly shown), with the mandrel tool 112 properly positioned relative to the tooling assembly 164, the first processing tool 104 moves linearly (for example, approximately vertically or downward) between an open position and a closed position relative to the second processing tool 106 and the mandrel tool 112.

[0040] In one or more embodiments, as shown in Figure 7-11, the mandrel tool 112 and composite structure 102 have an open cross-sectional shape (e.g., semicircular) used to form a semi-barrel-shaped composite product. The first processing tool 104 and the second processing tool 106 are appropriately designed to accommodate the open cross-sectional shape of the mandrel tool 112 and composite structure 102 for processing.

[0041] Generally, the tooling assembly 164 is configured to be complementary to the shape of the mandrel tool 112 and / or the shape of the composite structure 102 supported by the mandrel tool 112. The complementary shapes of the tooling assembly 164 and the mandrel tool 112 facilitate a reduction in the size of the container 114 surrounding the composite structure 102. For example, in conventional autoclave and oven processing, the entire mandrel supporting the composite and the entire processing cart supporting the mandrel are located inside the processing container of the autoclave or oven. With the disclosed apparatus 100, a portion of the mandrel tool 112 (e.g., opposing ends 214 of the mandrel tool 112 (Figure 1)) and the entire processing cart 184 can be placed outside the container 114, significantly reducing the size of the container 114. Therefore, as shown in Figure 3-11, the configuration and / or shape of the first processing tool 104 and the second processing tool 106 may depend on the configuration and / or shape (e.g., closed section shape or open section shape) of the mandrel tool 112 and / or composite structure 102.

[0042] In addition, in the closed position 110, the tooling assembly 164 and the mandrel tool 112 may have various sealing configurations depending on the configuration and / or shape of the mandrel tool 112 (e.g., closed or open cross-sectional shape), or the configuration and / or shape of the composite structure 102 supported by the mandrel tool 112 (e.g., closed or open cross-sectional shape).

[0043] Figure 3 schematically shows an embodiment of the first configuration of the tooling assembly 164 in the open position 108, where the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106. The embodiment of the apparatus 100 shown in Figure 3 shows an end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the processing cart 184.

[0044] Figures 4-6 schematically show an embodiment of the first configuration of the tooling assembly 164 in the closed position 110, where the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106, and is sealed by the first processing tool 104 and the second processing tool 106 to form the container 114. The embodiment of the apparatus 100 shown in Figure 4 shows an end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the processing cart 184. The embodiment of the apparatus 100 shown in Figures 5-6 shows a cross-sectional end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the processing cart 184. Figure 5 shows an embodiment of the apparatus 100 utilizing compression bagging 162 surrounding the outer surface 212 of the composite structure 102. Figure 6 shows an embodiment of the apparatus 100 that utilizes a first compatible film 136 and a second compatible film 146 surrounding the outer surface 212 of the composite structure 102.

[0045] Figure 7 schematically shows an embodiment of a second configuration of the tooling assembly 164 in the open position 108, where the mandrel tool 112 supporting the composite structure 102 is located on the second processing tool 106. The embodiment shown in Figure 7 shows an end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the second processing tool 106.

[0046] Figures 8-10 schematically show an embodiment of a second configuration of the tooling assembly 164 in a closed position 110, where the mandrel tool 112 supporting the composite structure 102 is located between the first processing tool 104 and the second processing tool 106, and is sealed by the first processing tool 104 and the second processing tool 106 to form the container 114. The embodiment of the apparatus 100 shown in Figure 8 shows an end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the second processing tool 106. The embodiment of the apparatus 100 shown in Figure 9-10 shows a cross-sectional end view of the first processing tool 104, the second processing tool 106, and the mandrel tool 112 supporting the composite structure 102 and supported by the second processing tool 106. Figure 9 shows an embodiment of the apparatus 100 that utilizes compression bagging 162 surrounding the outer surface 212 of the composite structure 102. Figure 10 shows an embodiment of the apparatus 100 that utilizes a first compatible film 136 surrounding the outer surface 212 of the composite structure 102.

[0047] Figure 11 schematically shows an embodiment of a third configuration of the tooling assembly 164 in a closed position, where the mandrel tool 112 supporting the composite structure 102 is sealed with the first processing tool 104 to form the container 114. The embodiment shown in Figure 11 shows a cross-sectional end view of the first processing tool 104 and the mandrel tool 112 supporting the composite structure 102. Figure 11 shows an embodiment of the apparatus 100 that utilizes a first fitting membrane 136 surrounding the outer surface 212 of the composite structure 102. However, the configuration shown in Figure 11 may, alternatively or additionally, utilize compression bagging 162 surrounding the composite structure 102.

[0048] As will become clear from this disclosure, the apparatus 100 is not limited to the configuration shown in Figure 3-11, and other configurations are also possible.

[0049] As shown in Figure 4-6, in one or more embodiments, the mandrel tool 112 is located between the first processing tool 104 and the second processing tool 106. In the closed position 110, the first processing tool 104 and the second processing tool 106 are configured to seal each other along the first interface 124 via a portion of the interface seal 180 (Figure 1). In the closed position 110, the first processing tool 104 is configured to seal the outer surface 210 of the end 214 of the mandrel tool 112 along the second interface 126 via another portion of the interface seal 180 (Figure 1). In the closed position 110, the second processing tool 106 is configured to seal the outer surface 210 of the end 214 of the mandrel tool 112 along the third interface 132 via another portion of the interface seal 180 (Figure 1).

[0050] Referring to Figure 5-6, in the closed position 110, the first processing tool 104 and the second processing tool 106 form, for example, a portion (e.g., the outer portion) of the wall 216 that forms the outer shell or outer shroud of the container 114, which has a circular cross-sectional shape. In the closed position 110, the mandrel tool 112 forms, for example, another portion (e.g., the inner portion) of the wall 216 that forms the inner shell of the container 114, which has a circular cross-sectional shape. This configuration is advantageous for processing composite structures having a closed (e.g., circular) cross-sectional shape, such as shown in Figure 1-6.

[0051] As shown in Figure 8-10, in one or more embodiments, the mandrel tool 112 is positioned on or supported by the second processing tool 106. In the closed position 110, the first processing tool 104 and the second processing tool 106 are configured to seal each other along the first interface 124 via a portion of the interface seal 180. In the closed position 110, the first processing tool 104 is configured to seal the outer surface 210 of the end 214 of the mandrel tool 112 along the second interface 126 via another portion of the interface seal 180.

[0052] Referring to Figure 9-10, in the closed position 110, the first processing tool 104 and the second processing tool 106 form a portion (e.g., the outer portion) of the wall 216 of the container 114, for example, having a semicircular cross-sectional shape. In the closed position 110, the mandrel tool 112 forms another portion (e.g., the inner portion) of the wall 216 of the container 114, for example, having a semicircular cross-sectional shape. In the embodiment shown in Figure 7-10, the second processing tool 106 may be sealed with the mandrel tool 112, but it is not required to be sealed. This configuration is advantageous for processing composite structures having open cross-sectional shapes (e.g., semicircular), such as a planar cross-sectional shape or other complex cross-sectional shapes, as shown in Figure 7-10.

[0053] As shown in Figure 11, in one or more embodiments, the mandrel tool 112 also functions as a processing tool. In the closed position 110, the first processing tool 104 is configured to seal to the mandrel tool 112 along the second interface 126 via a portion of the interface seal 180. In these embodiments, the container 114 is formed by the first processing tool 104 and the mandrel tool 112 without the need to use the second processing tool 106. In short, the mandrel tool 112 functions as a processing tool. In the closed position 110, the first processing tool 104 forms a portion of the wall 216 of the container 114, and the mandrel tool 112 forms another portion of the wall 216 of the container 114.

[0054] In the closed position 110, the first processing tool 104 is configured to seal to the mandrel tool 112 along the second interface 126 via the interface seal 180. In one or more embodiments, the mandrel tool 112 includes a pair of opposite mandrel flanges 238 extending outward along the length of the mandrel tool 112. In the closed position 110, the first processing tool 104 is configured to seal to the mandrel flanges 238 along the second interface 126 via a portion of the interface seal 180 (Figure 1), and the end of the first processing tool 104 is configured to seal to the outer surface 210 of the end 214 of the mandrel tool 112 along the second interface 126 via another portion of the interface seal 180. Therefore, when the tooling assembly 164 is in the closed position 110, the container 114 is sealed via the interface seal 180, which is in direct contact with the opposite end 214 of the outer surface 210 of the mandrel tool 112, the mandrel flange 238, and the first processing tool 104. In short, the mandrel tool 112 and the first processing tool 104 form the outer circumference of the container 114 along the interface seal 180.

[0055] Referring to Figures 1 and 3-11, in one or more embodiments, the first processing tool 104 includes a first container wall 134 that forms part of the wall 216 of the container 114. In one or more embodiments, the first processing tool 104 also includes a pair of opposite first container ends 194 (only one of the first container ends 194 is shown in Figures 3, 4, 7 and 8) that form part of the wall 216 of the container 114. In the embodiments, one of each first container ends 194 extends from the first container wall 134 and is approximately perpendicular to the first container wall 134. In these embodiments, the first container wall 134 and the first container ends 194 form a first portion of the wall 216 of the container 114.

[0056] Referring to Figures 1 and 3-6, in one or more embodiments, the second processing tool 106 includes a second container wall 144 that forms part of the wall 216 of the container 114. In one or more embodiments, the second processing tool 106 also includes a pair of opposite second container ends 196 (only one of the second container ends 196 is shown in Figure 3-4) that form part of the wall 216 of the container 114. In the embodiments, one of each second container end 196 extends from the second container wall 144 and is approximately perpendicular to the second container wall 144. In these embodiments, the second container wall 144 and the second container ends 196 form a second portion of the wall 216 of the container 114.

[0057] As shown in Figures 5-6, in one or more embodiments, in the closed position 110, the first container wall 134 and the second container wall 144 are sealed at the first interface 124 via a portion of the interface seal 180 (Figure 1). In the closed position 110 shown in Figure 4, each portion of the first container end 194 and each portion of the second container end 196 are sealed at the first interface 124 via another portion of the interface seal 180. In the closed position 110 shown in Figure 4, each other portion of the first container end 194 (only one of the first container end 194 is shown in Figure 4) and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the second interface 126 via another portion of the interface seal 180. In the closed position 110 shown in Figure 4, each other portion of the second container end 196 (only one of the second container end 196 is shown in Figure 4) and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the third interface 132 via another portion of the interface seal 180.

[0058] Accordingly, in one or more embodiments, with the tooling assembly 164 in the closed position 110, the container 114 is formed by a first container wall 134, a first container end 194, a second container wall 144, a second container end 196, and a mandrel tool 112. The container 114 is sealed along a first interface 124, a second interface 126, and a third interface 132 via an interface seal 180 (Figure 1) that is in direct contact with the outer surface 210 of the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the end 214 of the mandrel tool 112.

[0059] Referring to Figure 7-10, in one or more embodiments, the second processing tool 106 includes a second container wall 144 that forms part of the wall 216 of the container 114. In these embodiments, the second container wall 144 forms a second portion of the wall 216 of the container 114.

[0060] As shown in Figures 9-10, in one or more embodiments, in the closed position 110, the first container wall 134 and the second container wall 144 are sealed at the first interface 124 via a portion of the interface seal 180. As shown in Figure 8, in the closed position 110, each portion of the first container end 194 (only one of the first container end 194 is shown in Figure 8) and the second container wall 144 are sealed at the first interface 124 via another portion of the interface seal 180. As shown in Figure 8, in the closed position 110, each other portion of the first container end 194 and the outer surface 210 of the end 214 of the mandrel tool 112 are sealed together at the second interface 126 via another portion of the interface seal 180.

[0061] Therefore, in one or more embodiments, with the tooling assembly 164 in the closed position 110, the container 114 is formed by a first container wall 134, a first container end 194, a second container wall 144, and a mandrel tool 112. The container 114 is sealed along the first interface 124 and the second interface 126 via an interface seal 180 that is in direct contact with the outer surface 210 of the first container wall 134, the first container end 194, the second container wall 144, and the end 214 of the mandrel tool 112.

[0062] As shown in Figure 11, in one or more embodiments, in the closed position 110, the first container wall 134 and the first container end 194 (not shown in Figure 11) are sealed to the mandrel tool 112 at the second interface 126 via part of the interface seal 180 to form the container 114. In one or more embodiments, in the closed position 110, one part each of the first container wall 134 and the first container end 194 (not shown in Figure 11) and the mandrel flange 238 are sealed at the second interface 126 via part of the interface seal 180. In the closed position 110, one other part each of the first container end 194 and the end 214 of the outer surface 210 of the mandrel tool 112 are sealed together at the second interface 126 via another part of the interface seal 180.

