GB2556043A - A method of de-bulking a pre-form for a composite component - Google Patents
A method of de-bulking a pre-form for a composite component Download PDFInfo
- Publication number
- GB2556043A GB2556043A GB1619077.9A GB201619077A GB2556043A GB 2556043 A GB2556043 A GB 2556043A GB 201619077 A GB201619077 A GB 201619077A GB 2556043 A GB2556043 A GB 2556043A
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- United Kingdom
- Prior art keywords
- tool
- bulking
- membrane
- sealed region
- low pressure
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
A de-bulking assembly for de-bulking a composite component comprising a first 130 and second 120 tool, a pre-form 112 received on the first tool, a first membrane 140 sealed over the pre-form defining a first sealed region disposed between the pre-form and the second tool, wherein the second tool moves relative to the first tool to compress the pre-form therebetween. A second membrane 146 may sealingly enclose the second tool 120 to define a second sealed region fluidically coupled to a low pressure/vacuum source and the pre-form may be heated. A controller may switch between first/second configurations wherein the first sealed region/second sealed region is fluidically coupled to the low pressure or vacuum source. A second independent claim defining a de-bulking method comprising providing a pre-form 112 on a first tool 130, applying a first membrane 140 over the pre-form to define a first sealed region which is fluidically coupled to a low pressure/vacuum source to apply a pressure load on the pre-form in a first de-bulking phase, and pressing a second tool 120 against the first membrane to compress the pre-form between the first and second tools for a second de-bulking phase.
Description
(71) Applicant(s):
Composite Technology and Applications Limited PO Box 31, Moor Lane, DERBY, DE24 8BJ,
United Kingdom (72) Inventor(s):
Robert Doorly (74) Agent and/or Address for Service:
Haseltine Lake LLP
Redcliff Quay, 120 Redd iff Street, BRISTOL, BS1 6HU, United Kingdom (51) INT CL:
B29C 70/44 (2006.01) B29C 70/34 (2006.01) (56) Documents Cited:
EP 0319895 A2 WO 2009/044194 A2
US 6484776 B1 US 20060017200 A1
US 20050183818 A1 (58) Field of Search:
INT CL B29C
Other: EPODOC, WPIAP (54) Title of the Invention: A method of de-bulking a pre-form for a composite component
Abstract Title: An assembly and method of de-bulking a pre-form for a composite component (57) A de-bulking assembly for de-bulking a composite component comprising a first 130 and second 120 tool, a preform 112 received on the first tool, a first membrane 140 sealed over the pre-form defining a first sealed region disposed between the pre-form and the second tool, wherein the second tool moves relative to the first tool to compress the pre-form therebetween. A second membrane 146 may sealingly enclose the second tool 120 to define a second sealed region fluidically coupled to a low pressure/vacuum source and the pre-form may be heated. A controller may switch between first/second configurations wherein the first sealed region/second sealed region is fluidically coupled to the low pressure or vacuum source. A second independent claim defining a debulking method comprising providing a pre-form 112 on a first tool 130, applying a first membrane 140 over the preform to define a first sealed region which is fluidically coupled to a low pressure/vacuum source to apply a pressure load on the pre-form in a first de-bulking phase, and pressing a second tool 120 against the first membrane to compress the pre-form between the first and second tools for a second de-bulking phase.
At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.
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A METHOD OF DE-BULKING A PRE-FORM FOR A COMPOSITE COMPONENT
The invention relates to a method of de-bulking a pre-form for a composite component.
Composite components are increasingly used in advanced industries owing to the ability to combine desirable material properties, such as high strength and low weight. Composite components are increasingly being implemented in the aerospace industry for this reason.
There are several known methods for automatically laying up composite material for a component, including Automatic Fibre Placement (AFP) and Automatic Tape Laying (ATL). In AFP, several individual fibres of composite material are gathered to form a tow, and the tow is laid over a tool and periodically cut to form a course of composite material. A narrow width of tape could be used instead of individual fibres or tows. In ATL, a wider tape is applied directly to the tool over a course.
Typically, once composite material is laid-up to produce a pre-form, the pre-form is formed to the desired shape (if necessary), and the composite material is cured to form the component.
