Method and apparatus for consolidating a bulk molding compound

Abstract

Methods and apparatus are presented. A bulk molding compound is compacted by sending the bulk molding compound through a die breaker and an extrusion die of a compaction system.

Description

Technology Field

[0001] The present disclosure generally relates to the manufacture of composite structures, and more specifically to composite materials used in molding processes. More specifically, the present disclosure provides methods and apparatus for consolidating a bulk molding compound. Background Technology

[0002] Bulk molding compounds are used to form composite structures through molding processes. A bulk molding compound is a compound formed from chopped fibers and at least one resin material. The chopped fibers impart strength to the composite structures formed by the bulk molding compound. Composite structures formed from bulk molding compounds may not be as strong as desired.

[0003] Therefore, it would be desirable to have methods and devices that consider not only the problems discussed above, but also at least some of other possible problems. For example, it would be desirable to form composite structures with lower porosity through molding processes. As another example, it would be desirable to form composite structures with fewer discrepancies through molding processes.

[0004] An exemplary embodiment of the present disclosure provides a method. A bulk molding compound is compacted by passing the bulk molding compound through a die breaker and an extrusion die of a compaction system.

[0005] Another exemplary embodiment of the present disclosure provides a method. A bulk forming compound is heated to form a heated bulk forming compound. The heated bulk forming compound is loaded into a consolidation system. The heated bulk forming compound is pressed to form a compressed material. The compressed material is extruded through an extrusion die of the consolidation system.

[0006] Another exemplary embodiment of the present disclosure provides a consolidation system. The consolidation system includes a die breaker and an extrusion die.

[0007] Further exemplary embodiments of the present disclosure provide a method. A bulk forming compound is heated to form a heated bulk forming compound. The heated bulk forming compound is degassed in a consolidation system. The heated bulk forming compound is consolidated after degassing, wherein consolidation comprises pressurizing the heated bulk forming compound through a die breaker to form a compressed material. The compressed material is relaxed. After relaxing the compressed material, the compressed material is extruded through an extrusion die of the consolidation system.

[0008] Features and functions may be achieved independently in various embodiments of the present disclosure or combined in other embodiments, further details of which can be identified by reference to the following description and drawings. Brief explanation of the drawing

[0009] Novel features considered to be characteristics of the exemplary embodiments are set forth in the appended claims. However, not only the exemplary embodiments but also their preferred modes of use, additional purposes, and features will be best understood by reference to the following detailed description of exemplary embodiments of the disclosure when read together with the accompanying drawings. FIG. 1 is an example of a block diagram of a manufacturing environment in which a bulk molding compound is compacted according to an exemplary embodiment. FIG. 2 is an example of a manufacturing environment in which a bulk molding compound is compacted according to an exemplary embodiment. FIG. 3 is an example of a cross-sectional view of a consolidation system in which a bulk molding compound is consolidated according to an exemplary embodiment. FIG. 4 is an example of a cross-sectional view of a consolidation system in which a bulk molding compound is consolidated according to an exemplary embodiment. FIG. 5 is an example of an isometric projection of a die breaker of a consolidation system according to an exemplary embodiment. FIG. 6 is an example of a front view of a die breaker of a consolidation system according to an exemplary embodiment. Figure 7 is an example of a flowchart of a method for compacting a bulk molding compound according to an exemplary example. Figure 8 is an example of a flowchart of a method for compacting a bulk molding compound according to an exemplary example. FIG. 9 is an example of a flowchart of a method for compacting a bulk molding compound according to an exemplary example. FIG. 10 is an example of a block diagram of an aircraft manufacturing and service method according to an exemplary example. FIG. 11 is an example of a block diagram of an aircraft in which an exemplary example can be implemented. Specific details for implementing the invention

[0010] The exemplary embodiments recognize and consider one or more different considerations. For example, the exemplary embodiments recognize and consider that bulk molding compounds (BMCs) or bulk molding composites are used in various industries and on various different platforms, such as mobile platforms, stationary platforms, land-based structures, water-based structures, or space-based structures. More specifically, a platform may be a surface vessel, tank, troop transport vehicle, train, spacecraft, space station, satellite, submarine, automobile, power plant, bridge, dam, house, manufacturing facility, building, facility, or any other suitable platform. The exemplary embodiments recognize and consider that bulk molding compounds may be used in electrical applications, corrosion-resistant applications, or other applications having specific technical or performance standards.

[0011] The exemplary embodiments recognize and consider that the bulk molding compound may comprise commercially available staple fibers of any preferred type or a mixture of types. The exemplary embodiments recognize and consider that the staple fibers may comprise glass, carbon, Kevlar, or any other preferred type of fiber. The exemplary embodiments recognize and consider that the bulk molding compound may comprise a thermosetting or thermoplastic resin system. The exemplary embodiments recognize and consider that the bulk molding compound may comprise any preferred type of polymer resin system, such as epoxy, phenol, polyester resin, vinyl ester, polyetheretherketone (PEEK) / polyetherketoneketone (PEKK), polyphenylsulfone (PPSU), polyamide, or any other preferred type of resin system.

[0012] The exemplary embodiments recognize and consider that the bulk molding compound is commercially available and provided in a molding-ready state. The exemplary embodiments recognize and consider that the bulk molding compound may be provided in bulk or in logs.

[0013] The exemplary embodiments recognize and consider that a bulk molding compound can be prepared by mixing strands of short fibers with a resin in a mixer. The exemplary embodiments recognize and consider that the short fibers of the bulk molding compound contribute to the strength characteristics of the composite structures formed by the bulk molding compound. The exemplary embodiments recognize and consider that in some cases, the short fibers of the bulk molding compound can produce greater strength than a pure resin system, e.g., an epoxy without fiber reinforcement.

[0014] The exemplary embodiments recognize and consider that at high fiber volume fractions, completely wetting all staple fibers of a bulk molding compound may be more difficult than desired. The exemplary embodiments recognize and consider that preparing a fully compacted bulk molding compound for final application may be more difficult than desired.

[0015] The exemplary embodiments recognize and consider that bulk molding compounds that are not fully compacted may cause inconsistencies in the cured composite material. The exemplary embodiments recognize and consider that bulk molding compounds that are not fully compacted may produce lower quality than desirable in the cured material. The exemplary embodiments recognize and consider that bulk molding compounds that are not fully compacted may produce higher porosity levels than desirable in the cured material.

[0016] The exemplary examples recognize and consider that composite materials may be used to form composite radius fillers or composite "noodles." The exemplary examples recognize and consider that composite radius fillers preferably have axially aligned fibers to provide tensile strength.

[0017] Now, referring to the drawings, and particularly to FIG. 1, an example of a block diagram of a manufacturing environment in which a bulk molding compound is compacted according to an exemplary embodiment is shown. The manufacturing environment (100) has a compaction system (102) configured to compact a bulk molding compound (104). The bulk molding compound (104) is a loose composite material (106) formed from a resin (108) and fillers (110). In some exemplary examples, the fillers (110) take the form of fibers (112). The fibers (112) can be formed from any preferred material and can have any preferred size. In some exemplary embodiments, the fibers (112) have lengths ranging from 0.125" to 1.0". By compressing the bulk molding compound (104), the porosity (114) of the compressed material (116) is lower than the porosity (118) of the bulk molding compound (104).