[0063] Therefore, in one or more embodiments, with the tooling assembly 164 in the closed position 110, the container 114 is formed by the first container wall 134 and the mandrel tool 112. The container 114 is sealed along the second interface 126 via an interface seal 180 that is in direct contact with the first container wall 134, the first container end 194, the mandrel flange 238, and the outer surface 210 of the mandrel tool 112.

[0064] Figures 12-13 schematically show an embodiment of the interface seal 180. With the tooling assembly 164 in the closed position 110, the interface seal 180 is configured to seal the tooling assembly 164 and the mandrel tool 112 together to form a container 114 surrounding the composite structure 102. Figure 12 shows a first portion of the interface seal 180 associated with a first processing tool 104, and Figure 13 shows a second portion of the interface seal 180 associated with a second processing tool 106.

[0065] Referring to Figures 12 and 14-15, in one or more embodiments, the first processing tool 104 includes a first interface seal 122. The first interface seal 122 is an embodiment of or forms part of an interface seal 180. In the closed position 110, the first interface seal 122 is configured to seal the first interface 124 between the first processing tool 104 and the second processing tool 106. In the closed position 110, the first interface seal 122 is also configured to seal the second interface 126 between the first processing tool 104 and the mandrel tool 112. For example, the first interface seal 122 extends along the outer circumference of the first container wall 134 and the first container end 194. The first interface seal 122 forms at least part of the seal between the first container wall 134 and the second container wall 144. The first interface seal 122 forms at least a portion of the seal between the first container end 194 and the second container end 196. The first interface seal 122 forms a seal between the first container end 194 and the outer surface 210 of the end 214 of the mandrel tool 112.

[0066] In one or more embodiments, the first processing tool 104 includes a first interface surface 120. In one or more embodiments, the first interface surface 120 forms the outer periphery of the first container wall 134. In one or more embodiments, the first interface surface 120 also forms the outer periphery of each of the first container ends 194. In one or more embodiments, the first interface seal 122 extends along the entire first interface surface 120. Generally, the first interface seal 122 is a reusable seal.

[0067] Referring to Figures 13 and 16-17, in one or more embodiments, the second processing tool 106 includes a second interface seal 130. The second interface seal 130 is an embodiment of or forms part of an interface seal 180. In the closed position 110, the second interface seal 130 is configured to seal the first interface 124 between the first processing tool 104 and the second processing tool 106. In the closed position 110, the second interface seal 130 is configured to seal the third interface 132 between the second processing tool 106 and the mandrel tool 112. For example, the second interface seal 130 extends along the outer circumference of the second container wall 144 and the second container end 196. The second interface seal 130 forms at least part of the seal between the first container wall 134 and the second container wall 144. The second interface seal 130 forms at least a portion of the seal between the first container end 194 and the second container end 196. The second interface seal 130 forms a seal between the second container end 196 and the outer surface 210 of the end 214 of the mandrel tool 112.

[0068] In one or more embodiments, the second processing tool 106 includes a second interface surface 128. In one or more embodiments, the second interface surface 128 forms the outer periphery of the second container wall 144. In one or more embodiments, the second interface surface 128 also forms the outer periphery of each of the second container ends 196. In one or more embodiments, the second interface seal 130 extends along the entire second interface surface 128. Generally, the second interface seal 130 is a reusable seal.

[0069] As shown in Figures 15 and 17, in one or more embodiments, the first interface seal 122 and the second interface seal 130 have complementary geometric shapes. The complementary geometric shapes of the first interface seal 122 and the second interface seal 130 are configured to fit together and make contact with each other in the closed position 110, thereby forming a seal. The complementary geometric shapes are particularly advantageous at the three-way intersection of the first interface 124 between the first processing tool 104 and the second processing tool 106, the second interface 126 between the first processing tool 104 and the mandrel tool 112, and the third interface 132 between the second processing tool 106 and the mandrel tool 112.

[0070] Referring to Figures 2, 4, and 8, in one or more embodiments, the tooling assembly 164 is temporarily fixed in a closed position 110, where the tooling assembly 164 and the mandrel tool 112 are sealed together to form a container 114 during processing of the composite structure 102. In one or more embodiments, the tooling assembly 164 includes at least one fastening device 236. As shown in Figure 2, the at least one fastening device 236 includes or takes the form of any suitable mechanism used to firmly hold and secure the first processing tool 104 and the second processing tool 106 together to prevent movement or separation, such as a clamp. As shown in Figure 4, the at least one fastening device 236 includes or takes the form of any suitable mechanism used to firmly hold and secure the first processing tool 104 and the mandrel tool 112 together to prevent movement or separation, such as a clamp.

[0071] Referring to Figures 6, 10, and 12, in one or more embodiments, the apparatus 100, such as a first processing tool 104, includes a first fitting membrane 136. In the closed position 110, the first fitting membrane 136 is configured to be pressed against the composite structure 102, as shown in Figures 6 and 10. Generally, the first fitting membrane 136 is a reusable component of the apparatus 100. In one or more embodiments, the first fitting membrane 136 compresses the composite structure 102 between the first fitting membrane 136 and the outer surface 210 of the mandrel tool 112. (compress) In one or more embodiments, the first compatible film 136 serves as a disposable alternative to vacuum bagging or compression bagging.

[0072] In one or more embodiments, in the closed position 110, the composite structure 102 is positioned between the mandrel tool 112 and the first fitting membrane 136. During processing, the first fitting membrane 136 applies pressure to the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112. In one or more embodiments, as will be further described herein, the first fitting membrane 136 is pressed against the outer surface 212 of the composite structure 102 via at least one of positive pressure applied by the pressure system 140 and / or negative pressure applied by the vacuum system 138.

[0073] As best shown in Figure 12, in one or more embodiments, the first outer periphery 220 of the first fitting film 136 is coupled to and sealed to the first processing tool 104. In one or more embodiments, a portion of the first fitting film 136, such as two first outer periphery-first side portions 222 on the opposite side of the first outer periphery 220 of the first fitting film 136, is coupled to and sealed to the first container wall 134 of the first processing tool 104. In one or more embodiments, another portion of the first fitting film 136, such as two first outer periphery-second side portions 224 on the opposite side of the first outer periphery 220 of the first fitting film 136, is coupled to and sealed to the first container end portion 194 of the first processing tool 104.

[0074] The first fitting film 136 is bonded to the first processing tool 104 by any suitable method or technique. In one or more embodiments, the first fitting film 136 is bonded to and sealed (e.g., airtight) to the first processing tool 104, for example, along the first outer circumference 220, by mechanical fasteners, chemical bonds (e.g., adhesives or other binders), or a combination of mechanical fasteners and chemical bonds.

[0075] Referring to Figures 6 and 13, in one or more embodiments, the apparatus 100, such as a second processing tool 106, includes a second fitting membrane 146. In the closed position 110, the second fitting membrane 146 is configured to press against the composite structure 102, as shown in Figure 6. Generally, the second fitting membrane 146 is a reusable component of the apparatus 100. In one or more embodiments, the second fitting membrane 146 compresses the composite structure 102 between the second fitting membrane 146 and the outer surface 210 of the mandrel tool 112. In one or more embodiments, the second fitting membrane 146 serves as a consumable alternative to vacuum bagging or compression bagging.

[0076] In one or more embodiments, in the closed position 110, the composite structure 102 is positioned between the mandrel tool 112 and the second fitting membrane 146. During processing, the second fitting membrane 146 applies pressure to the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112. As will be further described herein, in one or more embodiments, the second fitting membrane 146 is pressed against the outer surface 212 of the composite structure 102 via at least one of positive pressure applied by the pressure system 140 and / or negative pressure applied by the vacuum system 138.

[0077] As shown in Figure 13, in one or more embodiments, the second outer periphery 226 of the second fitting film 146 is bonded to and sealed by the second processing tool 106. In one or more embodiments, a portion of the second fitting film 146, such as two second outer peripheries—first side portions 228—on the opposite side of the second outer periphery 226 of the second fitting film 146, is bonded to and sealed by the second container wall 144 of the second processing tool 106. In one or more embodiments, another portion of the second fitting film 146, such as two second outer peripheries—second side portions 230—on the opposite side of the second outer periphery 226 of the second fitting film 146, is bonded to and sealed by the second container end portion 196 of the second processing tool 106.

[0078] The second fitting film 146 is bonded to the second processing tool 106 by any suitable method or technique. In one or more embodiments, the second fitting film 146 is bonded to and sealed (e.g., airtight) to the second processing tool 106, for example, along the second outer circumference 226, by mechanical fasteners, chemical bonds (e.g., adhesives), or a combination of mechanical fasteners and chemical bonds.

[0079] In one or more embodiments, the first and second compatible films 136 and 146 comprise or are formed by broad, flat, and flexible pieces (e.g., sheets) of elastomer material. The elastomer material of the first and second compatible films 136 and 146 is impermeable and can therefore be used to apply mechanical pressure to the composite structure 102 during processing by applying positive and / or negative pressure.

[0080] In one or more embodiments, the first compatible film 136 and the second compatible film 146 are constructed from an elastomer or a combination of elastomers (but not limited to natural rubber, synthetic rubber, fluoropolymer elastomers (e.g., Viton®), silicone, ethylene propylene diene monomer (EPDM) rubber, etc.). In one or more embodiments, the elastomer or combination of elastomers of the first compatible film 136 and the second compatible film 146 are reinforced with reinforcing materials such as glass fibers, carbon fibers, etc. (but not limited to these).

[0081] The elastomer materials selected for the first compatible film 136 and the second compatible film 146 may depend on the processing cycle parameters (e.g., heat and pressure) used during the processing of the composite structure 102.

[0082] As shown in Figure 12, in one or more embodiments, the apparatus 100, such as a first processing tool 104, includes a first backing plate 142. In one or more embodiments, the first backing plate 142 is bonded to a first fitting film 136. In the closed position 110, the first backing plate 142 is configured to shape and / or smooth the outer surface 212 of the composite structure 102. For example, in the closed position 110, the first backing plate 142 is positioned between the first fitting film 136 and the outer surface 212 of the composite structure 102, and a portion of the composite structure 102 is positioned between the outer surface 210 of the mandrel tool 112 and the first backing plate 142. During processing, the first backing plate 142, together with the first fitting film 136, is pressed against the outer surface 212 of the composite structure 102, shaping and / or smoothing the outer surface 212 of the composite structure 102.

[0083] The first backing plate 142 is bonded to the first compatible film 136 by any suitable method or technique. In one or more embodiments, the first backing plate 142 is chemically bonded to the surface of the first compatible film 136 (for example, via an adhesive or other binder).

[0084] As shown in Figure 13, in one or more embodiments, the apparatus 100, such as a second processing tool 106, includes a second backing plate 148. In one or more embodiments, the second backing plate 148 is bonded to a second fitting film 146. In the closed position 110, the second backing plate 148 is configured to shape and / or smooth the outer surface 212 of the composite structure 102. For example, in the closed position 110, the second backing plate 148 is positioned between the second fitting film 146 and the outer surface 212 of the composite structure 102, and a portion of the composite structure 102 is positioned between the outer surface 210 of the mandrel tool 112 and the second backing plate 148. During processing, the second backing plate 148, together with the second fitting film 146, is pressed against the outer surface 212 of the composite structure 102, shaping and / or smoothing the outer surface 212 of the composite structure 102.

[0085] The second backing plate 148 is bonded to the second compatible film 146 by any suitable method or technique. In one or more embodiments, the second backing plate 148 is chemically bonded to the surface of the second compatible film 146 (e.g., via an adhesive or other binder).

[0086] Generally, the first backing plate 142 and the second backing plate 148 include or are formed from a broad, flat, and flexible material piece (such as a sheet) that is substantially free of surface defects. The first backing plate 142 and the second backing plate 148 are used to make close contact with the outer surface 212 of the composite structure 102 during the processing operation and to provide the composite structure 102 with a smooth outer surface.

[0087] In one or more embodiments, the first backing plate 142 and the second backing plate 148 are constructed from fiber-reinforced polymer materials, including but not limited to carbon fiber-reinforced polymers and carbon fiber-reinforced epoxy. As in the examples, the first backing plate 142 and the second backing plate 148 are constructed from carbon fiber-reinforced benzoxazine or carbon fiber-reinforced bismaleimide. In one or more embodiments, the first backing plate 142 and the second backing plate 148 are constructed from metallic materials, including but not limited to aluminum. In one or more embodiments, the first backing plate 142 and the second backing plate 148 are constructed from metallic alloys, including but not limited to nickel-iron alloys (e.g., Invar).