It is known that spaces between the individual pieces of composite material affect the shape and size of the pre-form during the manufacturing process. For example, spaces form where there are gaps and overlaps between individual tows (in Automatic Fibre Placement, AFP), and between courses of tows. Further, there are spaces owing to the roughness and profile of the composite material as it is deposited.
Before curing, a pre-form typically has extra volume when compared to the volume of the cured component. The extra volume is referred to as pre-form bulk, or simply “bulk”.
When a pre-form for a composite component is cured under temperature and pressure, such spaces are eliminated as the resin (or matrix material) in the composite material becomes less viscous and the pre-form is consolidated. Any air (or other gas) in such spaces migrates out of the pre-form during curing.
However, the presence of the bulk before curing presents a number of challenges, in particular with regards to complex geometry components or components having variable thickness. For example, the bulk factor (expressed as the ratio of bulk thickness to cured thickness) may be constant over a variable-thickness component, but thicker regions will consequently have a larger absolute bulk to remove. Accordingly, in closed-tool curing (in which a pre-form is cured between two opposing tools), a tool may only engage the thicker regions initially, which may cause the composite material to redistribute in an undesirable manner and cause wrinkles within the laminate (i.e. the preform being formed/cured) during forming/curing, which may affect the eventual component.
It is therefore desirable to provide an improved method of de-bulking a composite component.
According to an aspect of the invention there is provided a method of de-bulking a preform for a composite component comprising: providing a pre-form for the composite component on a first tool; applying a first membrane over the pre-form to seal the preform in a first sealed region; fluidically coupling a low pressure or vacuum source to the first sealed region so that a pressure load is applied on the pre-form through the first membrane for (or in) a first de-bulking phase; and subsequently pressing a second tool against the first membrane to compress the pre-form between the first tool and the second tool for (or in) a second de-bulking phase.
The first sealed region may be defined between the first tool and the first membrane. The first membrane may be sealingly coupled to the first tool.
The pre-form may be compacted during the first de-bulking phase and in the second de-bulking phase. The first de-bulking phase may comprise or consist of the period in which the low pressure of vacuum source is coupled to the first sealed region so that a pressure load is applied on the pre-form through the first membrane before the second tool is pressed against the first membrane. Pressing the second tool against the first membrane may comprise causing an external force (i.e. a motive force) to be applied on the second tool to press it against the first membrane (and the pre-form, first tool). Pressing the second tool against the first membrane may not include the weight of the second tool being supported on the first membrane in the absence of an external pressing force.
The second tool may be pressed against the first membrane so that at least part of a support surface of the second tool abuts the first membrane. Part of the support surface may be spaced from the first membrane.
The second tool may be supported on the pre-form and the first membrane during the first de-bulking phase. Accordingly, the second tool may apply a compression force through the membrane during the first de-bulking phase corresponding to the weight of the second tool.
Alternatively, the pressure load acting through the first membrane may result only from a difference in fluid pressure across the membrane caused by fluidically coupling the low pressure or vacuum source to the first sealed region. For example, the second tool may be spaced apart from the first membrane during the first de-bulking phase so that the pressure load applied on the pre-form through the first membrane for the first debulking phase is substantially uniform and results only from the difference in fluid pressure across the membrane.
The first sealed region may be fluidically decoupled from the respective low pressure or vacuum source before the second de-bulking phase. De-coupling the first sealed region from the low pressure or vacuum source may comprise fluidically coupling the first sealed region to ambient conditions (i.e. the gas surrounding the tool).
Alternatively, the first sealed region may remain fluidically coupled to the low pressure or vacuum source during the second phase, or a valve between the first sealed region and the low pressure or vacuum source may be closed for the second phase.
Pressing the second tool against the first membrane may comprise: applying a second membrane to define a second sealed region enclosing or partly defined by the second tool, and fluidically coupling a low pressure or vacuum source to the second sealed region so that a pressure load is applied on the second tool to press the second tool against the first membrane.
The second membrane may be applied over the first membrane and may seal with the second tool such that the second sealed region is at least partly defined by the second membrane and the second tool.
Alternatively, the second membrane may be applied over the second tool such that the second tool is disposed in the second sealed region. The first sealed region may be disposed in (or enclosed by) the second sealed region. The second sealed region may be defined between the second membrane and the first tool.
The low pressure or vacuum source may be the same for the first and second sealed regions, and wherein the method comprises switching from a first suction configuration in which the first sealed region is fluidically coupled to the low pressure or vacuum source to a second suction configuration in which the second sealed region is fluidically coupled to the low pressure or vacuum source.