[0018] The compaction system (102) includes a die breaker (120) and an extrusion die (122). In some exemplary examples, the bulk molding compound (104) is compacted by passing the bulk molding compound (104) through the die breaker (120) and the extrusion die (122).

[0019] The compaction system (102) further includes a piston (124) and a cylindrical housing (126). A die breaker (120) is contained within the cylindrical housing (126). An extrusion die (122) is connected to an end (128) of the cylindrical housing (126). In some exemplary examples, the compaction system (102) is referred to as a "ram extruder."

[0020] The relaxation chamber (130) is formed by a die breaker (120), a cylindrical housing (126), and an extrusion die (122). The bulk molding compound (104) is pressurized through the die breaker (120) to become a compressed material (132) within the relaxation chamber (130). The relaxation chamber (130) is used to stabilize the shape of the material.

[0021] Relaxation provides time for the compressed material (132) to remix and expand before extrusion through the extrusion die (122). Relaxation reduces expansion after extrusion through the extrusion die (122). In some exemplary examples, relaxation reduces the porosity of the compressed material (116).

[0022] In some exemplary examples, the relaxation chamber (130) may also be referred to as the "extrusion zone." In the relaxation chamber (130), the compressed material (132) is relaxed before being remixed after the die breaker (120) and extruded through the extrusion die (122). Remixing the compressed material (132) helps to evenly wet the fillers (110) by the resin (108). By relaxing the compressed material (132), the shape of the plurality of holes (144) or plurality of slots (146) of the die breaker (120) is not maintained.

[0023] If the die breaker (120) is present, it provides an increase in back pressure for the extrusion die (122). When the die breaker (120) is present, the compacted material (116) expands less after extrusion than when the die breaker (120) is not present. When the die breaker (120) is present, the die breaker (120) increases the homogenization of the compacted material (116).

[0024] The die breaker (120) has any desired size and shape. For example, the die breaker (120) has a thickness (121). The thickness (121) is selected to provide consolidation to the bulk forming compound (104). The thickness (121) is selected so that sufficient time is spent for the bulk forming compound (104) to move through the die breaker (120) to be consolidated. In some exemplary examples, the thickness (121) is within the range of 0.25 inches to 1.0 inch. In some exemplary examples, the thickness (121) is approximately 0.5 inches.

[0025] The bulk molding compound (104) is loaded into a compression chamber (134) before being pressurized through a die breaker (120). The compression chamber (134) is formed by a die breaker (120), a piston (124), and a cylindrical housing (126).

[0026] In some exemplary examples, the compression chamber (134) may be referred to as a "material supply chamber." The bulk molding compound (104) in the compression chamber (134) has a lower density than the compressed material (132) in the relaxation chamber (130). More specifically, the density (135) of the bulk molding compound (104) is lower than the density (137) of the compressed material (132).

[0027] As the piston (124) moves toward the extrusion die (122), the bulk molding compound (104) is mixed and compacted. The movement of the bulk molding compound (104) within the compression chamber (134) mixes the resin (108) and the fillers (110). The bulk molding compound (104) is compacted through at least one of applied force, heating, or degassing.

[0028] In some exemplary examples, before loading the bulk molding compound (104) into the compaction system (102), heating (136) is applied to the bulk molding compound (104) to form a heated bulk molding compound (138). In these exemplary examples, the heated bulk molding compound (138) is loaded into the compaction system (102).

[0029] In these exemplary examples, the bulk molding compound (104) is heated above the glass transition temperature (Tg) of the resin (108) so that the bulk molding compound (104) is significantly softened. The temperature must also be sufficiently lower than the curing temperature of the resin (108) so that no chemical reaction occurs due to this operation. In some exemplary embodiments, heating (136) is performed until the resin (108) becomes fluid.

[0030] After loading the heated bulk molding compound (138) into the compaction system (102), the heated bulk molding compound (138) is degassed. To degas the heated bulk molding compound (138), a vacuum is applied to the heated bulk molding compound (138). The vacuum is applied through a vacuum port (140) within the cylindrical housing (126). The vacuum applied through the vacuum port (140) initially degasses the heated bulk molding compound (138) within the compression chamber (134). The vacuum also discharges gases from the compression chamber (134) and the relaxation chamber (130).

[0031] Degassing the heated bulk molding compound (138) removes gases from the heated bulk molding compound (138). Removing gases from the heated bulk molding compound (138) increases the density (135) of the bulk molding compound (104) within the cylindrical housing (126).

[0032] To degas the heated bulk molding compound (138), the cylindrical housing (126) is sealed. The cylindrical housing (126) is sealed by attaching an airtight component, such as a plug (141), to the end (128) of the cylindrical housing (126) and another airtight component, such as a piston (124), to the end (168) of the cylindrical housing (126).

[0033] In some exemplary examples, the piston (124) seals the cylindrical housing (126) so that a vacuum can be applied to draw gas from the heated bulk molding compound (138). In these exemplary examples, the piston (124) forms an airtight seal with the cylindrical housing (126). In some other exemplary examples, the piston (124) does not form an airtight seal with the cylindrical housing (126). In these exemplary examples, a separate sealing component (not shown) is coupled to the end (168) to seal the cylindrical housing (126).

[0034] In some exemplary examples, a vacuum is applied through a vacuum port (140) before pressurizing the heated bulk molding compound (138), and after the piston (124) extends past the vacuum port (140), no longer a vacuum is applied through the vacuum port (140). In these exemplary examples, the piston (124) forms a hermetic seal with the cylindrical housing (126).

[0035] In some exemplary examples, a vacuum is applied by pressurizing the heated bulk molding compound (138) through the die breaker (120) of the compaction system (102). In these exemplary examples, a separate sealing component (not shown) seals the cylindrical housing (126) at the end (168).

[0036] The plug (141) is coupled to the end (128) of the cylindrical housing (126). The plug (141) seals the end (128) of the cylindrical housing (126) for the application of vacuum through the vacuum port (140). The plug (141) seals the cylindrical housing (126) by blocking the opening (152) of the extrusion die (122). The plug (141) maintains a vacuum within the cylindrical housing (126).

[0037] The plug (141) is held in place until the compressed material (132) pushes the plug (141) out of the opening (152). When the compressed material (132) pushes the plug (141) out of the opening (152), the compressed material (132) passing through the opening (152) maintains a vacuum within the cylindrical housing (126).

[0038] After applying a vacuum through the vacuum port (140), the actuator (142) moves the piston (124) to pressurize the heated bulk molding compound (138) within the cylindrical housing (126) of the compaction system (102). Pressurizing the heated bulk molding compound (138) through the die breaker (120) of the compaction system (102) includes driving the piston (124) toward the extrusion die (122).

[0039] As described, pressing the heated bulk forming compound (138) of the consolidation system (102) to form the compressed material (132) comprises pressing the heated bulk forming compound (138) through the die breaker (120) of the consolidation system (102). The die breaker (120) comprises at least one of a plurality of holes (144) or a plurality of slots (146).

[0040] As used herein, when used in a list of items, the phrase “at least one of” means that different combinations of one or more of the enumerated items may be used, and that only one of each item in the list may be required. That is, “at least one of” means that any combination of items and any number of items from the list may be used, but not all of the items in the list are required. An item may be a specific object, thing, or category.