[0088] In one or more embodiments, the first backing plate 142 and the second backing plate 148 have a thickness ranging from approximately 0.030 inches (0.76 millimeters) to approximately 0.125 inches (3.17 millimeters).

[0089] In one or more embodiments, the outer surfaces of the first backing plate 142 and the second backing plate 148 (for example, surfaces configured to contact the outer surface 212 of the composite structure 102) have surface roughness values ​​between approximately 32Ra and approximately 63Ra.

[0090] The materials and / or thicknesses selected for the first backing plate 142 and the second backing plate 148 may depend on the processing cycle parameters (e.g., heat and pressure) used during the processing of the composite structure 102.

[0091] Referring to Figures 1, 2, 5, 9-11, 14, and 16, in one or more embodiments, the apparatus 100 includes a heating system 116. The heating system 116 is configured to heat the composite structure 102 supported on the mandrel tool 112 during processing. In one or more embodiments, the heating system 116 debulks the composite structure 102. Heat the composite structure 102 to a temperature sufficient for this purpose. death, and, sustained period over Maintain the composite structure 102 at the debulk temperature. ruyoIt is composed of the following. The debulking process typically involves both temperature and pressure elements, but this is because the compressive pressure removes voids during debulking. Helps compaction Therefore, in one or more embodiments, the heating system 116 cures the composite structure 102. Heat the composite structure 102 to a temperature sufficient for this purpose. , sustained period over Maintain the composite structure 102 at the curing temperature. ruyo It is composed of sea urchin. hardening The process typically involves both temperature and pressure elements, where the compressive pressure removes the air gap. hardening inside Helps compaction That is the reason.

[0092] In one or more embodiments, the heating system 116 is configured to heat a gas 118 located inside (e.g., surrounded by) a container 114 (Figures 5, 6, and 9-11). For example, the heating system 116 is thermally in communication with the gas 118. In these embodiments, heat is transferred from the heated gas 118 to the composite structure 102.

[0093] In one or more embodiments, the heating system 116 is configured to heat the tooling assembly 164. For example, the heating system 116 is coupled to and / or thermally communicates with at least one of the first processing tool 104, the second processing tool 106, the first fitting film 136, and / or the second fitting film 146. In these embodiments, heat is transferred from the heated tooling assembly 164 to the composite structure 102.

[0094] In one or more embodiments, the heating system 116 is configured to heat the mandrel tool 112. For example, the heating system 116 is coupled to and / or thermally communicates with the mandrel tool 112. In these embodiments, heat is transferred from the mandrel tool 112 to the composite structure 102.

[0095] In one or more embodiments, the heating system 116 is configured to heat at least one of the first processing tool 104, the second processing tool 106, the gas 118 located in the container 114, and the mandrel tool 112, or a combination of two or more of these, so that the composite structure 102 is brought to and held at a desired processing temperature.

[0096] The heating system 116 includes or takes the form of any suitable arrangement of heating devices and / or heating elements configured to heat components associated with the heating devices. In one or more embodiments, the heating system 116 includes at least one electric heater (e.g., a resistance heat source) configured to generate electric heat. In one or more embodiments, the heating system 116 includes at least one gas heater (e.g., a gas heat source) configured to generate gas heat. In one or more embodiments, the heating system 116 includes a combination of electric heaters and gas heaters.

[0097] In one or more embodiments, at least one heating element of the heating system 116, such as a resistance heating element, is coupled to and thermally communicates with a first processing tool 104, such as a first container wall 134 and a first container end 194.

[0098] In one or more embodiments, at least one heating element of the heating system 116, such as a resistance heating element, is coupled to and thermally communicates with at least one of the first fitting film 136 and / or the first backing plate 142. Positioning the heating element of the heating system 116 on the first fitting film 136 and / or the first backing plate 142 can facilitate effective heat transfer to the composite structure 102. In addition, positioning the heating element of the heating system 116 on the first fitting film 136 and / or the first backing plate 142 can allow for selective heating of different areas or portions of the composite structure 102. For example, thicker portions of the composite structure 102 may be heated more than thinner portions of the composite structure 102.

[0099] In one or more embodiments, a heating system 116, such as an electric heater, is coupled to and thermally communicates with a second processing tool 106, such as a second container wall 144 and / or a second container end 196.

[0100] In one or more embodiments, at least one heating element of the heating system 116, such as a resistance heating element, is coupled to and thermally communicates with at least one of the second fitting film 146 and / or the second backing plate 148. Positioning the heating element of the heating system 116 on the second fitting film 146 and / or the second backing plate 148 can facilitate effective heat transfer to the composite structure 102. In addition, positioning the heating element of the heating system 116 on the second fitting film 146 and / or the second backing plate 148 can selectively heat different areas or portions of the composite structure 102. For example, thicker portions of the composite structure 102 may be heated more than thinner portions of the composite structure 102.

[0101] In one or more embodiments, at least one heating element of the heating system 116, such as a resistance heating element, is coupled to and thermally communicates with the mandrel tool 112.

[0102] In one or more embodiments, at least one heating element of the heating system 116, such as an electric heat exchanger or a gas heat exchanger, is positioned to be thermally in communication with the gas 118 located in the container 114 in order to heat the gas 118. In one or more embodiments, the heating system 116 heats the gas 118 before it is introduced into the container 114 (e.g., preheated gas). In one or more embodiments, the heating system 116 heats the gas 118 after it has been introduced into the container 114 (e.g., postheated gas).

[0103] Referring further to Figures 1, 2, 5, 9-11, 14, and 16, in one or more embodiments, the apparatus 100 includes a pressurizing system 140. The pressurizing system 140 is coupled to and communicates with a tooling assembly 164, such as at least one of a first processing tool 104 and a second processing tool 106. With the tooling assembly 164 and mandrel tool 112 sealed together in the closed position 110, the pressurizing system 140 is configured to pressurize the gas 118 located inside the container 114 (Figures 5, 6, and 9-11). In these embodiments, the apparatus 100 uses positive pressure to process the composite structure 102.

[0104] As shown in Figures 5 and 9, in one or more embodiments, the apparatus 100 is Using the positive pressure applied to the composite structure 102 by the pressurized gas 118 to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112 Processing of composite structure 102 do (for example, compaction , debulk or harden (ru) .

[0105] As shown in Figures 5 and 9, in one or more embodiments, in the closed position 110, the gas 118 located between (e.g., surrounded by) the first container wall 134, the first container end 194, and the mandrel tool 112 is pressurized using a pressurization system 140. The pressurized gas 118 applies positive pressure to the composite structure 102, compressing a portion of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0106] As shown in Figure 5, in one or more embodiments, in the closed position 110, the gas 118 located between (e.g., surrounded by) the second container wall 144, the second container end 196, and the mandrel tool 112 is pressurized using the pressurization system 140. The pressurized gas 118 applies positive pressure to the composite structure 102, compressing a portion of the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0107] In one or more embodiments, in the closed position 110, the gas 118 is surrounded by the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112. In the closed position 110, the pressurizing system 140 is configured to pressurize the gas 118 located between (e.g., surrounded by) the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112, thereby compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0108] In one or more embodiments, the pressurized gas 118 compresses the composite structure 102 by directly applying positive pressure to the outer surface 212 of the composite structure 102. In one or more embodiments, the distance between the first container wall 134 and the outer surface 212 of the composite structure 102 is relatively small (e.g., a few inches or less), so that the volume required to be pressurized during processing of the composite structure 102 is relatively small. In one or more embodiments, the distance between the second container wall 144 and the outer surface 212 of the composite structure 102 is relatively small (e.g., a few inches or less), so that the volume required to be pressurized during processing of the composite structure 102 is relatively small.

[0109] In one or more embodiments, as shown in Figures 5 and 9, the pressurized gas 118 directly applies positive pressure to the compression bagging 162 surrounding the composite structure 102, and the compression bagging 162 is then pressed against the outer surface 212 of the composite structure 102, compressing the composite structure 102 between the compression bagging 162 and the mandrel tool 112. In one or more embodiments, the distance between the first container wall 134 and the compression bagging 162 surrounding the composite structure 102 is relatively small (e.g., a few inches or less), and therefore the volume required to be pressurized during processing of the composite structure 102 is relatively small.

[0110] In one or more embodiments, as shown in Figures 6, 10, and 11, the pressurized gas 118 applies positive pressure directly to the first fitting membrane 136, which is then pressed against the outer surface 212 of the composite structure 102, compressing the composite structure 102 between the first fitting membrane 136 and the mandrel tool 112. In these embodiments, the pressurized gas 118 is surrounded by the first container wall 134, the first container end 194, and the first fitting membrane 136. In one or more embodiments, the distance between the first container wall 134 and the outer surface 212 of the composite structure 102, the distance between the first container wall 134 and the first fitting membrane 136, and / or the distance between the first fitting membrane 136 and the outer surface 212 of the composite structure 102 are relatively small (e.g., a few inches or less), so that the volume required to be pressurized during processing of the composite structure 102 is relatively small.

[0111] In one or more embodiments, as shown in Figure 6, the pressurized gas 118 applies positive pressure directly to the second fitting membrane 146, which is then pressed against the outer surface 212 of the composite structure 102 (e.g., with or without compression bagging 162), compressing the composite structure 102 between the second fitting membrane 146 and the mandrel tool 112. In these embodiments, the pressurized gas 118 is surrounded by the second container wall 144, the second container end 196, and the second fitting membrane 146. In one or more embodiments, the distance between the second container wall 144 and the outer surface 212 of the composite structure 102, the distance between the second container wall 144 and the first fitting film 146, and / or the distance between the second fitting film 146 and the outer surface 212 of the composite structure 102 are relatively small (e.g., a few inches or less), so that the volume requiring pressurization during processing of the composite structure 102 is relatively small.

[0112] In one or more embodiments, in the closed position 110, one of the first processing tool 104 or the second processing tool 106 is in communication with the pressurizing system 140, and the first processing tool 104 and the second processing tool 106 are in fluid communication with each other, so that the pressurizing system 140 is configured to pressurize the gas 118 surrounded by (for example, located between) the first container wall 134, the first container end 194, the second container wall 144, the second container end 196, and the mandrel tool 112.

[0113] In one or more embodiments, each of the first processing tool 104 and the second processing tool 106 is coupled to and in communication with a pressurization system 140, so that the pressurization system 140 is configured to pressurize a gas 118 surrounded by (for example, located between) a first container wall 134, a first container end 194, a second container wall 144, a second container end 196, and a mandrel tool 112.

[0114] In one or more embodiments, the apparatus 100 includes a plurality of pressurizing systems 140, each dedicated to a first processing tool 104 and a second processing tool 106, and communicating with them. In these embodiments, the first pressurizing system is associated with the first processing tool 104 and is configured to pressurize a gas 118 surrounded by (e.g., located between) a first container wall 134, a first container end 194, and a mandrel tool 112. The second pressurizing system is associated with the second processing tool 106 and is configured to pressurize a gas 118 surrounded by (e.g., located between) a second container wall 144, a second container end 196, and a mandrel tool 112.

[0115] As shown in Figures 6, 10, and 11, in one or more embodiments, the apparatus 100 processes the composite structure 102 by using the positive pressure applied to at least one of the first and second fitting membranes 136 and 146 by pressurized gas 118 to press at least one of the first and second fitting membranes 136 and 146 against the composite structure 102 in order to compress the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0116] As shown in Figures 6, 10, and 11, in one or more embodiments, in the closed position 110, the pressurizing system 140 is configured to apply positive pressure between the first container wall 134 and the first fitting membrane 136. For example, the first outer circumference 220 of the first fitting membrane 136 is connected to and sealed to the first container wall 134 and the first container end 194. The gas 118 surrounded by (for example, located between) the first container wall 134, the first container end 194, and the first fitting membrane 136 is pressurized using the pressurizing system 140. The pressurized gas 118 applies positive pressure between the first container wall 134 and the first fitting membrane 136, pressing the first fitting membrane 136 against the composite structure 102 and compressing the composite structure 102 against the mandrel tool 112. Therefore, in these embodiments, the first compatible film 136 functions as a substitute for consumable compression bagging or vacuum bagging, which are typically used in composite processing.

[0117] As shown in Figure 6, in one or more embodiments, in the closed position 110, the pressurizing system 140 is configured to apply positive pressure between the second container wall 144 and the second fitting membrane 146. For example, the second outer circumference 226 of the second fitting membrane 146 is connected to and sealed to the second container wall 144 and the second container end 196. The gas 118 surrounded by (for example, located between) the second container wall 144, the second container end 196 (Figure 3-4), and the second fitting membrane 146 is pressurized using the pressurizing system 140. The pressurized gas 118 applies positive pressure between the second container wall 144 and the second fitting membrane 146, pressing the second fitting membrane 146 against the composite structure 102 and compressing the composite structure 102 against the mandrel tool 112. Therefore, in these embodiments, the second compatible film 146 functions as a substitute for consumable compression bagging or vacuum bagging, which are typically used in composite processing.