The method may further comprise heating the pre-form during the first de-bulking phase and/or the second de-bulking phase. Heating may be conducted in an autoclave.
The method may further comprise switching from the first de-bulking phase to the second de-bulking phase whilst the first tool, pre-form and second tool are disposed in the autoclave. The duration of the first de-bulking phase may be at least 60 minutes, and the duration of the second de-bulking phase may be at least 60 minutes.
According to a second aspect of the invention there is provided a de-bulking assembly, comprising: a first tool and a second tool arranged to compress a pre-form therebetween; a pre-form received on the first tool; a first membrane disposed between the pre-form and the second tool, the first membrane being sealed over the pre-form to define a first sealed region; wherein the second tool is configured to move relative to the first tool to compress the pre-form therebetween in a de-bulking operation.
The de-bulking assembly may comprise a mechanical actuator, such as a hydraulic piston, for pressing the second tool against the first membrane and the pre-form.
Alternatively, the de-bulking assembly may further comprise a second membrane enclosing the second tool or sealing with the second tool to define a second sealed region such that, in use, fluidically coupling the second sealed region to a low pressure or vacuum source causes the second tool to move relative the first tool to compress the pre-form.
The de-bulking assembly may further comprise a low pressure or vacuum apparatus for fluidically coupling to the first sealed region and/or second sealed region. The debulking assembly may further comprise a controller for selectively fluidically coupling the first sealed region and/or the second sealed region to a low pressure or vacuum apparatus. The controller may be configured to switch from a first suction configuration in which the first sealed region is fluidically coupled to the low pressure or vacuum source to a second suction configuration in which the second sealed region is fluidically coupled to the low pressure or vacuum source.
The controller may be configured to fluidically couple the first sealed region to the low pressure or vacuum source so that a pressure load is applied on the pre-form through the first membrane for (or in) a first de-bulking phase; and subsequently to cause the second tool to move relative the first tool to compress the pre-form between the first tool and the second tool for (or in) a second de-bulking phase.
The controller may be configured to implement the first de-bulking phase for a duration of at least 60 minutes; and wherein the controller is configured to implement the second de-bulking phase for a duration of at least 60 minutes.
The de-bulking assembly may further comprise heating apparatus for heating the preform. The heating apparatus may comprise one or more heating elements thermally coupled to the first tool and/or second tool to heat the pre-form by conduction through the respective tool to the pre-form.
The pre-form may be a pre-form for a fan blade for a gas turbine engine..
The invention will now be described, by way of example, with reference to the following drawings, in which:
Figure 1 schematically shows a cross-sectional view of a previously-considered curing assembly;
Figure 2 schematically shows an exploded view of a de-bulking assembly according to the invention; and
Figure 3 schematically shows a cross-sectional view of the de-bulking assembly of Figure 2.
Figure 1 shows a previously-considered curing assembly for curing a pre-form 12 for a composite component between opposing first and second tools 18, 20 arranged in a closed-mould configuration.
In use, the pre-form 12 is received on the first tool 18 and comprises pre-preg fibrereinforcement material (such as carbon fibre) infused with matrix material (such as epoxy resin). Before curing, the pre-form is thicker than the desired thickness of the composite component since it includes a pre-form bulk. The thickness of the pre-form bulk is illustrated in Figure 1 as a region 16 of the pre-form sitting above a region corresponding to the desired thickness (or profile) of the component.
In this example, the pre-form 12 is for a composite fan blade and includes a relatively thick root section 22 and a relatively thin blade section 24. Since pre-form bulk tends to accumulate as a proportion of the desired thickness of the pre-form 12, the pre-form bulk 16 is correspondingly thicker (in absolute terms) in the root section 22 than in the blade section 24.
The first tool 18 has a first support surface 26 corresponding to the desired profile (or shape) for one side of the component, and the second tool 20 has an opposing second support surface 28 corresponding to the desired profile for the other side of the component. The first and second tools 18, 20 are arranged to oppose one another on opposite sides of the pre-form 12 and compress the pre-form 12 between them during a curing operation, so as to remove the pre-form bulk 16 and produce a component having the desired shape.