[0041] For example, “at least one of item A, item B, or item C” may include, without limitation, item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items may exist. In other examples, “at least one of” may be, for example, without limitation, 2 items A; 1 item B; and 10 items C; 4 items B and 7 items C; or other suitable combinations.

[0042] As illustrated, the compaction system (102) includes a heater system (148) coupled with a cylindrical housing (126). The heater system (148) includes any desirable amount of heaters and any desirable type of heaters. The heater system (148) may be either a convection heating system or a conduction heating system. By being coupled with the cylindrical housing (126), the heater system (148) is configured to heat the cylindrical housing (126). In some exemplary examples, the heater system (148) is coupled with the cylindrical housing (126) by being directed toward the cylindrical housing (126). For example, the heater system (148) may be a heated air source directed to blow heated air across the cylindrical housing.

[0043] In some exemplary examples, the heater system (148) is coupled to the cylindrical housing (126) by contacting the cylindrical housing (126). For example, a heating blanket may be wrapped around the cylindrical housing (126) to heat the cylindrical housing (126) to form the heater system (148). In some exemplary examples, the heater system (148) is coupled to the cylindrical housing (126) by being embedded in the cylindrical housing (126). For example, resistive heating elements may be embedded in the cylindrical housing (126) to form the heater system (148).

[0044] The heater system (148) applies heat (150) to the cylindrical housing (126) to reduce the viscosity of the bulk molding compound (104) within the cylindrical housing (126). By reducing the viscosity of the bulk molding compound (104) within the cylindrical housing (126), the force provided by the actuator (142) to pressurize the bulk molding compound (104) through the die breaker (120) is reduced. Reducing the viscosity of the bulk molding compound (104) within the cylindrical housing (126) produces better processability. Reducing the viscosity also leads to better degassing of the bulk molding compound (104).

[0045] In some exemplary examples, the extrusion die (122) may also be referred to as a forming die. The extrusion die (122) has an opening (152), through which the compacted material (116) exits the compaction system (102). The extrusion die (122) forms the compacted material (116) into either a slug (154) or an ingot (156).

[0046] The ingot (156) has any desirable profile, such as a circular, square, rectangular, triangular, or any other desirable profile. The opening (152) is shaped to produce a slug (154) or ingot (156) of the desired profile. The opening (152) has any desirable size or shape based on the desired shape for the slug (154) or ingot (156). The opening (152) has a cross-sectional shape (157). The cross-sectional shape (157) is any desirable shape, such as a circular, square, rectangular, triangular, or any other desirable shape. In some exemplary examples, the extrusion die (122) has an opening (152) having a cross-sectional shape (157) configured to form a composite radius filler.

[0047] In one exemplary example, the extrusion die (122) is a rectangular die with slots. In this exemplary example, the opening (152) of the extrusion die (122) is used to extrude material into thin sheets to form bracket or thin-shell panel structures. In one exemplary example, the extrusion die (122) has a triangular opening (152). In this exemplary example, the extrusion die (122) having a triangular opening (152) can be used to extrude a bulk molding compound (104) for the application of a radius filler.

[0048] The compacted material (116) is a material to be used to form a composite structure, such as a composite structure (158). The compacted material (116) exiting the extrusion die (122) is prepared for a forming process, such as forming (160). As illustrated, after exiting the compaction system (102), the compacted material (116) undergoes forming (160) to form a composite structure (158). In some exemplary examples, the compacted material (116) may be stored for a desired period of time prior to forming (160).

[0049] The composite structure (158) may have at least one of lower porosity, fewer irregularities, or higher strength than the composite structure formed from the bulk molding compound (104). Condensing the bulk molding compound (104) to produce a compressed material (116) before forming the composite structure (158) improves the quality of the composite structure (158). In some exemplary examples, the composite structure (158) is an aircraft part.

[0050] Consolidating a bulk molding compound (104) using a consolidation system (102) is a batch process. The consolidation system (102) may have any desirable dimensions. The volume (162) of the compression chamber (134) affects the amount of bulk molding compound (104) that can be processed in batches.

[0051] The diameter (164) of the cylindrical housing (126) affects the amount of force supplied by the actuator (142). An increase in the diameter (164) increases the amount of force supplied by the actuator (142) to compress the bulk molding compound (104).

[0052] The diameter (164) of the cylindrical housing (126) also affects the volume (162) of the compression chamber (134). An increase in the diameter (164) of the cylindrical housing (126) increases the volume (162) of the compression chamber (134). The volume (162) of the compression chamber (134) is also affected by the distance (166) between the die breaker (120) and the end (168) of the cylindrical housing (126). For example, an increase in the distance (166) between the die breaker (120) and the end (168) increases the volume (162). The end (128) and the end (168) of the cylindrical housing (126) are opposite ends of the cylindrical housing (126).

[0053] The extrusion die (122) has any desirable dimensions. In some exemplary examples, the cross-sectional area (172) of the opening (152) is at least 25% smaller than the cross-sectional area (174) of the cylindrical housing (126). In some exemplary examples, when the opening (152) is circular, the diameter (170) of the opening (152) of the extrusion die (122) is at least 25% smaller than the diameter (164) of the cylindrical housing (126).

[0054] The example of the manufacturing environment (100) of FIG. 1 is not intended to imply physical or structural limitations on the manner in which the exemplary embodiment may be implemented. Other components may be used in addition to or instead of those exemplified. Some components may be unnecessary. Additionally, blocks are presented to exemplify some functional components. When implemented as an exemplary embodiment, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0055] For example, a bulk forming compound (104) or a heated bulk forming compound (138) may be loaded into a consolidation system (102) and consolidated using the consolidation system (102). As another example, a die breaker (120) is present, but in some exemplary examples, the die breaker (120) may not be present in the consolidation system (102).

[0056] As another example, the extrusion die (122) is illustrated as having only one opening (152), but the extrusion die may have any desired number of openings. In some exemplary examples, the extrusion die (122) has more than one opening.

[0057] In some exemplary examples, the compaction system (102) is moved within the manufacturing environment (100) by an automated moving system, such as a robotic arm. In these exemplary examples, the compaction system (102) may be part of an end effector. In some exemplary examples, tooling is moved to the compaction system (102) to receive the compacted material (116).

[0058] As an additional example, forming (160) is illustrated, but forming (160) may be optional. In some exemplary examples, the compacted material (116) forms a composite structure (158) without forming (160). For example, the cross-sectional shape (157) of the opening (152) can form the compacted material (116) within a slug (154) having a desired cross-sectional shape for the composite radius filler.

[0059] In some of these exemplary examples, the consolidation system (102) may be part of a composite radius filler end effector. In one exemplary example, the consolidation system (102) is an end effector (not shown) configured to extrude a composite radius filler to form a composite structure (158). In some exemplary examples, the consolidation system (102) forms a composite radius filler by extruding the consolidated material (116) directly onto another composite material. In some exemplary examples, the consolidation system (102) forms a composite radius filler by extruding the consolidated material (116) onto a tool.

[0060] Now, referring to FIG. 2, an example of a manufacturing environment in which a bulk molding compound is compacted according to an exemplary embodiment is illustrated. The manufacturing environment (200) is a physical implementation of the manufacturing environment (100) of FIG. 1. The manufacturing environment (200) includes a compaction system (202) and a bulk molding compound (204). The bulk molding compound (204) is a physical implementation of the bulk molding compound (104) of FIG. 1.