[0118] In one or more embodiments, in the closed position 110, the tooling assembly 164 is configured such that the pressurizing system 140 simultaneously pressurizes the gas 118 surrounded by (e.g., located between) the first container wall 134, the first container end 194, and the first fitting membrane 136, and the gas 118 surrounded by (e.g., located between) the second container wall 144, the second container end 196, and the second fitting membrane 146, thereby compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0119] In one or more embodiments, at the closed position 110, one of the first processing tool 104 or the second processing tool 106 is coupled to and communicates with the pressurizing system 140 (e.g., fluid communication). The first processing tool 104 and the second processing tool 106 are fluid communication with each other, so that the pressurizing system 140 is configured to simultaneously pressurize the gas 118 surrounded by the first container wall 134, the first container end 194, and the first fitting membrane 136 (e.g., located between them) and the gas 118 surrounded by the second container wall 144, the second container end 196, and the second fitting membrane 146 (e.g., located between them).

[0120] In another embodiment, each of the first processing tool 104 and the second processing tool 106 is coupled to and communicates with (e.g., fluid communication with) a pressurizing system 140, so that the pressurizing system 140 is configured to independently pressurize the gas 118 surrounded by (e.g., located between) the first container wall 134, the first container end 194, and the first fitting membrane 136, and to independently pressurize the gas 118 surrounded by (e.g., located between) the second container wall 144, the second container end 196, and the second fitting membrane 146.

[0121] In one or more embodiments, the apparatus 100 includes a plurality of pressurizing systems 140, each dedicated to a first processing tool 104 and a second processing tool 106, and communicating with them. In these embodiments, the first pressurizing system is associated with the first processing tool 104 and is configured to pressurize a gas 118 surrounded by (e.g., located between) a first container wall 134, a first container end 194, and a first fitting membrane 136. The second pressurizing system is associated with the second processing tool 106 and is configured to pressurize a gas 118 surrounded by (e.g., located between) a second container wall 144, a second container end 196, and a second fitting membrane 146.

[0122] The pressurization system 140 includes any one or a combination thereof of various types of systems configured to control the pressure inside the sealed container 114.

[0123] In one or more embodiments, the pressurization system 140 is configured to utilize liquid nitrogen, which is allowed to change to a gaseous state when introduced into a sealed container 114. As the nitrogen expands, the pressure inside the sealed container 114 increases.

[0124] In one or more embodiments, the pressurization system 140 includes a compressor or pump coupled to a first processing tool 104 and a second processing tool 106, which is in fluid communication with the internal space of the container 114. The operation of the compressor or pump is configured to selectively control the pressure within the sealed container 114.

[0125] In one or more embodiments, pressurization of the sealed container 114 is controlled by increasing the temperature of the gas 118 located inside the sealed container 114. Increasing the temperature of the gas 118 inside the sealed container 114 causes the gas 118 to expand, resulting in a pressure increase inside the sealed container 114. In one or more embodiments, the temperature of the gas 118 is controlled via a heating system 116, as described above.

[0126] Referring to Figures 12, 13, and 18, in one or more embodiments, in the closed position 110, the tooling assembly 164 is configured to transfer pressurized and / or heated gas 118 between the first processing tool 104 and the second processing tool 106. For example, in the closed position 110, the tooling assembly 164 is configured to provide a path for transferring gas 118 between the first processing tool 104 and the second processing tool 106. These embodiments are advantageous when the first and second fitting membranes 136 and 146 are coupled to the first and second processing tools 104 and 106, respectively, and used to compress the composite structure 102 against the mandrel tool 112.

[0127] As shown in Figures 12 and 18, in one or more embodiments, the first processing tool 104 includes a first partition wall 150. The first partition wall 150 is coupled to and extends from the first container wall 134. In one or more embodiments, the first processing tool 104 includes a plurality of first partition walls 150. In one or more embodiments, as shown in Figure 12, the first processing tool 104 includes two first partition walls 150. Each first partition wall 150 extends along a portion of the first interface surface 120 configured to bond to or contact with the second processing tool 106. Only one first partition wall 150 is shown in Figure 18.

[0128] As shown in Figures 13 and 18, in one or more embodiments, the second processing tool 106 includes a second partition wall 154. The second partition wall 154 is coupled to and extends from the second container wall 144. In one or more embodiments, the second processing tool 106 includes a plurality of second partition walls 154. In one or more embodiments, as shown in Figure 13, the second processing tool 106 includes two second partition walls 154. Each second partition wall 154 extends along a portion of the second interface surface 128 configured to bond to or contact the first processing tool 104. Only one second partition wall 154 is shown in Figure 18.

[0129] Referring to Figure 18, in one or more embodiments, the first partition wall 150 includes a first opening 152. In one or more embodiments, as shown in Figure 12, the first partition wall 150 includes a plurality of first openings 152. In one or more embodiments, the second partition wall 154 includes a second opening 156. In one or more embodiments, as shown in Figure 13, the second partition wall 154 includes a plurality of second openings 156.

[0130] As shown in Figure 18, in the closed position 110, the teeth of the first partition wall 150 and the second partition wall 154 come into contact with each other, and thus the first opening 152, or a plurality of first openings 152 (Figure 12), and the second opening 156, or a plurality of second openings 156 (Figure 13) are aligned with respect to the gas passage 118 between the first processing tool 104 and the second processing tool 106, for example, in the direction of arrow 198.

[0131] As shown in Figure 18, in one or more embodiments, the gas 118 moves through the aligned first opening 152 and second opening 156 (for example, in the direction of arrow 198) from container-first portion 114-1 of container 114, formed by the first processing tool 104 and mandrel tool 112, to container-second portion 114-2 of container 114, formed by the second processing tool 106 and mandrel tool 112. In some embodiments, such as the embodiment shown in Figures 12 and 13, where the first partition wall 150 and the second partition wall 154 are located along the entire first interface 124 between the first processing tool 104 and the second processing tool 106, and around the composite structure 102, etc., the gas 118 can circulate through container 114 between the first processing tool 104 and the second processing tool 106, and around the composite structure 102, etc. In short, together, the first partition wall 150 and the second partition wall 154, with the alignment of the associated first opening 152 and second opening 156, function as a manifold configured to share the supply of gas 118 between the first processing tool 104 and the second processing tool 106.

[0132] As shown in Figure 18, in one or more embodiments, the first partition wall 150 includes a first opening-seal 200 extending around the outer periphery of the first opening 152. In one or more embodiments, alternatively or additionally, the second partition wall 154 includes a second opening-seal 202 extending around the outer periphery of the second opening 156. In the closed position 110, the first opening-seal 200 and / or the second opening-seal 202 form a seal between the first partition wall 150 and the second partition wall 154 around the aligned first opening 152 and second opening 156 with respect to the gas passage 118. The first opening-seal 200 and / or the second opening-seal 202 prevent the gas 118 from entering the space between the first fitting membrane 136, the second fitting membrane 146 and the composite structure 102.

[0133] Figure 19-20 schematically shows a partial embodiment of the first processing tool 104, including the first partition 150 and the first fitting film 136. Although not explicitly shown, an equivalent embodiment of the second processing tool 106, including the second partition 154 and the second fitting film 146, is equally shown in Figure 19-20.

[0134] Referring to Figure 18-20, in one or more embodiments, the first fitting membrane 136 is coupled to the first partition wall 150. In one or more embodiments, the first fitting membrane 136 is sealed to the first partition wall 150. In one or more embodiments, the first outer circumference-first side portion 222 on the opposite side of the first fitting membrane 136 is coupled to and sealed to the first partition wall 150 (only one first partition wall 150 and one first outer circumference-first side portion 222 of the first fitting membrane 136 are shown in Figure 18-20).

[0135] In one or more embodiments, the first partition wall 150 supports the first fitting membrane 136. In the closed position 110, the first partition wall 150 positions the first fitting membrane 136 closer to the surface of the composite structure 102 than the first container wall 134. The first processing tool 104 may have any number (e.g., one or more) of the first partition walls 150 that are coupled to the first container wall 134 and support the first fitting membrane 136 at any number of positions.

[0136] In one or more embodiments, the second fitting membrane 146 is coupled to the second partition wall 154. In one or more embodiments, the second fitting membrane 146 is sealed to the second partition wall 154. In one or more embodiments, the second outer circumference-first side portion 228 on the opposite side of the second fitting membrane 146 is coupled to and sealed to the second partition wall 154 (only one second partition wall 154 and one second outer circumference-first side portion 228 of the second fitting membrane 146 are shown in Figure 18).

[0137] In one or more embodiments, the second partition 154 supports the second fitting membrane 146. In the closed position 110, the second partition 154 positions the second fitting membrane 146 closer to the surface of the composite structure 102 than the second container wall 144. The second processing tool 106 may have any number (e.g., one or more) second partitions 154 that are coupled to the second container wall 144 and support the second fitting membrane 146 at any number of positions.

[0138] Referring to Figures 1, 2, 5, 9-11, 14, and 16, in one or more embodiments, the apparatus 100 includes a vacuum system 138. In one or more embodiments, the vacuum system 138 is in fluid communication with the space formed between the outer surface 210 of the mandrel tool 112 and the compression bagging 162 (Figures 5 and 9). In one or more embodiments, the vacuum system 138 is in fluid communication with the space formed between the outer surface 210 of the mandrel tool 112 and the first fitting membrane 136 (Figures 6, 10, and 11), or with the space formed between the outer surface 210 of the mandrel tool 112 and the first fitting membrane 136 and the second fitting membrane 146 (Figure 6). In short, with the tooling assembly 164 and mandrel tool 112 sealed together in the closed position 110, the vacuum system 138 is configured to apply a vacuum within the container 114, for example, between the mandrel tool 112 and one of the following: compression bagging 162 (Figures 5 and 9), the first fitting membrane 136 (Figures 6, 10, and 11), or the first fitting membrane 136 and the second fitting membrane 146 (Figure 6). In these embodiments, the apparatus 100 uses negative pressure to process the composite structure 102.

[0139] As shown in Figures 6, 10, and 11, in one or more embodiments, the vacuum system 138 is configured to apply a vacuum between the first fitting membrane 136 and the mandrel tool 112. The vacuum applies negative pressure to expel gas between the first fitting membrane 136 and the outer surface 210 of the mandrel tool 112. By expelling gas between the first fitting membrane 136 and the outer surface 210 of the mandrel tool 112, a higher pressure is induced on the outside of the first fitting membrane 136, and therefore the first fitting membrane 136 is pressed against the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0140] As shown in Figure 6, in one or more embodiments, the vacuum system 138 is configured to apply a vacuum between the second fitting membrane 146 and the mandrel tool 112. The vacuum applies negative pressure to expel gas between the second fitting membrane 146 and the outer surface 210 of the mandrel tool 112. By expelling gas between the second fitting membrane 146 and the outer surface 210 of the mandrel tool 112, a higher pressure is induced on the outside of the second fitting membrane 146, and therefore the first fitting membrane 136 is pressed against the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0141] In one or more embodiments, the vacuum system 138 includes one or more vacuum pumps. In one or more embodiments, the vacuum system 138 is coupled to the mandrel tool 112. In one or more embodiments, the vacuum system 138 is coupled to a tooling assembly 164, such as at least one of the first processing tool 104 and / or the second processing tool 106. In one or more embodiments, the vacuum system 138 is coupled to the tooling assembly 164 and the mandrel tool 112.

[0142] Referring to Figures 1, 2, 14, 15, and 21, in one or more embodiments, the vacuum system 138 is coupled to the mandrel tool 112 via the mandrel-manifold 206. As shown in Figure 21, in one or more embodiments, the mandrel tool 112 includes a plurality of vacuum openings 240 formed through the outer surface 210 of the mandrel tool 112. Generally, the vacuum openings 240 are positioned toward the end of the mandrel tool 112, beyond the outer boundary line of the composite structure 102 supported on the mandrel tool 112. The vacuum openings 240 are in fluid communication with the mandrel-manifold 206 via a plurality of mandrel-vacuum lines 242.