In this example, the pre-form 12 has been laid up on the first support surface 26 of the first tool 18, and so the underside of the pre-form 12 already corresponds to the first support surface 26. However, owing to the pre-form bulk 16, the upper side of the preform 12 does not correspond to the second support surface 28 of the second tool 20, as shown in Figure 1. In particular, since the absolute amount of pre-form bulk 16 varies along the pre-form 12 generally in dependence on the pre-form thickness, the second support surface 28 of the second tool 20 only engages the thickest section of the pre-form 12 (i.e. at the root). This results in other portions of the second support surface 28 being spaced apart from the pre-form 12, such as over the blade section 24.
Whilst the pre-form bulk 16 can be removed during cure, the applicant has found that curing with a closed-mould configuration as shown can result in undesirable forming defects. In particular, as the pre-form 12 is heated and the matrix material becomes viscous, compression of the root section 22 of the pre-form may cause the matrix and/or the reinforcement material to flow along the blade from the root section 22 towards the blade section 24. This may result in wrinkles and an undesired distribution of material in the cured component.
A de-bulking assembly and method of de-bulking a composite component will now be described, by way of example, with reference to Figures 2 and 3.
Figure 2 shows a de-bulking assembly 100 according to the invention comprising a first tool 118 and a second tool 120 arranged in a closed-mould configuration, a preform 112 disposed between the tools 118, 120 and a first membrane disposed between the pre-form 112 and the second tool 120. The first tool 118 and the second tool 120 are similar to the first and second tools 12, 18 described above.
In this example embodiment the pre-form 112 and tools 118, 120 are configured to form a fan blade for a gas turbine engine, although the method and arrangement of the de-bulking assembly is more generally applicable.
The first tool 118 comprises a generally planar base 130 and a die 132 mounted on the base 130 and defining the first support surface 126 for the component, which in this embodiment corresponds to the suction side of the fan blade. The die 132 also includes side walls 134 for supporting the sides of the pre-form 112, including the leading edge and trailing edges of the fan blade. In this embodiment the first tool 118 is composed of nickel-iron alloy, such as FeNi36, known as Invar®. In other embodiments, the die 132 may include one or more supporting side walls for additional side walls, including the root and tip side walls of the component.
The first support surface 126 defines a root region 136 which is recessed or deeper with respect to a blade region 138 so as to correspond to the desired thickness profile of the composite component, which has a thick root section and a thin blade region.
The first support surface 126 is curved between the root region 136 and blade region 138.
The second tool 120 is disposed above the first tool 118 and defines a second support surface 128 which opposes the first support surface 126. In this embodiment the second support surface 128 mirrors the first support surface 126 as the example component has a symmetrical profile. In other embodiments, the component may not have a symmetrical profile. The second tool 120 is in the form of a profiled sheet of material, in this particular example a silicone rubber (such as Mosite #14206 silicone, available from Mosites Rubber Company, Inc of Texas, USA) which in this embodiment is approximately 1-2mm thick. In use, the second tool 120 rests on the pre-form 112 for the composite component, which itself is received on the first tool 118.
The first and second tools 118, 120 may be manufactured by casting, forging, milling, additive manufacture or any other suitable manufacturing process.
In use, the first tool 118 is provided and the pre-form 112 is received on the first support surface 126 of the first tool 118. In this example, the pre-form 112 is laid up onto the first tool 118 by applying a plurality of successive plies of pre-preg fibre reinforcement material onto the first support surface 126. In this example, the pre-form 112 is laid up using an automatic lay-up procedure, such as Automatic Tape Laying (ATL) or Automatic Fibre Placement (AFP). More fibre reinforcement material is applied to form the thicker root section 22 than the thinner blade section 24.
Once the pre-form 112 is laid up on the first tool 120, a first membrane 140 (also known as a vacuum bag or vacuum film) composed of silicone rubber is placed over the pre-form 112 and sealed with sealing tape 142 to the base 132 of the first tool 118 (as best shown in Figure 3). A first sealed region is thereby defined between the first tool 130 and the first membrane 140, which envelopes the pre-form 112 on the first tool 118.