[0061] As illustrated, the compacted material (206) is extruded from the compaction system (202). The compacted material (206) has a porosity (not illustrated) less than the porosity (not illustrated) of the bulk molding compound (204).

[0062] To form a compacted material (206), the bulk molding compound (204) is loaded into a compaction system (202). In some exemplary examples, the bulk molding compound (204) is heated before being loaded into a cylindrical housing (208).

[0063] After loading the bulk molding compound (204) into the cylindrical housing (208), the piston (210) engages with the cylindrical housing (208) to seal the cylindrical housing (208). After sealing the cylindrical housing (208) using the piston (210), the bulk molding compound (204) inside the cylindrical housing (208) is degassed. To degas the material inside the cylindrical housing (208), a vacuum is applied inside the cylindrical housing (208). The vacuum is applied through a vacuum port (not shown) inside the cylindrical housing (208). The vacuum is applied to the vacuum port (not shown) inside the cylindrical housing (208) by a vacuum source.

[0064] To form a compacted material (206), an actuator (212) drives a piston (210) toward an extruder die (214). The extruder die (214) is connected to the end (216) of a cylindrical housing (208). By driving the piston (210) toward the extruder die (214), a material such as a bulk molding compound (204) is pressurized within the cylindrical housing (208) and extruded through the extruder die (214). As illustrated, the compacted material (206) exits the extruder die (214) as a slug (218).

[0065] In some exemplary examples, the slug (218) undergoes an additional molding process to form a composite structure. In some other exemplary examples, the slug (218) is used in an extruded cross section. For example, in some exemplary examples, the slug (218) may be placed as a composite radius filler.

[0066] In some exemplary examples, the consolidation system (202) is part of an end effector for applying the slug (218) to a composite material or tooling. In some exemplary examples, the consolidation system (202) is part of a composite radius filler extrusion end effector in which the slug (218) is used as a composite radius filler.

[0067] Now, referring to FIG. 3, an example of a cross-sectional view of a consolidation system in which a bulk molding compound is consolidated according to an exemplary embodiment is shown. The consolidation system (300) is a physical implementation of the consolidation system (102) of FIG. 1. As shown, the consolidation system (300) has a die breaker (302) and an extrusion die (304). The consolidation system (300) also has a piston (306) and a cylindrical housing (308). The die breaker (302) is contained within the cylindrical housing (308). The extrusion die (304) is connected to the end (310) of the cylindrical housing (308).

[0068] The compression chamber (312) is formed by a die breaker (302), a piston (306), and a cylindrical housing (308). The relaxation chamber (314) is formed by a die breaker (302), a cylindrical housing (308), and an extrusion die (304).

[0069] The vacuum port (316) is located within the cylindrical housing (308). The heater system (318) is coupled to the cylindrical housing (308). As illustrated, the heater system (318) is integrated into the cylindrical housing (308).

[0070] As illustrated, the piston (306) seals the cylindrical housing (308). The piston (306) is in contact with the cylindrical housing (308) and has a hermetic seal. The bulk molding compound (320) in the compression chamber (312) is degassed using the vacuum port (316). The plug (321) seals the cylindrical housing (308) for degassment. The plug (321) blocks the opening (not illustrated) of the extrusion die (304).

[0071] As illustrated, the extrusion die (304) has a taper (323). Due to the taper (323), the opening (not illustrated) of the extrusion die (304) has a smaller cross-section than the cross-section of the cylindrical housing (308). The smaller cross-section of the opening (not illustrated) of the extrusion die (304) helps maintain higher pressure during extrusion. The smaller cross-section of the opening (not illustrated) of the extrusion die (304) helps maintain lower porosity in the extruded ingot (not illustrated).

[0072] In drawing (322), the piston (306) is in an initial position (324). From the initial position (324), the piston (306) is driven by an actuator (326) in a direction (328) toward the extrusion die (304). When the piston (306) moves in the direction (328), the piston (306) will compress the bulk molding compound (320) as shown in FIG. 4.

[0073] When the piston (306) passes through the vacuum port (316), the vacuum from the vacuum port (316) can be released. When the piston (306) passes through the vacuum port (316), the airtight seal between the piston (306) and the cylindrical housing (308) maintains the vacuum within the bulk molding compound (320).

[0074] In some exemplary examples, the bulk molding compound (320) is preheated before being placed in the cylindrical housing (308). In these exemplary examples, the bulk molding compound (320) may be referred to as the "heated bulk molding compound."

[0075] Now, referring to FIG. 4, an example of a cross-sectional view of a consolidation system in which a bulk molding compound is consolidated according to an exemplary embodiment is shown. In the drawing (400), a piston (306) moves in the direction (328) to press the bulk molding compound (320) through a die breaker (302). The bulk molding compound (320) is pressed through the die breaker (302) to form a compressed material (402).

[0076] When the bulk molding compound (320) is pressurized through the die breaker (302), greater pressure is applied to the bulk molding compound (320) due to the size of the multiple holes (403) of the die breaker (302). The greater pressure applied to the bulk molding compound (320) compresses the bulk molding compound (320).

[0077] When the bulk molding compound (320) is pressed through the die breaker (302), at least some of the fibers within the bulk molding compound (320) are aligned axially. Aligning the fibers within the bulk molding compound (320) may be desirable for some composite structures to be produced from the compressed material (404). As illustrated, the bulk molding compound (320) is pressed through a plurality of holes (403) of the die breaker (302) to form the compressed material (402).

[0078] The compressed material (402) in the relaxation chamber (314) is pressurized through the die breaker (302). The compressed material (402) is remixed and relaxed in the relaxation chamber (314).

[0079] The relaxation chamber (314) is used to stabilize the shape of the material. Relaxation provides time for the compressed material (402) to remix and expand before extrusion through the extrusion die (304). Relaxation reduces expansion after extrusion through the extrusion die (304). In some exemplary examples, relaxation reduces the porosity of the compressed material (404).

[0080] In some exemplary examples, the relaxation chamber (314) may also be referred to as the "extrusion zone." In the relaxation chamber (314), the compressed material (402) is remixed after the die breaker (302) and relaxed before being extruded through the extrusion die (304). Remixing the compressed material (402) helps to evenly wet the fillers of the compressed material (402) with the resin of the compressed material (402). By relaxing the compressed material (402), the shape of the plurality of holes (403) or plurality of slots of the die breaker (302) is not maintained.

[0081] The die breaker (302) provides back pressure enhancement for the extrusion die (304). When the die breaker (302) is present, the die material (404) expands less after extrusion than when the die breaker (302) is not present. When the die breaker (302) is present, the die breaker (302) increases the homogenization of the compacted material (404).

[0082] When the piston (306) moves in the direction (328), the compressed material (402) is extruded through the extrusion die (304) of the compaction system (300). The compacted material (404) is extruded from the extrusion die (304). The compacted material (404) takes the form of a slug (406). The slug (406) has a lower (unillustrated) porosity than the (unillustrated) porosity of the bulk molding compound (320) loaded into the cylindrical housing (308) of FIG. 3. The slug (406) has a lower porosity than the bulk molding compound (320) due to the compression applied by the heating, degassing, and compression system (300). The slug (406) has a lower porosity than the bulk molding compound (320) due to compaction through the die breaker (302). The slug (406) also has better wetting of the fillers in the slug (406) by the resin in the slug (406) than by the bulk molding compound (320) due to compression applied by the consolidation system (300).

[0083] After exiting the compaction system (300), the compacted material (404) is prepared to be formed in a separate manufacturing process. In some exemplary examples, the compacted material (404) is used for molding purposes. Forming a component (not shown) by molding the compacted material (404) produces a component of higher quality than a component formed by directly molding the bulk molding compound (320). The reduced porosity of the compacted material (404) results in a component of higher quality than a component formed by directly molding the bulk molding compound (320).

[0084] In some exemplary examples, the compacted material (404) in the slug (406) does not undergo an additional molding process to form a composite structure. In some exemplary examples, the slug (406) is used in an extruded section. For example, the slug (406) may be placed as a composite radius filler in some exemplary examples.

[0085] In some exemplary examples, the consolidation system (300) is part of an end effector for applying the slug (406) to a composite material or tooling. In some exemplary examples, the consolidation system (300) is part of a composite radius filler extrusion end effector in which the slug (406) is used as a composite radius filler.

[0086] The slug (406) may have any desired shape. In some exemplary examples, the shape of the slug (406) is selected based on the composite structure to be formed. In some exemplary examples, the slug (406) may instead be one or more thin sheets. The thin sheets may be formed into a bracket, a panel, or any other desired composite structure.

[0087] Now, referring to FIG. 5, an example of an isometric view of a die breaker of a consolidation system according to an exemplary embodiment is shown. The die breaker (500) is a physical implementation of the die breaker (120) of FIG. 1. The die breaker (500) can be used in the consolidation system (102) of FIG. 1. The die breaker (500) may be the same as the die breaker (302) of FIG. 3 and FIG. 4.

[0088] A die breaker (500) comprises at least one of a plurality of holes or a plurality of slots. As illustrated, the die breaker (500) has a plurality of holes (502). In other exemplary examples not illustrated, the die breaker (500) has one or more slots in addition to the plurality of holes. In other exemplary examples not illustrated, the die breaker (500) has a plurality of slots without the plurality of holes (502).

[0089] When the bulk molding compound is pressurized through the die breaker (500), greater pressure is applied to the bulk molding compound due to the size of the plurality of holes (502) of the die breaker (500). As illustrated, the diameter of each of the plurality of holes (502) is 0.25". As illustrated, the thickness of the die breaker (500) is about 0.5". The thickness of the die breaker (500) is selected so that the bulk molding compound passes through the die breaker (500) for a sufficient period of time to compact the bulk molding compound. The greater pressure applied to the bulk molding compound compacts the bulk molding compound.

[0090] When the bulk molding compound is pressurized through the die breaker (500), at least some of the fibers within the bulk molding compound are aligned axially. Aligning the fibers within the bulk molding compound may be desirable when some composite structures are produced from a compacted material formed using a compaction system including the die breaker (500).

[0091] Now, referring to FIG. 6, an example of a front view of a die breaker of a consolidation system according to an exemplary embodiment is shown. The die breaker (600) is a physical implementation of the die breaker (120) of FIG. 1. The die breaker (600) can be used in the consolidation system (102) of FIG. 1. The die breaker (600) may be the same as the die breaker (302) of FIG. 3 and FIG. 4.

[0092] A die breaker (600) comprises at least one of a plurality of holes or a plurality of slots. As illustrated, the die breaker (600) has a plurality of slots (602). In other exemplary examples not illustrated, the die breaker (600) has one or more holes in addition to the plurality of slots (602). In other exemplary examples not illustrated, the die breaker (600) has a plurality of holes without the plurality of slots (602).

[0093] When the bulk molding compound is pressurized through the die breaker (600), greater pressure is applied to the bulk molding compound due to the size of the multiple slots (602) of the die breaker (600). As illustrated, the lengths of the multiple slots (602) are not uniform. In some exemplary examples, the length of each of the multiple slots (602) is within the range of 0.25" to 0.5". The greater pressure applied to the bulk molding compound compresses the bulk molding compound.

[0094] When the bulk molding compound is pressurized through the die breaker (600), at least some of the fibers within the bulk molding compound are aligned axially. Aligning the fibers within the bulk molding compound may be desirable when some composite structures are produced from a compacted material formed using a compaction system including the die breaker (600).

[0095] The different components illustrated in FIGS. 2–6 may be combined with the components of FIG. 1, used with the components of FIG. 1, or a combination of both. Additionally, some of the components of FIGS. 2–6 may be exemplary examples of how the components illustrated in the block form of FIG. 1 can be implemented as physical structures.

[0096] Now, referring to FIG. 7, an example of a flowchart of a method for compacting a bulk molding compound is illustrated according to an exemplary embodiment. The method (700) may be used to compact a bulk molding compound (104) using the compaction system (102) of FIG. 1. The method (700) may be implemented using the compaction system (202) of FIG. 2 in a manufacturing environment (200). The method (700) may be performed using the compaction system (300) of FIG. 3 and FIG. 4. The die breaker (500) of FIG. 5 may be used to perform the method (700).

[0097] The method (700) compacts the bulk molding compound by sending the bulk molding compound through the die breaker and extrusion die of the compaction system (operation (702)). After that, the method (700) is terminated.

[0098] In some exemplary examples, the method (700) heats the bulk forming compound before loading the bulk forming compound into a compaction system (operation (704)). By preheating the bulk forming compound before loading it into the compaction system, the initiation of pressure by the piston may begin earlier than by heating the entire bulk forming compound by a heating system combined with a cylindrical housing.

[0099] In some exemplary examples, the method (700) degasses a bulk molding compound within a cylindrical housing (operation (706)). Degassing the bulk molding compound removes gases from the bulk molding compound, thereby increasing the density of the compacted material. In some exemplary examples, the method (700) degasses the bulk molding compound by applying a vacuum to the bulk molding compound. In some exemplary examples, the vacuum is applied until the piston passes through the vacuum port.

[0100] In some exemplary examples, compacting a bulk forming compound comprises sending the bulk forming compound through a die breaker within a compaction system (operation (708)); and extruding the bulk forming compound through an extrusion die of the compaction system after sending the bulk forming compound through the die breaker (operation (710)). In some exemplary examples, sending the bulk forming compound through the die breaker comprises compressing the bulk forming compound within a cylindrical housing of the compaction system using a piston (operation (712)). The piston may also be referred to as a "compression piston." The piston may be driven by an actuator or any other preferred driving mechanism.

[0101] In some exemplary examples, sending a bulk forming compound through a die breaker in a consolidation system comprises sending the bulk forming compound through at least one of a plurality of holes or a plurality of slots (operation (714)). At least one of the plurality of holes or a plurality of slots may have any preferred layout, any preferred size, and any preferred amount. In some exemplary examples, sending the bulk forming compound through at least one of the plurality of holes or a plurality of slots consolidates the bulk forming compound (operation (716)).

[0102] In some exemplary examples, sending the bulk forming compound through a die breaker aligns at least some of the fibers of the bulk forming compound axially (operation (718)). When the bulk forming compound is pressurized through the die breaker, greater pressure is applied to the bulk forming compound due to the size of the multiple holes or multiple slots of the die breaker. The greater pressure applied to the bulk forming compound compresses the bulk forming compound. In some exemplary examples, the method (700) relaxes the bulk forming compound between sending the bulk forming compound through the die breaker and extruding the bulk forming compound (operation (720)).

[0103] In some exemplary examples, the method (700) heats the cylindrical housing of the consolidation system (operation (722)). By heating the cylindrical housing, the bulk forming compound within the cylindrical housing is heated. Heating the bulk forming compound reduces the viscosity of the bulk forming compound.

[0104] The cylindrical housing is heated using any preferred heating process. The heater system may be coupled to the cylindrical housing by being directed toward the cylindrical housing, in contact with the cylindrical housing, connected to the cylindrical housing, or formed within the cylindrical housing.

[0105] Now, referring to FIG. 8, an example of a flowchart of a method for compacting a bulk molding compound is illustrated according to an exemplary example. The method (800) can be used to compact a bulk molding compound (104) using the compaction system (102) of FIG. 1. The method (800) can be implemented using the compaction system (202) of FIG. 2 in a manufacturing environment (200). The method (800) can be performed using the compaction system (300) of FIG. 3 and FIG. 4. The die breaker (500) of FIG. 5 can be used to perform the method (800).

[0106] Method (800) heats a bulk molding compound to form a heated bulk molding compound (operation (802)). Method (800) loads the heated bulk molding compound into a compaction system (operation (804)). Method (800) pressurizes the heated bulk molding compound to form a compacted material (operation (806)). Method (800) extrudes the compacted material through an extrusion die of the compaction system (operation (808)). After that, Method (800) is terminated.

[0107] In some exemplary examples, the method (800) heats the cylindrical housing of the compaction system (operation (810)). The cylindrical housing may be heated in any preferred manner and by any preferred heater system. The heater system may be coupled to the cylindrical housing by being directed toward the cylindrical housing, in contact with the cylindrical housing, connected to the cylindrical housing, or formed within the cylindrical housing.

[0108] In some exemplary examples, the method (800) degasses the heated bulk molding compound after loading it into a compaction system (operation (812)). The heated bulk molding compound is degassed within the compaction system by applying a vacuum to the heated bulk molding compound. Before degassing the heated bulk molding compound, the compaction system is sealed.

[0109] In some exemplary examples, pressing a heated bulk forming compound of a consolidation system to form a compressed material includes pressing the heated bulk forming compound through a die breaker of the consolidation system (operation (814)). In some exemplary examples, pressing the heated bulk forming compound through a die breaker of the consolidation system includes driving a piston toward an extrusion die (operation (816)).

[0110] In some exemplary examples, pressurizing a heated bulk molding compound through a die breaker of a compaction system comprises passing the heated bulk molding compound through at least one of a plurality of holes or a plurality of slots (operation (818)). At least one of the plurality of holes or a plurality of slots of the die breaker may have any preferred layout, any preferred size, and any preferred amount.

[0111] When a heated bulk forming compound is pressurized through a die breaker, at least some of the fibers within the heated bulk forming compound are axially aligned. In some composite structures, the axially aligned fibers preferably reinforce the composite structure. Having axially aligned fibers will make the composite structure more tensile. In some exemplary examples, a compacted material extruded from a compaction system forms a composite radius filler. Having axially aligned fibers will preferably make the composite radius filler more tensile.

[0112] When a heated bulk forming compound is pressurized through a die breaker, greater pressure is applied to the heated bulk forming compound due to the size of the multiple holes or multiple slots of the die breaker. This greater pressure applied to the heated bulk forming compound compresses the bulk forming compound.

[0113] Now, referring to FIG. 9, an example of a flowchart of a method for compacting a bulk molding compound is illustrated according to an exemplary example. The method (900) can be used to compact a bulk molding compound (104) using the compaction system (102) of FIG. 1. The method (900) can be implemented using the compaction system (202) of FIG. 2 in a manufacturing environment (200). The method (900) can be performed using the compaction system (300) of FIG. 3 and FIG. 4. The die breaker (500) of FIG. 5 can be used to perform the method (900).

[0114] Method (900) heats a bulk molding compound to form a heated bulk molding compound (operation (902)). Method (900) degasses the heated bulk molding compound in a compaction system (operation (904)). After degassing, Method (900) compacts the heated bulk molding compound, wherein compaction includes pressing the heated bulk molding compound through a die breaker to form a compacted material (operation (906)). Method (900) relaxes the compacted material (operation (908)). After relaxing the compacted material, Method (900) extrudes the compacted material through an extrusion die of the compaction system (operation (910)). After that, Method (900) terminates.

[0115] In some exemplary examples, pressing the heated bulk molding compound through a die breaker aligns at least some of the fibers of the heated bulk molding compound axially (operation (912)). In some exemplary examples, extruding the compressed material aligns at least some of the fibers of the compressed material axially (operation (914)). In some exemplary examples, extruding the compressed material forms a composite radius filler.

[0116] The flowcharts and block diagrams of the different embodiments illustrated illustrate the architecture, function, and operation of some possible implementations of the devices and methods of the exemplary embodiments. In this regard, each block within the flowcharts or block diagrams may represent a module, segment, function, and / or part of an operation or step.

[0117] In some alternative implementations of the exemplary embodiments, the functions or functions mentioned in the blocks may occur differently from the order mentioned in the drawings. For example, in some cases, two blocks depicted consecutively may be executed substantially simultaneously, or the blocks may occasionally be performed in reverse order depending on the functions involved. Additionally, other blocks may be added in addition to the blocks illustrated in the flowchart or block diagram.

[0118] In some exemplary examples, not all blocks of method (700), method (800), or method (900) are performed. For example, some of the operations (704 to 716) may be optional. In some exemplary examples, some of the operations (810 to 818) may be optional. In some exemplary examples, the operations (912 to 914) may be optional.

[0119] Exemplary examples of the present disclosure may be described in relation to an aircraft manufacturing and service method (1000) as shown in FIG. 10 and an aircraft (1100) as shown in FIG. 11. First, referring to FIG. 10, an example of an aircraft manufacturing and service method according to an exemplary example is shown. During pre-production, the aircraft manufacturing and service method (1000) may include the specifications and design (1002) and material procurement (1004) of the aircraft (1100) of FIG. 11.

[0120] During production, the manufacturing (1006) of components and sub-parts of the aircraft (1100) and system integration (1008) are carried out. Subsequently, the aircraft (1100) may undergo certification and delivery (1010) to be operated (1012). During operation (1012) by a customer, the aircraft (1100) is scheduled for maintenance and service (1014), which may include modification, reconfiguration, retrofitting, and other maintenance or services.

[0121] Each of the processes of the aircraft manufacturing and service method (1000) may be performed or executed by a system integrator, a third party and / or an operator. In these examples, the operator may be a customer. For the purposes of this description, the system integrator may include any number of aircraft manufacturers or major system subcontractors without limitation; the third party may include any number of sales companies, subcontractors, or suppliers without limitation; and the operator may be an airline, a leasing company, a defense contractor, a service agency, etc.