[0143] Referring to Figures 1, 2, 14, 15, and 20, in one or more embodiments, the vacuum system 138 is coupled via a tooling-manifold 204 to a tooling assembly 164, such as a first processing tool 104 and / or a second processing tool 106. As shown in Figure 20, in one or more embodiments, the tooling assembly 164, such as a first processing tool 104 and / or a second processing tool 106, includes at least one vacuum connection 246 located on or coupled to a first fitting membrane 136 and / or a second fitting membrane 146 (not shown in Figure 20). The vacuum connection 246 is in fluid communication with the tooling-manifold 204 via a plurality of tool-vacuum lines 244. The vacuum connection 246 associated with the first fitting membrane 136 (Figure 20) is in fluid communication with the space between the first fitting membrane 136 and the outer surface 212 of the mandrel tool 112. The vacuum connection 246 associated with the second fitting film 146 (not shown in Figure 20) is in fluid communication with the space between the second fitting film 146 and the outer surface 212 of the mandrel tool 112.

[0144] As shown in Figures 5 and 9, in one or more embodiments, the apparatus 100 includes compression bagging 162. The compression bagging 162 is configured to surround a composite structure 102 supported by a mandrel tool 112. Generally, the compression bagging 162 is a consumable item. In one or more embodiments, the compression bagging 162 is sealed to the outer surface 210 of the mandrel tool 112 around the composite structure 102. In one or more embodiments, the compression bagging 162 is applied to the composite structure 102 before the tooling assembly 164 is closed and sealed to the mandrel tool 112 in order to form a container 114 around the composite structure 102.

[0145] In one or more embodiments, the pressurizing system 140 is configured to apply positive pressure between the first container wall 134 and the compression bagging 162 (Figures 5 and 9). In one or more embodiments, the pressurizing system 140 is configured to apply positive pressure between the second container wall 144 and the compression bagging 162 (Figure 5). In these embodiments, the compression bagging 162 is pressed against (e.g., compressed) against the outer surface 212 of the composite structure 102 by pressurized gas 118 located inside the container 114 in order to compress the composite structure 102 between the compression bagging 162 and the outer surface 210 of the mandrel tool 112.

[0146] In one or more embodiments, compression bagging 162 protects the composite structure 102 from interacting with the gas 118 located inside the container 114. In one or more embodiments, the gas 118 is air. In one or more embodiments, the gas 118 is an inert gas such as nitrogen.

[0147] In one or more embodiments, the vacuum system 138 is configured to apply a vacuum between the mandrel tool 112 and the compression bagging 162. In these embodiments, the outer circumference of the compression bagging 162 is coupled to and sealed with the outer surface 210 of the mandrel tool 112, beyond the location of a vacuum opening 240 (Figure 21) formed within the mandrel tool 112. The vacuum applies negative pressure to expel gas between the compression bagging 162 and the outer surface 210 of the mandrel tool 112. By expelling gas between the compression bagging 162 and the outer surface 210 of the mandrel tool 112, a higher pressure is induced on the outside of the compression bagging 162, and therefore the compression bagging 162 is pressed against the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0148] The exemplary configuration of the tooling assembly 164 shown in Figure 11 shows the use of a first fitting membrane 136, but in other embodiments of this configuration of the tooling assembly 164, compression bagging 162 is sealed to the mandrel tool 112 and surrounds the composite structure 102.

[0149] In various embodiments, the first fitting membrane 136 and / or the second fitting membrane 146 serve as a substitute for or substantially similar purpose to the compression bagging 162. In these embodiments, the apparatus 100 advantageously reduces the use of consumable materials such as the compression bagging 162. In other embodiments, the apparatus 100 uses both the compression bagging 162 and the first fitting membrane 136 and / or the second fitting membrane 146.

[0150] Referring to Figures 1, 2, 14, 16, and 20, in one or more embodiments, the tooling manifold 204 is located on or associated with the first processing tool 104. The tooling manifold 204 enables connections (e.g., electrical, data, fluid, etc.) of the pressurizing system 140, the heating system 116, and / or the vacuum system 138 to the tooling assembly 164. The tooling manifold 204 advantageously enables functional connections of the pressurizing system 140, the heating system 116, and the vacuum system 138 to the tooling assembly 164 outside the vessel 114.

[0151] In embodiments where the first processing tool 104 and the second processing tool 106 are in fluid communication with each other, such as those shown in Figures 12, 13 and 18-20, the tooling assembly 164 may use only one tooling manifold 204 associated with either the first processing tool 104 or the second processing tool 106. In embodiments where the first processing tool 104 and the second processing tool 106 are not in fluid communication with each other, the tooling assembly may use two tooling manifolds 204 (only one tooling manifold 204 is illustrated), each of which is associated with one of the first processing tool 104 and one of the second processing tool 106.

[0152] In one or more embodiments, the tooling-manifold 204 is configured to route the gas 118 heated by the heating system 116 into the container 114.

[0153] In one or more embodiments, the tooling-manifold 204 is configured to route power to a heating system 116 to heat at least one of the first vessel wall 134, the second vessel wall 144, the first fitting membrane 136, the second fitting membrane 146, the first backing plate 142, and the second backing plate 148.

[0154] In one or more embodiments, the tooling-manifold 204 is configured to route the gas 118 pressurized by the pressurization system 140 into the container 114.

[0155] Referring to Figures 1, 2, 14, 16, and 21, in one or more embodiments, the mandrel-manifold 206 enables connections (e.g., electrical, data, fluid, etc.) of the vacuum system 138 and the heating system 116 to the mandrel tool 112. The mandrel-manifold 206 advantageously enables functional connections of the vacuum system 138 and the heating system 116 to the mandrel tool 112 outside the vessel 114.

[0156] In one or more embodiments, the mandrel-manifold 206 is configured to route the gas removed by the vacuum system 138 between the compression bagging 162 and the mandrel tool 112, or between the first fitting membrane 136 and / or the second fitting membrane 146 and the mandrel tool 112.

[0157] In one or more embodiments, the mandrel-manifold 206 is configured to route power to a heating system 116 and heat the mandrel tool 112.

[0158] In one or more embodiments, the composite structure 102 may include a portion having a closed cross-sectional shape with an open interior. For example, the composite structure 102 may include a panel and reinforcing members (e.g., hat-shaped stringers) bonded to the panel. In such embodiments, an inflatable bladder (not shown) is located within the open interior formed by the closed cross-sectional shapes of the panel and reinforcing members. In one or more embodiments, the mandrel-manifold 206 is also configured to route pressurized gas from a pressurization system 140 or the like to the inflatable bladder from outside the tooling assembly 164. Generally, the inflatable bladder is located within a hollow space formed by the closed cross-sectional shapes of the panel and reinforcing members (e.g., within a hat-shaped stringer) to prevent the reinforcing members (e.g., stringers) from being crushed during processing.

[0159] As best illustrated in Figure 2, in one or more embodiments, in the closed position 110, a portion of the mandrel tool 112 is located outside the vessel 114. For example, the opposite end 214 of the mandrel tool 112 extends from the tooling assembly 164 (e.g., beyond the first vessel end 194 and the second vessel end 196) and is located outside the vessel 114. This configuration allows for the connection and disconnection of the heating system 116 and / or the vacuum system 138 to, for example, the mandrel-manifold 206 while the mandrel tool 112 is located inside the tooling assembly 164 in the closed position 110.

[0160] Referring to Figures 2, 4, and 8, in one or more embodiments, the apparatus 100 includes a pair of end caps 158. Only one of the end caps 158 is shown in Figures 2, 4, and 8. The end caps 158 are configured to seal the open end 232 (Figures 3 and 7) of the mandrel tool 112. Only one of the open end 232 of the mandrel tool 112 is shown in Figures 3 and 7. For example, the end caps 158 seal the open end 232 of the mandrel tool 112 and confine the internal space 160 of the mandrel tool 112 so that the internal space 160 can be pressurized during processing of the composite structure 102.

[0161] In one or more embodiments, the end cap 158 is configured to be coupled and sealed around the open end 232 of the mandrel tool 112, which is located outside the tooling assembly 164. By sealing the open end 232 with the end cap 158, the internal space 160 of the mandrel tool 112 is enclosed and sealed. With the internal space 160 of the mandrel tool 112 sealed, the internal space 160 can be pressurized, for example, using a pressurization system 140. Pressurizing the internal space 160 of the mandrel tool 112 increases the structural integrity of the mandrel tool 112 and responds to the positive pressure applied to the mandrel tool 112 by the tooling assembly 164 during processing.

[0162] In one or more embodiments, the end cap 158 is coupled to or forms part of the tooling assembly 164. In one or more embodiments, the end cap 158 is coupled to or forms part of the mandrel tool 112.

[0163] In one or more embodiments, the mandrel-manifold 206 is configured to route pressurized gas from a pressurizing system 140 or the like into the internal space 160 of the mandrel tool 112.

[0164] As best shown in Figure 1-2, one or more embodiments include a processing cart 184 in the apparatus 100. The processing cart 184 is configured to support the mandrel tool 112 during processing. In the closed position 110, the processing cart 184, for example, the entire processing cart 184, is located outside the container 114. By positioning the processing cart 184 outside the container 114 formed by the tooling assembly 164 and the mandrel tool 112, the volume required to process the composite structure 102 is reduced, and the thermal mass heated during processing of the composite structure 102 is reduced, thus reducing the cycle time and the energy required to process the composite structure 102.

[0165] Referring to Figure 22, in one or more embodiments, the mandrel tool 112 is configured to form the inner mold line (contour) 190 of the composite structure 102. In these embodiments, a tooling assembly 164, such as a first processing tool 104 or a first processing tool 104 and a second processing tool 106, is configured to form the outer mold line 192 of the composite structure 102. In embodiments, a first fitting film 136 or a first backing plate 142 forms at least a portion of the outer mold line 192 of the composite structure 102. In embodiments, the first fitting film 136 or the first backing plate 142 forms a portion of the outer mold line 192 of the composite structure 102, and a second fitting film 146 or a second backing plate 148 forms another portion of the outer mold line 192.

[0166] Referring to Figure 23, in one or more embodiments, the mandrel tool 112 is configured to form the outer mold line 192 of the composite structure 102. In these embodiments, a tooling assembly 164, such as a first processing tool 104 or a first processing tool 104 and a second processing tool 106, is configured to form the inner mold line 190 of the composite structure 102. In embodiments, a first fitting film 136 or a first backing plate 142 forms at least a portion of the inner mold line 190 of the composite structure 102. In embodiments, the first fitting film 136 or the first backing plate 142 forms a portion of the inner mold line 190 of the composite structure 102, and a second fitting film 146 or a second backing plate 148 forms another portion of the inner mold line 190.

[0167] As explained earlier and generally shown in Figure 3-11, the tooling assembly 164 has a cross-sectional shape complementary to the cross-sectional shape of the mandrel tool 112 and the composite structure 102 supported by the mandrel tool 112. The fact that the cross-sectional shape of the tooling assembly 164 is complementary to and closely matches the cross-sectional shape of the mandrel tool 112 is advantageous in that it reduces the size of the equipment required to properly process the composite structure 102 compared to conventional autoclave or oven processing equipment. This overall size reduction is advantageous in that it improves the efficiency of the equipment 100 and reduces the footprint of the equipment layout.

[0168] Referring to Figure 24, in one or more embodiments, the first processing tool 104 includes a first open section shape 168. In one or more embodiments, the first processing tool 104 (e.g., the first open section shape 168) is complementary to a first portion of the mandrel tool 112, such as a first half portion of the first side of the mandrel tool 112. In one or more embodiments, the first container wall 134 includes a first non-planar member 174. The first non-planar member 174 of the first container wall 134 surrounds a first portion of the mandrel tool 112. An embodiment of this configuration is shown in Figure 3-11.

[0169] In one or more embodiments, the second processing tool 106 includes a second open section shape 170. In one or more embodiments, the second processing tool 106 (e.g., the second open section shape 170) is complementary to a second portion of the mandrel tool 112, such as a second half of the second side opposite the mandrel tool 112. In one or more embodiments, the second container wall 144 includes a second non-planar member 178. The second non-planar member 178 of the second container wall 144 surrounds the second portion of the mandrel tool 112. An embodiment of this configuration is shown in Figure 3-6.

[0170] In one or more embodiments, the second processing tool 106 includes a first planar cross-sectional shape 172. In one or more embodiments, the second processing tool 106 (e.g., the first planar cross-sectional shape 172) is complementary to a portion of the mandrel tool 112, such as a second half of the second side opposite the mandrel tool 112. In one or more embodiments, the second container wall 144 includes a planar member 176. The planar member 176 supports the mandrel tool 112. An embodiment of this configuration is shown in Figure 7-10.

[0171] In one or more embodiments, the mandrel tool 112 has a closed cross-sectional shape 182. The first open cross-sectional shape 168 of the first container wall 134 is complementary to the first portion of the closed cross-sectional shape 182 of the mandrel tool 112. The second open cross-sectional shape 170 of the second container wall 144 is complementary to the second portion of the closed cross-sectional shape 182 of the mandrel tool 112.

[0172] In one or more embodiments, the closed cross-sectional shape 182 of the mandrel tool 112 is circular, and the first open cross-sectional shape 168 of the first container wall 134 and the second open cross-sectional shape 170 of the second container wall 144 are each semicircular. In this embodiment, the circular cross-sectional shape of the mandrel tool 112 and the semicircular cross-sectional shapes of the first and second container walls 134 and 144 can be used to form a composite structure 102 having a circular cross-sectional shape, such as the barrel section of an aircraft fuselage. An embodiment of this configuration is shown in Figure 3-6.

[0173] In one or more embodiments, the mandrel tool 112 includes a third open cross-sectional shape 186. The first open cross-sectional shape 168 of the first container wall 134 is complementary to the third open cross-sectional shape 186 of the mandrel tool 112. The first planar cross-sectional shape 172 of the second container wall 144 is configured to support the mandrel tool 112 for processing. An embodiment of this configuration is shown in Figure 7-10.

[0174] In one or more embodiments, the mandrel tool 112 includes a second planar cross-sectional shape 188. The first open cross-sectional shape 168 of the first container wall 134 is complementary to a first portion of the second planar cross-sectional shape 188 of the mandrel tool 112, such as the first surface of the mandrel tool 112. The first planar cross-sectional shape 172 of the second container wall 144 is complementary to a second portion of the second planar cross-sectional shape 188 of the mandrel tool 112, such as the second opposite surface of the mandrel tool 112, in order to support the mandrel tool 112.

[0175] In one or more embodiments, the mandrel tool 112 includes a complex cross-sectional shape 208. The first open cross-sectional shape 168 of the first container wall 134 is complementary to the first portion of the complex cross-sectional shape 208 of the mandrel tool 112. The second open cross-sectional shape 170 of the second container wall 144 is complementary to the second portion of the complex cross-sectional shape 208 of the mandrel tool 112. Alternatively, the first planar cross-sectional shape 172 of the second container wall 144 is complementary to the second portion of the complex cross-sectional shape 208 of the mandrel tool 112 in order to support the mandrel tool 112.

[0176] Other configurations are also conceivable, such as the first processing tool 104, the second processing tool 106, and other cross-sectional shapes of the mandrel tool 112.

[0177] Referring to Figure 25, as an example, the disclosure also covers a method 1000 for processing a composite structure 102. Generally referring to Figures 1-24, in one or more embodiments, embodiments of method 1000 are performed using the disclosed apparatus 100.

[0178] Open It is carried out according to the method 1000 shown. process This includes any suitable manufacturing process, and heat, pressure, or a combination of heat and pressure is used to process the composite structure 102. In the examples, method 1000 is compaction in the process It is directed towards A composite layup is used to remove trapped air. Compacted In another embodiment, method 1000 is used in the debulking process. It is directed towards Thick laminated boards, moderate heat and pressure and / or under vacuum Compacted This removes most of the air, ensures a secure fit on the tool, and prevents wrinkles. In yet another embodiment, method 1000 is used in the curing process. It is directed towards The properties of thermosetting resins are affected by heat and pressure. and / or it changes due to a chemical reaction under vacuum.

[0179] In one or more embodiments, Method 1000 includes a step of laying up the composite structure (block 1002). In one or more embodiments, the step of laying up the composite structure (block 1002) includes a step of laying up the composite structure 102 on a mandrel tool 112. The mandrel tool 112 is configured to support the composite structure 102 during processing and to provide shape to at least a portion of the composite structure 102.

[0180] In one or more embodiments, the step of laying up the composite structure (block 1002) also includes the steps of applying compression bagging 162 over the composite structure 102 and sealing the compression bagging 162 to the mandrel tool 112 to seal the composite structure 102 within the compression bagging 162. It should be understood that the use of compression bagging 162 is not necessarily required in all exemplary embodiments of the disclosed method 1000.

[0181] In one or more embodiments, method 1000 includes the step of positioning the mandrel tool 112 (block 1004). In one or more embodiments, the step of positioning the mandrel tool 112 (block 1004) includes the step of positioning the mandrel tool 112 relative to the tooling assembly 164, such as between the first processing tool 104 and the second processing tool 106. In one or more embodiments, the step of positioning the mandrel tool 112 relative to the tooling assembly 164 is performed using a processing cart 184 that supports the mandrel tool 112.

[0182] In one or more embodiments, the step of positioning the mandrel tool 112 (block 1004) includes positioning (e.g., moving) the mandrel tool 112 within the tooling assembly 164 in the open position 108, such as between the first processing tool 104 and the second processing tool 106.

[0183] In one or more embodiments, the mandrel tool 112 includes a closed cross-sectional shape 182. The first processing tool 104 includes a first open cross-sectional shape 168 complementary to the first portion of the closed cross-sectional shape 182 of the mandrel tool 112. The second processing tool 106 includes a second open cross-sectional shape 170 complementary to the second portion of the closed cross-sectional shape 182 of the mandrel tool 112. When the first processing tool 104 and the second processing tool 106 are sealed together, they surround the composite structure 102, including the mandrel tool 112, forming a container 114 in a closed position 110.

[0184] In one or more embodiments, the step of positioning the mandrel tool 112 (block 1004) includes positioning the mandrel tool 112, which supports the composite structure 102, on the second processing tool 106 in the open position 108 by the tooling assembly 164.

[0185] In one or more embodiments, the mandrel tool 112 includes a second planar cross-sectional shape 188. The second processing tool 106 includes a first planar cross-sectional shape 172 configured to support the second planar cross-sectional shape 188 of the mandrel tool 112. The first processing tool 104 includes a first open cross-sectional shape 168 complementary to the shape of the composite structure 102, such as an inner mold line 190 or an outer mold line 192 of the composite structure 102.

[0186] In one or more embodiments, Method 1000 includes a step of closing the tooling assembly 164 (block 1006). In one or more embodiments, the step of closing the tooling assembly 164 (block 1006) includes a step of positioning the first processing tool 104 and the second processing tool 106 of the tooling assembly 164 from an open position 108 in which the first processing tool 104 and the second processing tool 106 are spaced apart to a closed position 110. Generally, the step of closing the tooling assembly 164 (block 1006) (for example, by positioning the first processing tool 104 and the second processing tool 106 to a closed position 110) places the tooling assembly 164 (for example, the first processing tool 104 and the second processing tool 106) in contact with the mandrel tool 112 supporting the composite structure 102 to form a container 114 surrounding the composite structure 102.

[0187] In one or more embodiments, the step of positioning the tooling assembly 164 from an open position 108 to a closed position 110 includes the step of moving at least one of the first processing tool 104 and the second processing tool 106 relative to each other. In one embodiment, at least one of the first processing tool 104 and the second processing tool 106 moves linearly (for example, approximately horizontally or approximately vertically) relative to each other between the open position 108 and the closed position 110. In another embodiment, the first processing tool 104 moves pivotally relative to the second processing tool 106 between the open position 108 and the closed position 110.

[0188] In one or more embodiments, method 1000 includes the step of sealing the tooling assembly 164 with the mandrel tool 112 (block 1008). In one or more embodiments, the step of sealing the tooling assembly 164 with the mandrel tool 112 (block 1008) includes the step of sealing the tooling assembly 164 and the mandrel tool 112 together. Generally, the step of closing the tooling assembly 164 (block 1006) (for example, by positioning the first processing tool 104 and the second processing tool 106 in the closed position 110) seals the tooling assembly 164 (for example, by sealing the first processing tool 104 and the second processing tool 106 to each other) and seals the container 114 surrounding the composite structure 102 (for example, forming the sealed container 114) by sealing the tooling assembly 164 (for example, the first processing tool 104 and the second processing tool 106) with the mandrel tool 112 that supports the composite structure 102.

[0189] In one or more embodiments, the step of sealing the tooling assembly 164 and the mandrel tool 112 together (block 1008) includes sealing a first processing tool 104 to the mandrel tool 112 supporting the composite structure 102. The step of sealing the tooling assembly 164 and the mandrel tool 112 together (block 1008) also includes sealing a second processing tool 106 to the first processing tool 104 and the mandrel tool 112.

[0190] In one or more embodiments, the step of sealing the tooling assembly 164 and the mandrel tool 112 together (block 1008) includes the step of sealing the first processing tool 104 to the second processing tool 106 and the mandrel tool 112.

[0191] In one or more embodiments, the step of sealing the tooling assembly 164 and the mandrel tool 112 together (block 1008) includes the step of sealing the first processing tool 104 to the mandrel tool 112.

[0192] In one or more embodiments, method 1000 includes the step of forming a container 114 (block 1010). In one or more embodiments, the step of forming a container 114 (block 1010) is achieved by closing the tooling assembly (block 1006) and sealing the tooling assembly 164 and the mandrel tool 112 together (block 1008). The container 114 encloses the composite structure 102.

[0193] In one or more embodiments, the step of forming the container 114 (block 1010) includes forming the container 114 surrounding the composite structure 102 with a first processing tool 104, a second processing tool 106, and a mandrel tool 112.

[0194] In one or more embodiments, the step of forming the container 114 (block 1010) includes forming the container 114 surrounding the composite structure 102 with a first processing tool 104 and a mandrel tool 112.

[0195] In one or more embodiments, method 1000 includes a step of processing (block 1012) the composite structure 102. In one or more embodiments, the step of processing (block 1012) the composite structure 102 includes a step of applying heat. In one or more embodiments, the step of processing (block 1012) the composite structure 102 includes a step of applying pressure. In one or more embodiments, the step of processing (block 1012) the composite structure 102 includes applying heat and pressure. In one or more embodiments, the step of processing (block 1012) the composite structure 102 includes, for example, compaction The process includes applying at least one of pressure and heat to the composite structure 102 in order to carry out a process, a debulking process, or a curing process.

[0196] In one or more embodiments, the step of applying pressure includes the use of positive pressure. In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of pressurizing a gas 118 located in the container 114. In these embodiments, the pressurized gas 118 (positive pressure) presses against the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112.

[0197] In one or more embodiments, the step of applying pressure includes the use of negative pressure. In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of applying a vacuum (negative pressure) between the compression bagging 162 surrounding the composite structure 102 and the mandrel tool 112. In these embodiments, the negative pressure vents gas between the compression bagging 162 and the outer surface 212 of the composite structure 102, creating a pressure difference. Generally, venting gas under the compression bagging 162 (e.g., vacuum bagging) promotes higher pressure on the outside of the compression bagging 162 that presses against the compression bagging 162, resulting in compression of the composite structure 102. In these embodiments, a vacuum system 138 is used to apply a vacuum between the compression bagging 162 and the mandrel tool 112. In addition, venting gas under the compression bagging 162 removes air, water, vapor, and / or other volatile substances that may leak from the composite structure 102 during processing.

[0198] In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of applying positive pressure between the first container wall 134 of the first processing tool 104 and the first fitting membrane 136 coupled to the first container wall 134. For example, the step of applying positive pressure includes the step of increasing the atmospheric pressure inside the container 114, thereby increasing the compressive force on the composite structure 102 during processing. In these embodiments, the pressurized gas 118 in the container 114 presses the first fitting membrane 136 against a portion of the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112. In these embodiments, a pressurizing system 140 is used to pressurize the gas 118 located between the first container wall 134 and the first fitting membrane 136, thereby applying pressure to the first fitting membrane 136.

[0199] In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of applying a vacuum (negative pressure) between the mandrel tool 112 and the first fitting membrane 136. In these embodiments, the negative pressure vents gas between the first fitting membrane 136 and the outer surface 210 of the mandrel tool 112, creating a pressure difference. Generally, venting gas between the first fitting membrane 136 and the outer surface 210 of the mandrel tool 112 promotes higher pressure on the outside of the first fitting membrane 136 that presses against the first fitting membrane 136, resulting in compression of the composite structure 102. In these embodiments, a vacuum system 138 is used to apply a vacuum between the first fitting membrane 136 and the mandrel tool 112. In addition, venting gas between the first fitting membrane 136 and the mandrel tool 112 removes air, water, vapor, and / or other volatile substances that may leak from the composite structure 102 during processing. In these embodiments, the first fitted membrane 136 can replace or serve a similar purpose to the compression bagging 162.

[0200] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of forming a portion of the composite structure 102 using a first fitting film 136 and / or compression bagging 162.

[0201] In one or more embodiments, the first fitting membrane 136 and / or compression bagging 162 are pressed against a portion of the outer surface 212 of the composite structure 102 by applying positive pressure through the pressurized gas 118 of the container 114, and the shape of the outer surface 212 of the composite structure 102 is then formed.