The first membrane 140 is provided with an extraction port 144 which can be coupled to a low pressure or vacuum source, such as a vacuum pump, to remove gas from the first sealed region. In this particular example, the extraction port 144 is a conduit extending into the first sealed region from outside the first sealed region, such as a conduit lying along the base 130. The first membrane 140 may be placed over the preform 112 and first tool 118 so that it’s edge forms a seal with the first tool 130 and over a portion of the conduit, as shown in Figure 3. There may be a plurality of such extraction ports. Alternatively, or in addition, there may be one or more extraction ports formed through the base 130 and/or 118, to remove gas from the first sealed region.
In other embodiments, one or more extraction ports may extend through the first membrane 140, rather than between the membrane 140 and the base 130.
The second tool 120 is placed over the first membrane 140 so that the second support surface 128 opposes the first support surface 126 of the first tool. The de-bulking assembly 100 is provided with an alignment mechanism (not shown) for aligning the first and second tools with respect to each other. The alignment mechanism is configured to allow longitudinal movement (i.e. vertical movement in Figure 1) of the second tool 120 towards the first tool 118 to compress the pre-form 112 therebetween, but to prevent relative lateral movement, thereby ensuring that the pre-form is formed into a component having the desired geometry.
A second membrane 146, similar to the first membrane 140, is placed over the second tool 120, first membrane 140, and the pre-form 112, and is coupled to the base 132 of the first tool 118 using sealing tape 142 as described above. Accordingly, a second sealed region is defined between the second membrane 146 and the base 132 that envelops the second tool 120, the first membrane 140 and the pre-form 112. The second membrane 146 is also provided with an extraction port 147 for extracting gas from the second sealed region. In this particular example, the extraction port 147 is in the form of a conduit extending into the second sealed region in a similar manner to the extraction port 144 described above. The conduit may lie along the base 130, or may be coupled to or integrally formed with the conduit forming the extraction port 144 for the first sealed region, as shown in Figure 3. As described above, there may be one or more extraction ports formed through the base 130 and arranged to communicate with the second sealed region (for example, arranged to form a peripheral region of ports around one or more ports for the first sealed region), such that gas may be removed from the second sealed region. Any such extraction ports in the base may be specifically designed for a component and associated first and second sealed regions, or may be provided in a matrix, with vacuum source apparatus coupled to appropriate ones of the ports corresponding to the two sealed regions.
A vacuum source 148 is provided and is coupled to the extraction ports 144, 147 for the first and second sealed regions via a control valve operated by a controller.
The first and second tools 118, 120, together with the pre-form 112 and the first and second membranes 140, 146 are placed in an autoclave. The vacuum source 148, control valve and controller may be disposed outside of the autoclave.
The controller causes the vacuum source 148 to be fluidically coupled to the first sealed region to extract gas from the first sealed region through the extraction port 144. This causes a pressure difference over the first membrane 140 between the ambient pressure within the autoclave (which may be atmospheric pressure or a different pressure) and the low pressure in the sealed region. The pressure difference acts uniformly over the first sealed membrane to apply an evenly-distributed compression force onto the pre-form 112 between the tools. Under this compression force and the elevated temperature in the autoclave, the pre-form 112 undergoes a first de-bulking phase by the consolidation of the fibre-reinforcement and matrix material and the removal of gas. Furthermore, the consolidation takes place relatively uniformly over the pre-form 112, and the fibre-reinforcement and matrix material tends not to flow from one section of the pre-form to another. In this example, the controller 152 controls the application of the vacuum source to the first sealed region and the temperature in the autoclave to conduct the first de-bulking phase for a period of 60 minutes. This period may be shorter or longer and depends on the materials used, the compression force and temperature. The period is determined so that there has been sufficient time for de-bulk to commence, but the material of the pre-form is still sufficiently pliable for its shape to change and conform to the second support surface 128 of the second tool 120, as will be described in detail below. During the first de-bulking phase the weight of the second tool 118 is supported on the first membrane and the pre-form.
After the predetermined period of time for the first de-bulking phase has completed, the controller 152 initiates a second de-bulking phase by causing the control valve to switch over from a first suction configuration, in which the extraction port 144 for the first sealed region is coupled to the vacuum source, to a second suction configuration, in which the extraction port 147 for the second sealed region is coupled to the vacuum source.
The extraction of gas from the second sealed region causes a pressure difference over the second membrane 146 (as described above with respect to the first sealed region), which causes the second tool 120 to move closer to the first tool 118 along the longitudinal direction so that it is pressed against the first membrane 140 and the preform 112. The controller maintains the pressure difference for at least 60 minutes so that the remaining pre-form bulk is removed and the pre-form 112 conforms to the shape of the second support surface 128, as shown in Figure 3.