[0122] Now, referring to FIG. 11, an example of an aircraft in which an exemplary example can be implemented is illustrated. In this example, the aircraft (1100) is produced by the aircraft manufacturing and service method (1000) of FIG. 10 and may include a body (1102) with a plurality of systems (1104) and an interior (1106). Examples of systems (1104) include one or more of a propulsion system (1108), an electrical system (1110), a hydraulic system (1112), and an environmental system (1114). Any number of other systems may be included. An example of the aerospace industry is illustrated, but different exemplary examples may be applied to other industries such as the automotive industry.

[0123] The devices and methods implemented herein may be used during at least one step of the aircraft manufacturing and service method (1000). One or more exemplary examples may be used during the manufacturing of components and sub-parts (1006), system integration (1008), or maintenance and service (1014) of FIG. 10. For example, the compacted material (116) of FIG. 1, compacted by the compaction system (102) of FIG. 1, may be used to form components of the aircraft (1100) during the manufacturing of components and sub-parts (1006). As another example, the compacted material (116), compacted by the compaction system (102), may be used to form replacement parts during the maintenance and service (1014) of FIG. 10.

[0124] The devices and methods implemented in this specification may be used to manufacture at least one component of an aircraft (1100). For example, the compaction system (102) of FIG. 1 produces the compacted material (116) of FIG. 1 which can be formed into a component for either the body (1102) or the interior (1106).

[0125] Exemplary examples provide methods and apparatuses for compacting a bulk molding compound. The compacted material formed by compacting the bulk molding compound can be used to make high-quality composite products. The compacting of the compacted material results in at least one of reduced porosity or reduced irregularities in the molded composite parts. The compacting of the compacted material produces higher quality composite parts than the molding of the bulk molding compound. The compacting of the compacted material of the exemplary examples produces composite parts with better structural performance.

[0126] Handling of the compacted materials in exemplary examples is easier than handling of the bulk molded compounds. Bulk molded compounds are loose materials and can generate undesirable amounts of fine dust. Compacted materials have lower porosity and are in the form of slag or ingots. Handling of the compacted materials in exemplary examples generates less fine dust than handling of the bulk molded compounds.

[0127] At least some of the fibers of the bulk molding compound are axially aligned during the consolidation process. In some exemplary examples, the axially aligned fibers preferably reinforce the composite structure. For example, having axially aligned fibers will make the composite structure more tensile. In some exemplary examples, the consolidated material extruded from the consolidation system forms a composite radius filler. Having axially aligned fibers will preferably make the composite radius filler more tensile.

[0129] The system and method are also referred to in the following provisions, which should not be confused with the claims.

[0130] A1. Method (700) is:

[0131] The method includes a step (702) of compacting the bulk molding compound (104) by sending the bulk molding compound (104) through the die breaker (120) and extrusion die (122) of the compaction system (102).

[0133] A2. The method (700) of paragraph A1 is also provided, wherein the step of compacting the bulk molding compound (104) is:

[0134] Step (708) of sending the bulk molding compound (104) through a die breaker (120) in a compaction system (102); and

[0135] The method includes the step (710) of sending the bulk molding compound (104) through a die breaker (120) and then extruding the bulk molding compound (104) through an extrusion die (122) of a compaction system (102).

[0137] A3. The method (700) of paragraph A2 is also provided, wherein the step (718) of sending the bulk molding compound (104) through the die breaker (120) aligns at least some of the fibers (112) of the bulk molding compound (104) axially.

[0139] A4. The method (700) of paragraph A2 is also provided, and this method (700) is:

[0140] The method further includes a step (720) of relaxing the bulk molding compound (104) between the step of sending the bulk molding compound (104) through the die breaker (120) and the step of extruding the bulk molding compound (104).

[0142] A5. The method (700) of paragraph A2 is also provided, wherein the step (712) of sending the bulk forming compound (104) through the die breaker (120) includes the step of compressing the bulk forming compound (104) within the cylindrical housing (126) of the compaction system (102) using a piston (124).

[0144] A6. The method (700) of paragraph A5 is also provided, and this method (700) is:

[0145] The method further includes a step (706) of degassing the bulk molding compound (104) within a cylindrical housing (126).

[0147] A7. The method (700) of paragraph A5 is also provided, and this method (700) is:

[0148] It further includes the step (722) of heating the cylindrical housing (126) of the compaction system (102).

[0150] A8. The method (700) of paragraph A2 is also provided, wherein the step (714) of sending the bulk forming compound (104) through the die breaker (120) in the compaction system (102) includes sending the bulk forming compound (104) through at least one of the plurality of holes (144) or the plurality of slots (146).

[0152] A9. The method (700) of paragraph A8 is also provided, wherein the step (716) of sending the bulk molding compound (104) through at least one of the plurality of holes (144) or the plurality of slots (146) compresses the bulk molding compound (104).

[0154] A10. The method (700) of paragraph A1 is also provided, and this method (700) is:

[0155] The method further includes a step (704) of heating the bulk molding compound (104) before loading the bulk molding compound (104) into the compaction system (102).

[0157] A11. The method (700) of paragraph A1 is also provided, wherein the bulk molding compound (104) is a loose composite material (106) formed from a resin (108) and fillers (110).

[0159] A12. The method (700) of paragraph A1 is also provided, wherein the step of consolidating the bulk molding compound (104) forms a consolidated material (116), and this method:

[0160] The method further includes the step of forming a composite structure (158) from a compacted material (116), wherein the composite structure (158) is a component of an aircraft.

[0162] A13. The method (700) of paragraph A12 is also provided, where the composite structure (158) is a composite radius filler.

[0164] Depending on additional aspects of this method, the following is provided:

[0165] B1. Method (800) is:

[0166] Step (802) of heating the bulk molding compound (104) to form a heated bulk molding compound (138);

[0167] Step (804) of loading the heated bulk molding compound (138) into a compaction system (102);

[0168] A step (806) of pressing a heated bulk molding compound (138) to form a compressed material (132); and

[0169] It includes the step (808) of extruding the compressed material (132) through the extrusion die (122) of the compression system (102).

[0171] B2. The method (800) of paragraph B1 is also provided, and this method (800) is:

[0172] The method further includes the step (810) of heating the cylindrical housing (126) of the compaction system (102).

[0174] B3. The method (800) of paragraph B1 is also provided, and this method (800) is:

[0175] After loading the heated bulk molding compound (138) into the compaction system (102), the method further includes the step (812) of degassing the heated bulk molding compound (138).

[0177] B4. The method (800) of paragraph B1 is also provided, wherein the step of pressing the heated bulk forming compound (138) of the consolidation system (102) to form the compressed material (132) comprises the step (814) of pressing the heated bulk forming compound (138) through the die breaker (120) of the consolidation system (102), and the step (816) of pressing the heated bulk forming compound (138) through the die breaker (120) of the consolidation system (102) comprises the step of driving the piston (124) toward the extrusion die (122).

[0179] B5. The method (800) of paragraph B4 is also provided, wherein the step (818) of pressurizing the heated bulk molding compound (138) through the die breaker (120) of the compaction system (102) includes the step of sending the heated bulk molding compound (138) through at least one of a plurality of holes or a plurality of slots (146).

[0181] B6. The method (800) of paragraph B1 is also provided, wherein the bulk molding compound (104) is a loose composite material (106) formed from a resin (108) and fillers (110).

[0183] B7. The method (800) of paragraph B1 is also provided, wherein the step of extruding the compressed material (132) through the extrusion die (122) of the consolidation system (102) forms a consolidated material (116), and this method:

[0184] The method further includes the step of forming a composite structure (158) from a compacted material (116), wherein the composite structure (158) is a component of an aircraft.

[0186] Depending on additional aspects of this method, the following is provided:

[0187] C1. Method (900) is:

[0188] Step (902) of heating the bulk molding compound (104) to form a heated bulk molding compound (138);

[0189] In a compaction system (102), a step (904) of degassing the heated bulk molding compound (138);

[0190] After degassing, a step (906) of compacting the heated bulk molding compound (138) — the compacting step includes a step of pressing the heated bulk molding compound (138) through a die breaker (120) to form a compacted material (132) —;

[0191] Step (908) of relaxing the compressed material (132); and

[0192] After relaxing the compressed material (132), the method includes the step (910) of extruding the compressed material (132) through the extrusion die (122) of the compression system (102).

[0194] C2. The method (900) of paragraph C1 is also provided, wherein the step (912) of pressing the heated bulk molding compound (138) through the die breaker (120) aligns at least some of the fibers (112) of the heated bulk molding compound (138) axially.

[0196] C3. The method (900) of paragraph C1 is also provided, wherein the step (914) of extruding the compressed material (132) aligns at least some of the fibers (112) of the compressed material (132) axially.

[0198] C4. The method (900) of paragraph C1 is also provided, wherein the step of extruding the compressed material (132) forms a composite radius filler.

[0200] Depending on additional aspects of this system, the following is provided:

[0201] D1. A consolidation system (102) configured to consolidate a bulk molding compound (104), wherein the consolidation system (102) is:

[0202] Die breaker (120); and

[0203] It includes an extrusion die (122).

[0205] D2. A consolidation system (102) of paragraph D1 is also provided, and this consolidation system (102) is:

[0206] Piston (124); and

[0207] It further includes a cylindrical housing (126), a die breaker (120) is contained within the cylindrical housing (126), and an extrusion die (122) is connected to an end (128) of the cylindrical housing (126).

[0209] D3. A consolidation system (102) of paragraph D2 is also provided, and this consolidation system (102) is:

[0210] It further includes a relaxation chamber (130) formed by a die breaker (120), a cylindrical housing (126), and an extrusion die (122).

[0212] D4. A consolidation system (102) of paragraph D2 is also provided, and this consolidation system (102) is:

[0213] It further includes a compression chamber (134) formed by a die breaker (120), a piston (124), and a cylindrical housing (126).

[0215] D5. A consolidation system (102) of paragraph D2 is also provided, and this consolidation system (102) is:

[0216] It further includes a vacuum port (140) inside a cylindrical housing (126).

[0218] D6. A consolidation system (102) of paragraph D2 is also provided, and this consolidation system (102) is:

[0219] It further includes a heater system (148) combined with a cylindrical housing (126).

[0221] D7. A consolidation system (102) of paragraph D2 is also provided, wherein the diameter (170) of the opening (152) of the extrusion die (122) is at least 25% smaller than the diameter (164) of the cylindrical housing (126).

[0223] D8. A consolidation system (102) of paragraph D1 is also provided, wherein the die breaker (120) includes at least one of a plurality of holes (144) or a plurality of slots (146).

[0225] D9. A consolidation system (102) of paragraph D1 is also provided, wherein the extrusion die (122) has an opening (152) having a cross-sectional shape (157) that is one of a circle, a square, a rectangle, or a triangle.

[0227] D10. A consolidation system (102) of paragraph D1 is also provided, wherein the extrusion die (122) has an opening (152) having a cross-sectional shape (157) configured to form a composite radius filler.

[0229] D11. A consolidation system (102) of paragraph D1 is also provided, wherein the consolidation system (102) is part of an end effector.

[0231] The description of different exemplary embodiments is provided for illustrative and illustrative purposes only and is not intended to encompass or limit the embodiments in the disclosed form. Many modifications and variations will be apparent to those skilled in the art. Additionally, different exemplary embodiments may provide different features compared to other exemplary embodiments. Selected embodiments or embodiments are chosen and described to best explain the principles and practical applications of the embodiments, and to enable others skilled in the art to understand the disclosure regarding various embodiments having various modifications suitable for the specific use being considered.

Claims

Claim 1 A method (700) comprising the step (702) of consolidating the bulk molding compound (104) by passing the bulk molding compound (104) through a die breaker (120) and an extrusion die (122) of a consolidation system (102). Claim 2 In claim 1, the step of compacting the bulk molding compound (104) is Step (708) of sending the bulk molding compound (104) through a die breaker (120) in the compaction system (102); and A method (700) comprising the step (710) of sending the bulk molding compound (104) through the die breaker (120) and then extruding the bulk molding compound (104) through the extrusion die (122) of the consolidation system (102). Claim 3 In claim 2, the step (718) of sending the bulk molding compound (104) through the die breaker (120) is a method (700) of aligning at least some of the fibers (112) of the bulk molding compound (104) in an axial direction. Claim 4 A method (700) further comprising, in claim 2, a step (720) of relaxing the bulk molding compound (104) between the step of sending the bulk molding compound (104) through the die breaker (120) and the step of extruding the bulk molding compound (104). Claim 5 In claim 2, the step (712) of sending the bulk forming compound (104) through the die breaker (120) includes the step of compressing the bulk forming compound (104) within the cylindrical housing (126) of the consolidation system (102) using a piston (124), method (700). Claim 6 In claim 2, the step (714) of sending the bulk forming compound (104) through a die breaker (120) in the consolidation system (102) comprises sending the bulk forming compound (104) through at least one of a plurality of holes (144) or a plurality of slots (146), method (700). Claim 7 A method (700) further comprising the step (704) of heating the bulk forming compound (104) before loading the bulk forming compound (104) into the consolidation system (102) in claim 1. Claim 8 In claim 1, the bulk molding compound (104) is a loose composite material (106) formed from a resin (108) and fillers (110), method (700). Claim 9 In claim 1, the step of consolidating the bulk molding compound (104) forms a consolidated material (116), and the method is: The method (700) further includes the step of forming a composite structure (158) from the above-mentioned compacted material (116), wherein the composite structure (158) is a component of an aircraft. Claim 10 A consolidation system (102) configured to consolidate a bulk molding compound (104), comprising a die breaker (120); and an extrusion die (122). Claim 11 In claim 10, a compaction system (102) further comprising a piston (124); and a cylindrical housing (126), wherein the die breaker (120) is contained within the cylindrical housing (126), and the extrusion die (122) is connected to the end (128) of the cylindrical housing (126). Claim 12 In claim 10, the die breaker (120) comprises at least one of a plurality of holes (144) or a plurality of slots (146), forming a compaction system (102). Claim 13 In claim 10, the extrusion die (122) has an opening (152) having a cross-sectional shape (157) that is one of a circle, a square, a rectangle, or a triangle, in a consolidation system (102). Claim 14 In claim 10, the extrusion die (122) has an opening (152) having a cross-sectional shape (157) configured to form a composite radius filler, in a consolidation system (102). Claim 15 In claim 10, the consolidation system (102) is a consolidation system (102) that is part of an end effector.

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