[0202] In one or more embodiments, a compressive force is applied to the composite structure 102 during processing due to the pressure difference between the container atmospheric pressure and the pressure between the first fitting membrane 136 and the mandrel tool 112 or the vacuum under the compression bagging 162.

[0203] In one or more embodiments, a portion of the composite structure 102 formed by the first fitting film 136 or compression bagging 162 is at least a portion of the outer mold line 192 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the inner mold line 190 of the composite structure 102.

[0204] In one or more embodiments, a portion of the composite structure 102 formed by the first fitting film 136 or compression bagging 162 is at least a portion of the inner mold line 190 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the outer mold line 192 of the composite structure 102.

[0205] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of shaping and / or smoothing a portion of the composite structure 102 using a first backing plate 142 bonded to a first fitting film 136. In these embodiments, pressure (e.g., positive pressure) and / or vacuum (e.g., negative pressure) are applied to the first fitting film 136 so that the first backing plate 142 presses against a portion of the outer surface 212 of the composite structure 102, shaping and / or smoothing the outer surface 212 of the composite structure 102. For example, the first backing plate 142 is pressed into the composite structure 102 by the pressure difference on both sides of the first fitting film 136, shaping and / or smoothing the outer surface 212 of the composite structure 102.

[0206] In one or more embodiments, a portion of the composite structure 102 formed by the first backing plate 142 is at least a portion of the outer mold line 192 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the inner mold line 190 of the composite structure 102.

[0207] In one or more embodiments, a portion of the composite structure 102 formed by the first backing plate 142 is at least a portion of the inner mold line 190 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the outer mold line 192 of the composite structure 102.

[0208] In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of applying positive pressure between the second container wall 144 of the second processing tool 106 and the second fitting membrane 146 coupled to the second container wall 144. For example, the step of applying positive pressure includes the step of increasing the atmospheric pressure inside the container 114, thereby increasing the compressive force on the composite structure 102 during processing. In these embodiments, the pressurized gas 118 in the container 114 presses the second fitting membrane 146 against a portion of the outer surface 212 of the composite structure 102, compressing the composite structure 102 against the outer surface 210 of the mandrel tool 112. In these embodiments, a pressurizing system 140 is used to pressurize the gas 118 located between the second container wall 144 and the second fitting membrane 146, thereby applying pressure to the first fitting membrane 136.

[0209] In one or more embodiments, the step of applying pressure to the composite structure 102 includes the step of applying a vacuum (negative pressure) between the mandrel tool 112 and the second fitting membrane 146. In these embodiments, the negative pressure vents gas between the second fitting membrane 146 and the outer surface 210 of the mandrel tool 112, creating a pressure difference. Generally, venting gas between the second fitting membrane 146 and the outer surface 210 of the mandrel tool 112 promotes higher pressure on the outside of the second fitting membrane 146 that presses against the second fitting membrane 146, resulting in compression of the composite structure 102. In these embodiments, a vacuum system 138 is used to apply a vacuum between the second fitting membrane 146 and the mandrel tool 112. In addition, venting gas between the second fitting membrane 146 and the mandrel tool 112 removes air, water, vapor, and / or other volatile substances that may leak from the composite structure 102 during processing. In these embodiments, the second fitting membrane 146 can replace or serve a similar purpose to the compression bagging 162.

[0210] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of forming a portion of the composite structure 102 using a second fitting film 146 and / or compression bagging 162.

[0211] In one or more embodiments, the second fitting membrane 146 and / or compression bagging 162 are pressed against a portion of the outer surface 212 of the composite structure 102 by applying positive pressure through the pressurized gas 118 of the container 114, thereby forming the shape of the outer surface 212 of the composite structure 102.

[0212] In one or more embodiments, a compressive force is applied to the composite structure 102 during processing due to the pressure difference between the container atmospheric pressure and the pressure between the second fitting membrane 146 and the mandrel tool 112 or the vacuum under the compression bagging 162.

[0213] In one or more embodiments, a portion of the composite structure 102 formed by the second fitting film 146 is at least a portion of the outer mold line 192 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the inner mold line 190 of the composite structure 102.

[0214] In one or more embodiments, a portion of the composite structure 102 formed by the second fitting film 146 is at least a portion of the inner mold line 190 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the outer mold line 192 of the composite structure 102.

[0215] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of shaping and / or smoothing a portion of the composite structure 102 using a second backing plate 148 bonded to a second fitting film 146. In these embodiments, pressure (e.g., positive pressure) and / or vacuum (e.g., negative pressure) is applied to the second fitting film 146 so that the second backing plate 148 presses against a portion of the outer surface 212 of the composite structure 102, shaping and / or smoothing the outer surface 212 of the composite structure 102. For example, the second backing plate 148 is pressed into the composite structure 102 by the pressure difference on both sides of the second fitting film 146, shaping and / or smoothing the outer surface 212 of the composite structure 102.

[0216] In one or more embodiments, a portion of the composite structure 102 formed by the second backing plate 148 is at least a portion of the outer mold line 192 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the inner mold line 190 of the composite structure 102.

[0217] In one or more embodiments, a portion of the composite structure 102 formed by the second backing plate 148 is at least a portion of the inner mold line 190 of the composite structure 102. In these embodiments, the mandrel tool 112 forms the outer mold line 192 of the composite structure 102.

[0218] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes heating at least one of the tooling assembly 164, the gas 118 located in the vessel 114, and the mandrel tool 112 to heat the composite structure 102.

[0219] In one or more embodiments, the step of applying at least one of pressure and heat to the composite structure 102 includes the step of transferring gas 118 between a first processing tool 104 and a second processing tool 106 in a closed position 110. In these embodiments, gas 118 is at least one of being heated or pressurized. In these embodiments, gas 118 is pressurized using a pressurization system 140. In these embodiments, gas 118 is heated using a heating system 116.

[0220] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes two or more of the following steps: (1) applying pressure between the first container wall 134 and the first fitting membrane 136; (2) applying pressure between the second container wall 144 and the second fitting membrane 146; (3) applying a vacuum between the mandrel tool 112 and the first fitting membrane 136; (4) applying a vacuum between the mandrel tool 112 and the second fitting membrane 146; (5) applying a vacuum between the compression bagging 162 and the mandrel tool 112; (6) heating the tooling assembly 164 (e.g., the first processing tool 104, the second processing tool 106, the first fitting membrane 136, the second fitting membrane 146, the first backing plate 142, and / or the second backing plate 148); (7) heating the gas 118 located inside the container 114; and (8) heating the mandrel tool 112.

[0221] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of using a mandrel tool 112 to form the inner mold line 190 of the composite structure 102 and the step of using a tooling assembly 164 to form at least a portion of the outer mold line 192 of the composite structure 102.

[0222] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of using a mandrel tool 112 to form the outer mold line 192 of the composite structure 102 and the step of using a tooling assembly 164 to form at least a portion of the inner mold line 190 of the composite structure 102.

[0223] In one or more embodiments, the mandrel tool 112 includes a closed cross-sectional shape 182. In one or more embodiments, the processing of the composite structure 102 (block 1012) includes the step of pressurizing the internal space 160 formed by the mandrel tool 112. By pressurizing the internal space 160 of the mandrel tool 112, the mandrel tool 112 becomes structurally responsive to the positive pressure applied to the composite structure 102 and the mandrel tool 112 during processing. In these embodiments, the internal space 160 of the mandrel tool 112 is enclosed using a pair of end caps 158, and the internal space 160 of the mandrel tool 112 is pressurized using a pressurization system 140.

[0224] In one or more embodiments, the mandrel tool 112 includes a third open cross-sectional shape 186. In one or more embodiments, processing the composite structure 102 (block 1012) includes the step of pressurizing the internal space 160 at least partially formed by the mandrel tool 112. By pressurizing the internal space 160 of the mandrel tool 112, the mandrel tool 112 becomes structurally responsive to the positive pressure applied to the composite structure 102 and the mandrel tool 112 during processing. In these embodiments, the internal space 160 of the mandrel tool 112 is confined using a pair of end caps 158, and the internal space 160 of the mandrel tool 112 is pressurized using a pressurization system 140.

[0225] In one or more embodiments, the step of processing the composite structure 102 (block 1012) is: compaction In response to applying pressure to the composite structure 102, the composite structure 102 compact Includes steps.

[0226] In one or more embodiments, the step of processing the composite structure 102 (block 1012) includes the step of debulking the composite structure 102 by applying at least one of debulking pressure and debulking heat to the composite structure 102.

[0227] In one or more embodiments, the step of processing the composite structure 102 (block 1012) is to process the composite structure 102 hard transformation Apply pressure koto o hardened transformation Apply heat The method includes curing the composite structure 102, depending on at least one of the following:

[0228] Accordingly, the disclosed apparatus 100 and method 1000 provide a minimum-sized container 114 (e.g., a processing chamber) by integrating a mandrel tool 112 with a tooling assembly 164 complementary to the mandrel tool 112 to form a container 114 around the composite structure 102. Minimizing the volume of the container 114 significantly reduces heating and exhaust of the container 114 compared to a conventional autoclave. For example, a smaller volume allows for faster pressurization, heating, and cooling during each processing cycle.

[0229] Referring to Figures 26-27, embodiments of the apparatus 100 and method 1000 can be used in reference to the aircraft manufacturing and maintenance method 1100 shown in the flowchart of Figure 26, and the aircraft 1200 schematically shown in Figure 27.

[0230] Referring to Figure 27, in one or more embodiments, the aircraft 1200 includes a fuselage 1202 and several higher-level systems 1204. Examples of higher-level systems 1204 include one or more of the propulsion system 1208, electrical system 1210, hydraulic system 1212, and environmental system 1214. In other embodiments, the aircraft 1200 may include any number of other types of systems, such as a communication system and a guidance system.

[0231] A composite structure 102 manufactured using apparatus 100 or according to method 1000 may be any one of the structures, assemblies, subassemblies, components, parts, or any other parts of an aircraft 1200, such as one or more of the airframe 1202, interior 1206, and high-level systems 1204. For example, the composite structure 102 may be any one of the aircraft spars, wing sections, fuselage barrel sections, interior panels, exterior skins, etc.

[0232] Referring to Figure 26, in the pre-manufacturing stage, Method 1100 includes the specification and design of the aircraft 1200 (block 1102) and the procurement of materials (block 1104). In the manufacturing stage of the aircraft 1200, the components and subassemblies of the aircraft 1200 are manufactured (block 1106), and system integration is performed (block 1108). Subsequently, the aircraft 1200 is licensed and delivered (block 1110) and put into operation (block 1112). Periodic maintenance and upkeep (block 1114) includes the modification, reconfiguration, and refurbishment of one or more systems of the aircraft 1200.

[0233] Each process of Method 1100 shown in Figure 26 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator includes, but is not limited to, any number of spacecraft manufacturers and subcontractors of key systems; a third party includes, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, service organization, etc.

[0234] Embodiments of the apparatus 100 and method 1000 illustrated or described herein may be used at one or more arbitrary stages of the manufacturing and maintenance method 1100 shown in the flowchart in Figure 26. In embodiments, embodiments of the disclosed apparatus 100 and method 1000 may form part of the manufacturing of components and subassemblies (block 1106) and / or system integration (block 1108). For example, the assembly of an aircraft 1200, airframe 1202, and / or their components using embodiments of the disclosed apparatus 100 and method 1000 corresponds to the manufacturing of components and subassemblies (block 1106) and may be prepared in a manner similar to components or subassemblies prepared during the operation of the aircraft 1200 (block 1112). Embodiments of the disclosed apparatus 100 and method 1000 may also be used during system integration (block 1108) and authorization and delivery (block 1110). Similarly, embodiments of the disclosed apparatus 100 and method 1000 may be used, for example, during the operation of the aircraft 1200 (block 1112) and during maintenance and servicing (block 1114), but are not limited to these uses.

[0235] Therefore, referring to Figure 1-27, a method for manufacturing a part of aircraft 1200 (Figure 11) using apparatus 100 is also disclosed. Also disclosed is a part of aircraft 1200 manufactured according to method 1000.

[0236] While examples from the aerospace industry are presented here, the embodiments and principles disclosed herein may also be applicable to the automotive, space, construction, and other design and manufacturing industries. Therefore, the embodiments and principles disclosed herein may also be applicable to composite structures and standalone structures of other vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) in addition to aircraft.

[0237] In this specification, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a particular function is not, in fact, capable of performing that particular function without any modification, and merely potentially capable of performing that particular function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a particular function is specifically selected, created, implemented, used, programmed, and / or designed for the purpose of performing that particular function. In this specification, the expression “configured to” refers to an existing characteristic of the system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a particular function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as “configured to” perform a particular function may additionally or alternatively be described as “adapted to” and / or “operative to” perform that function.

[0238] Unless otherwise specified, terms such as “First,” “Second,” and “Third” are used solely as symbols in this specification and are not intended to impose any sequential, positional, or hierarchical requirements on the items they represent. Furthermore, a reference to an item “Second,” for example, neither requires nor excludes the existence of an item numbered “First” or a smaller number, and / or an item numbered “Third” or a larger number.

[0239] For the purposes of this disclosure, “coupled,” “coupling,” and similar terms and expressions refer to two or more elements that are coupled, connected, fastened, attached, linked, communicated, or otherwise related to one another (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various embodiments, these elements may be related directly or indirectly. For example, element A may be directly related to element B. In another example, element A may be indirectly related to element B, for example, through another element C. It will be understood that the relationships between the various elements disclosed are not necessarily represented. Therefore, other couplings may exist besides those shown in the drawings.

[0240] In this specification, the terms “about” and “approximately” refer to conditions that approximate, but do not strictly adhere to, the specified conditions that still perform the desired function or achieve the desired result. For example, “about” and “approximately” refer to conditions within a given acceptable tolerance or accuracy range. For instance, “about” and “approximately” refer to conditions that are within 10% of the specified conditions. However, the terms “about” and “approximately” do not exclude conditions that are strictly the specified conditions.

[0241] In Figures 22 and 24 described above, blocks can represent functional elements, features, or components thereof, and the lines connecting the various blocks do not necessarily suggest any particular structure. Therefore, modifications, additions, and / or omissions can be made to the illustrated structures. In addition, those skilled in the art will understand that not all elements described and illustrated in Figures 1-24 and 27 described above are required to be included in all embodiments, and not all elements described herein are necessarily included in each exemplary embodiment. Unless otherwise explicitly stated, the schematic diagrams of the embodiments described in Figures 1-24 and 27 described above are not intended to suggest structural limitations relating to the exemplary embodiments. Rather, it should be understood that even if an exemplary structure is shown, that structure may be modified where appropriate.

[0242] In Figures 25 and 26 described above, blocks can represent processes, steps, and / or parts thereof, and the lines connecting the various blocks do not suggest any particular order or dependency of a group of processes or parts thereof. It will be understood that not all dependencies between the various processes disclosed are necessarily shown. Figures 25 and 26 illustrating the processes of the disclosed method presented herein, and the accompanying disclosures, should not be interpreted as necessarily determining the order in which the processes should be performed. Rather, while an exemplary order is shown, it should be understood that the order of the processes can be modified where appropriate. Accordingly, the illustrated processes may be modified, added to, and / or omitted, and certain groups of processes may be performed in different orders or simultaneously. In addition, it will be understood by those skilled in the art that it is not necessary to perform all the processes described.

[0243] Furthermore, throughout this specification, references to features and advantages, or similar expressions used herein, do not imply that all features and advantages that may be realized in the embodiments disclosed herein should be present in or are present in any single embodiment. Rather, expressions referring to features and advantages should be understood to mean that a particular feature, advantage, or characteristic described in relation to a particular embodiment is included in at least one embodiment. Thus, descriptions of features, advantages, and similar expressions used throughout this disclosure may, but not necessarily, refer to the same embodiment.

[0244] Features, advantages, and characteristics described in one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will recognize that the embodiments described herein can be implemented without one or more specific features or advantages of a particular embodiment. In other cases, further features and advantages may be recognized in a particular embodiment but not in all embodiments. Furthermore, although various embodiments of apparatus 100 and method 1000 have been shown and described, those skilled in the art will be able to recall modifications by reading this specification. This application includes such modifications and is limited only by the claims.

[0245] Furthermore, this disclosure includes the following enumerated clauses that define exemplary embodiments of this disclosure.

[0246] Clause 1. A method for processing a composite structure, Positioning the first processing tool and the second processing tool of the tooling assembly from an open position where the first and second processing tools are spaced apart to a closed position where the first and second processing tools are sealed to each other and to the mandrel tool supporting the composite structure, thereby forming a container surrounding the composite structure. Processing complex structures and Methods that include...

[0247] Clause 2. The method according to Clause 1, further comprising positioning the mandrel tool between the first processing tool and the second processing tool of the tooling assembly while the tooling assembly is in the open position.

[0248] Clause 3. The method according to Clause 1 or 2, wherein processing the composite structure includes pressurizing the gas located inside the container.

[0249] Clause 4. The method according to any one of Clauses 1 to 3, wherein processing the composite structure includes applying a vacuum between the compression bagging surrounding the composite structure and the mandrel tool.

[0250] Clause 5. Processing of composite structures Applying pressure between the first container wall of the tooling assembly and the first fitting membrane bonded to the first container wall, and Applying a vacuum between the mandrel tool and the first compatible film. The method described in any one of the provisions 1 to 4, including at least one of the following.

[0251] Clause 6. The method according to Clause 5, further comprising smoothing a portion of the composite structure using a first backing plate bonded to a first compatible film.

[0252] Clause 7. Processing of complex structures, Applying pressure between the second container wall of the tooling assembly and the second fitting membrane bonded to the second container wall, and Applying a vacuum between the mandrel tool and the second compatible membrane. The method described in any one of the provisions 1 to 6, including at least one of the following:

[0253] Clause 8. The method according to Clause 7, further comprising smoothing a portion of the composite structure using a second backing plate bonded to a second compatible film.

[0254] Clause 9. The method according to any one of Clauses 1 to 8, wherein processing the composite structure includes heating at least one of the tooling assembly, the gas located in the container, and the mandrel tool to heat the composite structure.

[0255] Clause 10. Processing the composite structure includes heating and pressurizing the gas, and transferring the gas between the first processing tool and the second processing tool at the closed position The method according to any one of Clauses 1 to 9, including at least one of the above.

[0256] Clause 11. Using a mandrel tool to form the inner mold line of the composite structure, and Using a tooling assembly to form the outer mold line of the composite structure The method according to any one of Clauses 1 to 10, further including the above.

[0257] Clause 12. Using a mandrel tool to form the outer mold line of the composite structure, and Using a tooling assembly to form the inner mold line of the composite structure The method according to any one of Clauses 1 to 11, further including the above.

[0258] Clause 13. The mandrel tool includes a closed cross-sectional shape, The method according to any one of Clauses 1 to 12, further including pressurizing the internal space formed by the mandrel tool.

[0259] Clause 14. The mandrel tool includes a third open cross-sectional shape, The method according to any one of Clauses 1 to 13, further including pressurizing the internal space at least partially formed by the mandrel tool.

[0260] Clause 15. The method according to any one of Clauses 1 to 14, wherein processing the composite structure includes debulking the composite structure in accordance with applying at least one of pressure and heat to the composite structure.

[0261] Clause 16. The method according to any one of Clauses 1 to 15, wherein processing the composite structure includes curing the composite structure by applying at least one of pressure and heat to the composite structure.

[0262] Article 17. Part of the manufacture of an aircraft by any one of the methods described in Articles 1 through 16.

[0263] Clause 18. A method for processing a composite structure, optionally according to any one of Clauses 1 through 17, The first processing tool is sealed to the mandrel tool supporting the composite structure, The second processing tool is sealed to the first processing tool and the mandrel tool, Using the first processing tool, the second processing tool, and the mandrel tool, a container surrounding the composite structure is formed. Methods that include...

[0264] Article 19. Applying at least one of pressure and heat to a composite structure. The method described in Article 18, further including the method described in Article 18.

[0265] Article 20. Applying pressure between the first container wall of the first processing tool and the first compatible membrane bonded to the first container wall, and between the second container wall of the second processing tool and the second compatible membrane bonded to the second container wall, Applying a vacuum between the mandrel tool and the first compatible film, and between the mandrel tool and the second compatible film. The method described in Article 18 or 19, further comprising at least one of the following:

[0266] The method according to clause 20, further comprising smoothing a composite structure using a first platen bonded to a first conforming film and a second platen bonded to a second conforming film.

[0267] Clause 22. A part of aircraft manufacturing by the method according to any one of clauses 18 - 21.

[0268] Clause 23. A method for processing a composite structure, optionally according to any one of clauses 1 - 21, comprising: positioning a mandrel tool supporting the composite structure on a second processing tool; sealing a first processing tool to the second processing tool and the mandrel tool; forming a container surrounding the composite structure using the first processing tool, the second processing tool, and the mandrel tool. A method comprising.

[0269] Clause 24. The method according to clause 23, further comprising applying at least one of pressure and heat to the composite structure. The method according to clause 23, further comprising applying at least one of pressure and heat to the composite structure.

[0270] Clause 25. Applying pressure between a first container wall of the first processing tool and a first conforming film bonded to the first container wall, and Applying a vacuum between the mandrel tool and the first conforming film. The method according to clause 23 or 24, comprising at least one of the above.

[0271] Clause 26. The method according to clause 25, further comprising smoothing the composite structure using a first platen bonded to the first conforming film.

[0272] Clause 27. A part of aircraft manufacturing by the method according to any one of clauses 23 - 26.

Claims

1. A method (1000) for processing a composite structure (102), The first processing tool (104) and the second processing tool (106) of the tooling assembly (164) are positioned from an open position (108) where the first processing tool (104) and the second processing tool (106) are spaced apart, to a closed position (110) where the first processing tool (104) and the second processing tool (106) are sealed to each other and to the mandrel tool (112) supporting the composite structure (102), thereby forming a container (114) surrounding the composite structure (102). Processing the composite structure (102) Includes, Processing the composite structure (102) Applying pressure between the first container wall (134) of the first processing tool (104) and the first compatible membrane (136) bonded to the first container wall (134), and Applying a vacuum between the mandrel tool (112) and the first compatible film (136) At least one of the following, Applying pressure between the second container wall (144) of the second processing tool (106) and the second compatible membrane (146) bonded to the second container wall (144), and Applying a vacuum between the mandrel tool (112) and the second compatible film (146) at least one of the following and A method (1000) including the following.

2. With the tooling assembly (164) in the open position (108), position the mandrel tool (112) between the first processing tool (104) and the second processing tool (106) of the tooling assembly (164). The method according to claim 1, further comprising (1000).

3. The method according to claim 1 or 2 (1000), wherein processing the composite structure (102) includes pressurizing the gas (118) located inside the container (114).

4. The method according to any one of claims 1 to 3 (1000), wherein processing the composite structure (102) includes applying a vacuum between the compression bagging (162) surrounding the composite structure (102) and the mandrel tool (112).

5. The method according to any one of claims 1 to 4 (1000), further comprising processing the composite structure (102) by smoothing a portion of the composite structure (102) using a first backing plate (142) bonded to the first compatible film (136).

6. The method according to any one of claims 1 to 5 (1000), further comprising processing the composite structure (102) by smoothing a portion of the composite structure (102) using a second backing plate (148) bonded to the second compatible film (146).

7. The method according to any one of claims 1 to 6 (1000), wherein processing the composite structure (102) includes heating at least one of the tooling assembly (164), the gas (118) located in the container (114), and the mandrel tool (112), and heating the composite structure (102).

8. Processing the composite structure (102) At least one of heating and pressurizing the gas (118), In the closed position (110), the gas (118) is transferred between the first processing tool (104) and the second processing tool (106). The method according to any one of claims 1 to 7, including (1000).

9. Using the mandrel tool (112), the inner mold line (190) of the composite structure (102) is formed, Using the tooling assembly (164), the outer mold line (192) of the composite structure (102) is formed. The method according to any one of claims 1 to 8, further comprising (1000).

10. Using the mandrel tool (112), the outer mold line (192) of the composite structure (102) is formed, Using the tooling assembly (164), the inner mold line (190) of the composite structure (102) is formed. The method according to any one of claims 1 to 9, further comprising (1000).

11. The mandrel tool (112) includes a closed cross-sectional shape (182), The method (1000) according to any one of claims 1 to 10, further comprising pressurizing the inner space (160) formed by the mandrel tool (112).

12. The mandrel tool (112) includes an open cross-sectional shape (186), The method (1000) according to any one of claims 1 to 11, further comprising pressurizing the inner space (160) formed at least partially by the mandrel tool (112).

13. The method according to any one of claims 1 to 12 (1000), wherein processing the composite structure (102) includes debulking the composite structure (102) by applying at least one of pressure and heat to the composite structure (102).

14. The method (1000) according to any one of claims 1 to 13, wherein processing the composite structure (102) includes curing the composite structure (102) by applying at least one of pressure and heat to the composite structure (102).

15. The method according to any one of claims 1 to 14 (1000), wherein processing the composite structure (102) includes compacting the composite structure (102) in response to applying a compaction pressure to the composite structure (102).

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