Once the second de-bulking phase is completed, the controller causes the vacuum source to be fluidically de-coupled from the second sealed region (and the first sealed region), and the first and second tools 118, 120, pre-form 112 and first and second membranes 140, 146 are removed from the autoclave. The second membrane 146 is subsequently removed from the de-bulking assembly and the second tool 120 is lifted from de-bulking assembly 100 to reveal the first membrane 140. The first membrane 140 is also removed so that the de-bulked component can be removed from the first tool 118. In this embodiment, the first and second de-bulking phases are controlled so that the component is fully cured during the two phases. Accordingly, the cured component can be removed from the first tool 118 following the second de-bulking phase. In other embodiments, there may be a further curing phase following the first and second de-bulking phases, which may use the same apparatus or a different apparatus.
Although an example method has been described in which the tools and pre-form are placed in an autoclave, it will be appreciated that in other embodiments an autoclave may not be used and heaters may be provided for heating the pre-form, for example, by conduction to the pre-form through the first and second tools.
Although an example embodiment has been described in which the second membrane is disposed over the second tool, it will be appreciated that in other embodiments the second membrane may seal with the second tool such that the second sealed region is at least partly defined by the second tool.
Claims (21)
1. A method of de-bulking a pre-form for a composite component comprising: providing a pre-form for the composite component on a first tool;
applying a first membrane over the pre-form to seal the pre-form in a first sealed region;
fluidically coupling a low pressure or vacuum source to the first sealed region so that a pressure load is applied on the pre-form through the first membrane for a first debulking phase; and subsequently pressing a second tool against the first membrane to compress the pre-form between the first tool and the second tool for a second de-bulking phase.
2. A method according to claim 1, wherein the second tool is supported on the preform and the first membrane during the first de-bulking phase.
3. A method according to claim 1, wherein the pressure load acting through the first membrane results only from a difference in fluid pressure across the membrane caused by fluidically coupling the low pressure or vacuum source to the first sealed region.
4. A method according to any preceding claim, wherein the first sealed region is fluidically decoupled from the respective low pressure or vacuum source before the second de-bulking phase.
5. A method according to any preceding claim, wherein pressing the second tool against the first membrane comprises:
applying a second membrane to define a second sealed region enclosing or partly defined by the second tool, and fluidically coupling a low pressure or vacuum source to the second sealed region so that a pressure load is applied on the second tool to press the second tool against the first membrane.
6. A method according to claim 5, wherein the second membrane is applied over the second tool such that the second tool is disposed in the second sealed region.
7. A method according to any of claims 5 or 6, wherein the low pressure or vacuum source is the same for the first and second sealed regions, and wherein the method comprises switching from a first suction configuration in which the first sealed region is fluidically coupled to the low pressure or vacuum source to a second suction configuration in which the second sealed region is fluidically coupled to the low pressure or vacuum source.
8. A method according to any preceding claim, further comprising heating the preform during the first de-bulking phase and/or the second de-bulking phase.
9. A method according to claim 8, wherein heating is conducted in an autoclave.
10. A method according to claim 9, further comprising switching from the first debulking phase to the second de-bulking phase whilst the first tool, pre-form and second tool are disposed in the autoclave.
11. A method according to any preceding claim, wherein the duration of the first debulking phase is at least 60 minutes, and wherein the duration of the second de-bulking phase is at least 60 minutes.
12. A de-bulking assembly, comprising:
a first tool and a second tool arranged to compress a pre-form therebetween; a pre-form received on the first tool;
a first membrane disposed between the pre-form and the second tool, the first membrane being sealed over the pre-form to define a first sealed region;
wherein the second tool is configured to move relative to the first tool to compress the pre-form therebetween in a de-bulking operation.
13. A de-bulking assembly according to claim 12, further comprising a second membrane enclosing the second tool or sealing with the second tool to define a second sealed region such that, in use, fluidically coupling the second sealed region to a low pressure or vacuum source causes the second tool to move relative the first tool to compress the pre-form.
14. A de-bulking assembly according to claim 12 or 13, further comprising a low pressure or vacuum apparatus for fluidically coupling to the first sealed region and/or second sealed region.
15. A de-bulking assembly according to any of claims 12 to 14, further comprising a controller for selectively fluidically coupling the first sealed region and/or the second sealed region to a low pressure or vacuum apparatus.
16. A de-bulking assembly according to claim 15, wherein the controller is configured to switch from a first suction configuration in which the first sealed region is fluidically coupled to the low pressure or vacuum source to a second suction configuration in which the second sealed region is fluidically coupled to the low pressure or vacuum source.
17. A de-bulking assembly according to claim 15 or 16, wherein the controller is configured to fluidically couple the first sealed region to the low pressure or vacuum source so that a pressure load is applied on the pre-form through the first membrane for a first de-bulking phase; and subsequently to cause the second tool to move relative the first tool to compress the pre-form between the first tool and the second tool for a second de-bulking phase.
18. A de-bulking assembly according to claim 17, wherein the controller is configured to implement the first de-bulking phase for a duration of at least 60 minutes; and wherein the controller is configured to implement the second de-bulking phase for a duration of at least 60 minutes.
19. A de-bulking assembly according to any of claims 12 to 16, further comprising heating apparatus for heating the pre-form.
20. A method of de-bulking a pre-form for a composite component in accordance with claim 1 and substantially as described herein.
21. A de-bulking assembly substantially as described herein.
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Application No: GB1619077.9 Examiner: Miss Evelyn Toalster
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1619077.9A GB2556043A (en) | 2016-11-11 | 2016-11-11 | A method of de-bulking a pre-form for a composite component |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1619077.9A GB2556043A (en) | 2016-11-11 | 2016-11-11 | A method of de-bulking a pre-form for a composite component |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2556043A true GB2556043A (en) | 2018-05-23 |
Family
ID=62043345
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1619077.9A Withdrawn GB2556043A (en) | 2016-11-11 | 2016-11-11 | A method of de-bulking a pre-form for a composite component |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2556043A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2020007916A1 (en) * | 2018-07-04 | 2020-01-09 | Rolls-Royce Plc | Method and tool set for manufacturing a composite component |
| CN113490583A (en) * | 2019-03-27 | 2021-10-08 | 赛峰飞机发动机公司 | Tool for preforming a fiber preform and method for preforming a fiber preform |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0319895A2 (en) * | 1987-12-07 | 1989-06-14 | The Boeing Company | Method for debulking partially precured thermoplastic composite laminae |
| US6484776B1 (en) * | 2000-04-07 | 2002-11-26 | Northrop Grumman Corporation | System for constructing a laminate |
| US20050183818A1 (en) * | 2004-02-25 | 2005-08-25 | Zenkner Grant C. | Apparatus and methods for processing composite components using an elastomeric caul |
| US20060017200A1 (en) * | 2004-07-26 | 2006-01-26 | Cundiff Thomas R | Methods and systems for manufacturing composite parts with female tools |
| WO2009044194A2 (en) * | 2007-10-04 | 2009-04-09 | Airbus Uk Limited | Method of moulding a charge |
-
2016
- 2016-11-11 GB GB1619077.9A patent/GB2556043A/en not_active Withdrawn
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0319895A2 (en) * | 1987-12-07 | 1989-06-14 | The Boeing Company | Method for debulking partially precured thermoplastic composite laminae |
| US6484776B1 (en) * | 2000-04-07 | 2002-11-26 | Northrop Grumman Corporation | System for constructing a laminate |
| US20050183818A1 (en) * | 2004-02-25 | 2005-08-25 | Zenkner Grant C. | Apparatus and methods for processing composite components using an elastomeric caul |
| US20060017200A1 (en) * | 2004-07-26 | 2006-01-26 | Cundiff Thomas R | Methods and systems for manufacturing composite parts with female tools |
| WO2009044194A2 (en) * | 2007-10-04 | 2009-04-09 | Airbus Uk Limited | Method of moulding a charge |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2020007916A1 (en) * | 2018-07-04 | 2020-01-09 | Rolls-Royce Plc | Method and tool set for manufacturing a composite component |
| US12083751B2 (en) | 2018-07-04 | 2024-09-10 | Rolls-Royce Plc | Method and tool set for manufacturing a composite component |
| CN113490583A (en) * | 2019-03-27 | 2021-10-08 | 赛峰飞机发动机公司 | Tool for preforming a fiber preform and method for preforming a fiber preform |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |