JP6392595B2 - System and method for compressing the charge of a composite material - Google Patents

Description

  The present invention relates generally to systems and methods for compressing composite charges, and more particularly to systems and methods utilizing a reusable vacuum compression apparatus to compress composite charges.

  Assembling the composite structure involves placing the composite charge on a layup mandrel, and then compressing the composite charge on the layup mandrel to form a compressed composite charge and a layup mandrel. Forming an intermediate structure comprising: Compression reduces the thickness of the composite load, removes gaps from the interior of the composite load, and bonds between multiple layers or plies that may be present inside the composite load Increasing the adhesion between the composite charge and the layup mandrel, increasing the adhesion between the composite charge and the material that may already be present on the layup mandrel, and / or Intermediate structures for further processing can be created in other ways.

  Historically, compression has been achieved by a “bagging” process in which a composite load and a portion of a layup mandrel are covered with a thin flexible polymer sheet. The polymer sheet is then fastened to the layup mandrel to insulate (or at least substantially insulate) the enclosed space from communication with the surrounding environment. Thereafter, a vacuum is applied to the enclosed space, the pressure in the enclosed space is reduced, and the atmospheric pressure acts on the composite material to compress the composite material.

  The above-described method may be effective in compressing composite charges, but requires the polymer sheets to be individually adapted and time consuming that the polymer sheets need to be multi-tasked to lay-up mandrels, This process is laborious and requires a large amount of material. In addition, the compression of the composite load onto the surface of the layup mandrel (such as the inner surface of the layup mandrel) may prevent the contamination of existing materials that may be present on the surface of the layup mandrel. It may require an overly large polymer sheet that extends to the periphery or periphery, extends beyond the periphery or periphery, and / or extends to the vicinity of the periphery or periphery, and / or a correspondingly long tape. May be required. Accordingly, a need exists for improved systems and methods for compressing composite charges.

  Systems and methods for compressing composite charges. These systems and methods can utilize a vacuum compression apparatus to compress the composite charge on the support surface. The vacuum compression device may be reusable and may be configured to define an enclosed space when placed on the support surface and compressed between the barrier structure and the support surface and the barrier structure. And a sealing structure configured to form a fluid seal when in contact. Further, the vacuum compression apparatus may include a vacuum distribution manifold that communicates with the enclosed space and is configured to selectively apply a vacuum to the enclosed space. By applying a vacuum to the enclosed space, the pressure in the enclosed space is reduced, and the vacuum compression apparatus is moved from the pre-deformation configuration to the post-deformation configuration, thereby loading the composite material on the support surface. Things can be compressed.

  In some embodiments, the barrier structure may be at least substantially planar when the vacuum compression device is in a pre-deformation configuration and of the support surface when the vacuum compression device is in a post-deformation configuration. It can at least partially match the outer shape. In some embodiments, the barrier structure can define a plurality of exhaust passages that provide communication between the vacuum distribution manifold and the enclosed space. In some embodiments, the barrier structure is configured to retain a composite charge on the first surface of the barrier structure prior to compression of the composite charge on the support surface. Can be further determined. In some embodiments, the barrier structure can comprise a double-walled panel that defines a plurality of elongated channels, and / or can be such a double-walled panel.

  In some embodiments, the support surface comprises a layup mandrel. In some embodiments, the support surface comprises a composite material charge that has been previously compressed.

FIG. 2 is an illustrative example of an aircraft with a composite structure that can be formed using the system and method according to the present invention, but is not limited thereto. FIG. 3 is an illustrative example of but not limited to a fuselage trunk comprising a composite structure that can be formed using the system and method according to the present invention. FIG. 2 is a schematic cross-sectional view of an illustrative example (but not limited to) a vacuum compression apparatus according to the present invention, the vacuum compression apparatus not yet disposed on a support surface. It is a schematic bottom view of the vacuum compression apparatus of FIG. FIG. 4 is a schematic cross-sectional view of the vacuum compression device of FIG. 3, and the vacuum compression device is arranged on a support surface but has a configuration before deformation. FIG. 4 is a schematic cross-sectional view of the vacuum compression apparatus of FIG. 3, where the vacuum compression apparatus is disposed on the support surface, has a deformed configuration, and compresses the composite material load. FIG. 4 is a schematic cross-sectional view of the vacuum compression apparatus of FIG. 3, where the vacuum compression apparatus finishes compressing the composite material charge, returns to the pre-deformation configuration, and is separated from the support surface. FIG. 2 is a schematic cross-sectional view of an illustrative example (but not limited to) a vacuum compression apparatus according to the present invention that compresses a composite load on a convex surface. FIG. 2 is a schematic cross-sectional view of an illustrative example (but not limited to) a vacuum compression apparatus according to the present invention that compresses composite load on a concave surface. Schematic cross-sectional view of an illustrative example (but not limited to) a vacuum compression apparatus according to the present invention in close contact with a support surface defined at least in part by a pre-compressed composite load It is. FIG. 3 is a schematic diagram of a portion of an illustrative example of a barrier structure that can be utilized in the systems and methods according to the present invention, but is not limited thereto. FIG. 2 is a flow diagram illustrating a method according to the present invention for compressing a composite charge. It is a flowchart of the method of manufacture and maintenance inspection of an aircraft. 1 is a block diagram of an aircraft.

  FIGS. 1-11 illustrate illustrative but not all examples of composite structure 800, composite structure manufacturing assembly 20, and / or its components in accordance with the present invention. In each of FIGS. 1-11, components that serve similar or at least substantially similar purposes are numbered similarly, and these components are associated with each of FIGS. Detailed discussions herein may be omitted. Similarly, not all components are numbered with reference numbers in each of FIGS. 1-11, but reference numbers combined with components may still be used consistently herein. it can. In general, components that are likely to be included in a given embodiment are shown as solid lines, while components that are optional for a given embodiment are shown as dashed lines. However, components shown in solid lines are not essential for all embodiments, and components shown in solid lines are omitted from certain embodiments without departing from the scope of the present invention. can do.

  FIG. 1 is an illustrative example (but not all) of an aircraft 700 comprising a composite structure 800 that can be formed using the systems and methods according to the present invention, and FIG. FIG. 5 is an illustrative example (but not all) of a fuselage barrel 730 that can form part and is provided with a composite structure 800. The aircraft 700 and / or the composite structure 800 of the aircraft 700 can include a plurality of skin portions 790, which can form the outer surface of any suitable portion of the aircraft 700, and The outer surface of a suitable portion can be covered and / or can be the outer surface of any suitable portion of aircraft 700. As most clearly shown in FIG. 2, the aircraft 700 can further include a plurality of longitudinal members 770 that can support the inner surface 792 of the skin portion 790 in cooperation with a plurality of frames 780. The plurality of fillers 760 can extend between the frame 780 and the inner surface 792 and can form part of the composite structure 800.

  It is within the scope of the present invention that any suitable portion of aircraft 700 may be formed from composite structure 800 and / or any suitable portion of aircraft 700 may be composite structure 800. As an illustrative example (but not limited to), the composite structure 800 may form a fuselage 710, fuselage 720, fuselage fuselage 730, wing 740, and / or stabilizer 750 of an aircraft 700, or a portion thereof. Can be formed.

  3-7 are illustrative of a vacuum compression apparatus 100 according to the present invention that can be utilized in and / or form part of a composite structure manufacturing assembly 20. A schematic cross-sectional view of an example of (but not limited to) is shown. The vacuum compression apparatus 100 of FIGS. 3-7 includes a barrier structure 110 having a first surface 114 and an opposite second surface 118. The vacuum compression apparatus 100 further includes a vacuum distribution manifold 140. The vacuum distribution manifold 140 communicates with the first surface 114 of the barrier structure 110 via a plurality of exhaust passages 122 that can be defined in the barrier structure 110 to selectively apply vacuum to the plurality of exhaust passages 122. It is configured to apply to. The vacuum compression apparatus 100 can be located between the barrier structure 110 and the support surface 200, can be located on the first surface 114 of the barrier structure 110, and / or is the first of the barrier structure 110. A seal structure 170 that may be operatively attached to the surface 114 may further be provided. Seal structure 170 is configured to form a fluid seal between barrier structure 110 and support surface 200 when compressed between barrier structure 110 and support surface 200.

  As shown in FIGS. 5 and 6, the vacuum compression device 100 and the support surface 200 can cooperatively define a space 250 that is enclosed when the vacuum compression device 100 is disposed on the support surface 200. Under these circumstances, the vacuum distribution manifold 140 communicates with the enclosed space 250 via the exhaust passage 122 and selectively applies a vacuum to the enclosed space 250 to reduce the pressure of the enclosed space 250. Configured to apply.

  As shown by the dashed lines in FIGS. 3-7, the barrier structure 110 may further define a plurality of retention paths 126, which are defined by the second vacuum distribution manifold 144 (herein). In some cases, referred to as a holding manifold 144) and the first surface 114 of the vacuum compression apparatus 100. Furthermore, the composite structure manufacturing assembly 20 generates a vacuum 152 that can be applied to the exhaust passage 122 by the vacuum distribution manifold 140 and / or the retention passage 126 by the second vacuum distribution manifold 144 as shown by the dashed line. A vacuum source 150 configured to generate a vacuum 152 that can be applied to and / or in communication with such a vacuum source 150. Where the barrier structure 110 defines both the exhaust passage 122 and the retention passage 126, the vacuum distribution manifold 140 may also be referred to herein as the first vacuum distribution manifold 140 and / or the exhaust manifold 140.

  As further indicated by the dashed line, the vacuum compression device 100 aligns and positions the vacuum compression device 100 relative to the support surface 200 when the vacuum compression device 100 is placed on the support surface 200, and And / or one or more indexing structures 180 configured to be positioned in other ways. Similarly, the support surface 200 may be coupled to and receive the indexing structure 180 and / or received by the indexing structure 180 when the vacuum compression apparatus 100 is placed in the correct position on the support surface 200. A plurality of counterpart indexing structures 210 configured as shown in FIG.

  As shown in FIG. 3 and described in more detail herein in connection with the method 400 of FIG. 11, a composite charge 810 is disposed between the vacuum compression apparatus 100 and the support surface 200. Can be done. This may include placing the load 810 on the support surface 200 as indicated by reference numeral 814 and / or placing the load 810 on the first surface 114 of the barrier structure 110 as indicated by reference numeral 818. Placing can include one, two, three, four, five, ten, or more of the composite materials between the vacuum compression apparatus 100 and the support surface 200. It is within the scope of the present invention to include disposing any suitable number of charges 810 of a composite material, such as a charge of.

  If the load 810 is placed on the support surface 200, the alignment jig 214 may be used to accurately place the load 810 on the support surface 200 and / or any suitable structure, such as the indexing structure 210. It can be used to accurately position the object and / or its shape. Further, an adhesive 820 can be disposed between the support surface and the composite load 810. This may include placing the adhesive 820 on the support surface 200 before placing the load 810 on the support surface 200 and / or placing the adhesive 820 on the support surface 200 prior to placing the load 810 on the support surface 200. Arranging on the load 810 can be included.

  When the load 810 is disposed on the first surface 114 of the barrier structure 110, a vacuum can be applied to the retention path 126 to hold the load 810 on the first surface 114. As shown in FIG. 4, which is a schematic bottom view of the vacuum compression apparatus 100 of FIG. 3, the retention path 126 is such that the load 810 is positioned above the retention path 126 and / or the load 810 is It can arrange | position so that the holding path 126 may be covered. In this way, when a vacuum is applied to the retention path 126, the vacuum locally reduces the pressure in the region between the first surface 114 and the load 810 and blocks the composite load 810. It can be held on the first surface 114 of the structure 110.

  After placing the load 810 between the vacuum compression device 100 and the support surface 200, the vacuum compression device 100 is placed on the support surface 200 to define an enclosed space 250, as shown in FIG. Can be done. This may include aligning the vacuum compression apparatus 100 with the support surface 200, for example by using indexing structures 180 and 210.

  It is within the scope of the present invention that placement can be achieved in any suitable manner. As an illustrative example (but not limited to), placement can include manual placement of vacuum compression device 100 and / or automatic placement of vacuum compression device 100. If the vacuum compression device 100 is automatically placed on the support surface 200, the automatic placement structure 190, such as the assembly robot 194, may place the vacuum compression device 100 on the support surface 200 and / or the load. It can be programmed to position 810 in a desired area of the support surface 200. The self-placement structure 190 is programmed to compress any suitable number of loads 810 of composite material on the support surface 200 using any of the methods 400 described in further detail herein. Can do.

  After the vacuum compression apparatus 100 is placed on the support surface 200, the pressure in the enclosed space 250 can be reduced, as shown in FIG. This may include selectively applying a vacuum from the vacuum source 150 to the enclosed space 250, for example via the vacuum distribution manifold 140 and / or the exhaust passage 122. The decrease in pressure in the enclosed space 250 creates a pressure differential across the vacuum compression device 100 and can exert a force F due to atmospheric pressure that can act on and / or be applied to the vacuum compression device 100. Can be generated.

  The force due to the atmospheric pressure is applied to the vacuum compression apparatus 100, so that the vacuum compression apparatus 100 is changed from the configuration 104 before deformation shown in, for example, FIGS. 3 to 5 and FIG. 10 may result in the vacuum compression device 100 and / or the barrier structure 110 of the vacuum compression device 100 being between the vacuum compression device 100 and the support surface 200. The charge 810 is compressed to produce a compressed charge 812 of the composite material. This compression may include a plurality of composites that may include the load 810 to remove gaps from the load 810, such as to remove air from the load 810, such as to reduce the thickness of the load 810. Compression and / or support of the load 810 against the support surface 200 to increase the interlayer adhesion between the plies and / or to increase the bond between the load 810 and the support surface 200. It can function as a driving force for compression on the surface 200.

  Following compression of the load 810 on the support surface 200, the pressure in the enclosed space 250 can be increased. This may include stopping the application of the vacuum 152 from the vacuum source 150 to the enclosed space 250 and / or bleed gas flow 162 (shown in dashed lines) to the enclosed space 250, for example via the bleed valve 160. As provided) can be included. By increasing the pressure of the enclosed space 250, the force F caused by the atmospheric pressure can be reduced and / or eliminated, and the vacuum compression apparatus 100 can be configured before deformation as shown in FIG. 104 can be returned. The vacuum compression apparatus 100 can then be separated from the support surface 200 as also shown in FIG. However, the compressed charge 812 can remain on the support surface 200.

  This process can be repeated any suitable number of times to form at least a portion of the composite structure 800 by compressing any suitable number of charges 810 of the composite material on the support surface 200. Further, the automatic placement structure 190 may be programmed to control the operation of the vacuum source 150, can control the operation of the bleed valve 160, and the vacuum from the vacuum source 150 to the vacuum distribution manifold 140 and / or 144. And / or can include a portion of a control system 198 that can control the flow of the bleed flow 162, and can be in communication with a portion of such a control system 198, and Alternatively, part of such a control system 198 can be formed. This can include control using any of the methods 400 described herein.

  It is within the technical scope of the present invention that the vacuum compression device 100 may be a reusable vacuum compression device 100. Accordingly, the vacuum compression apparatus 100 is configured, set, designed, selected, and / or re-used (or used multiple times) to compress a plurality of composite loads 810 on the support surface 200. Or can be constructed. In addition, or alternatively, the vacuum compression device 100 (any vacuum compression device or any suitable component of the vacuum compression device) may be deformed multiple times without causing damage to the vacuum compression device 100. Configuration, setting to move between configuration 104 and deformed configuration 108 and / or compress composite loads 810 on support surface 200 without damaging vacuum compression apparatus 100 Can be designed, selected, and / or constructed.

  After compressing the target or desired number of charges 810 on the support surface 200, the composite structure 800 formed from the composite charge 810 and / or including the composite charge 810 includes: Further processing can be performed prior to completion of the composite structure 800. As an illustrative example (but not limited to), the composite structure 800 can be cured. As another illustrative example (but not limited to), a layup mandrel that can form at least a portion of the support surface 200 and / or can support at least a portion of the plurality of loads 810 ( layup mandrel) 202 can be removed from the composite structure 800 and / or separated from the composite structure 800.

  More generally from FIG. 3 to FIG. 7, the barrier structure 110 can be configured to define an exhaust passage 122, a retention passage 126, a first surface 114, and / or a second surface 118. . Further, the barrier structure 110 can function as an at least partial barrier and / or at least partially against fluid flow between the enclosed space 250 and the surrounding environment surrounding the vacuum compression apparatus 100. Can be an effective barrier.

  The barrier structure 110 can include and / or define any suitable shape, form, contour, and / or profile. As an illustrative example (but not limited to), the barrier structure 110 may be a plane that may be defined, for example, by the first surface 114 and / or the second surface 118 at least in the configuration 104 prior to deformation. Or at least substantially planar form, shape, contour, and / or profile can be defined.

  As a further illustrative example (but not limited to), as will be described in more detail herein with reference to FIG. 11, the barrier structure 110, the first planar wall 130, and the second Defined by a plurality of planar walls 132 and a plurality of elongated webs 134 extending between the first planar walls 130 and the second planar walls 132 and defining a plurality of elongated channels 136. it can. Where the barrier structure 110 defines an elongated channel 136, at least a portion of the elongated channel can be in communication with the exhaust path 122 and / or the retention path 126. In addition or alternatively, a portion of the elongated channel 136 may form part of the vacuum distribution manifold 140 and / or the second vacuum distribution manifold 144.

  In addition or alternatively, the barrier structure 110 may include any suitable material and / or may be formed from any suitable material. As an illustrative example (but not limited to), the barrier structure 110 may include a flexible material and / or an elastic material and / or from a flexible material and / or an elastic material. May be formed. As a further illustrative example (but not limited to), the barrier structure 110 may be used to visualize the load 810 and / or the support surface 200 when the vacuum compression device 100 is placed on the support surface 200. Optically transmissive materials, translucent materials, and / or translucent materials may be included and / or formed from such materials so that inspection can be performed. As a further illustrative example (but not limited to), the barrier structure 110 may be formed from a polymeric material and / or a polycarbonate material and / or the barrier structure 110 may be a polymeric material and A polycarbonate material may be included.

  Further, as indicated by dashed lines in FIGS. 3-7, the first surface 114 of the barrier structure 110 can include a release surface 116 and / or the first surface 114 of the barrier structure 110. Can be defined by the release surface 116. The release surface 116 may prevent adhesion or possible adhesion between the load 810 and the barrier structure 110, chemical reaction between the load 810 and the barrier structure 110, and / or contamination of the load 810 by the barrier structure 110. It can be configured and / or selected to reduce. It is within the scope of the present invention that release surface 116 can be fabricated from any suitable material including the same material as barrier structure 110 or a different material from barrier structure 110. Illustrative examples (but not limited to) of materials that can make up the release surface 116 include chemically inert materials such as fluoropolymers.

  The vacuum distribution manifold 140 and / or the second vacuum distribution manifold 144 (sometimes referred to herein as the vacuum distribution manifolds 140 and 144) includes an exhaust path 122 and / or a holding path 126 and a vacuum source 150. Any suitable structure configured to selectively provide communication between and / or may be included. As shown in FIGS. 3 and 5-7 and described herein, at least a portion of the vacuum distribution manifold 140 and / or 144 may be defined by the barrier structure 110, and / or within the barrier structure 110. It is included in the technical scope of the present invention. As an illustrative example (but not limited to), an elongate channel 136 may define a portion of the vacuum distribution manifold 140 and / or 144. However, at least a portion of the vacuum distribution manifold 140 and / or 144 may be separated from the barrier structure 110 and / or as shown by the dashed lines separating the manifolds 140 and 144 from the barrier structure 110 and / or the barrier structure. It may be different from 110 and is also included in the technical scope of the present invention.

  Further, the vacuum distribution manifolds 140 and / or 144 can comprise any suitable additional structure. As an illustrative example (but not limited to), at least one of the vacuum distribution manifolds 140 and / or 144 may include the vacuum distribution manifold 140 and / or 144 and / or the enclosed space 250. A pressure detector 146 configured to detect pressure may be provided. As another illustrative example (but not limited to), at least one of the vacuum distribution manifolds 140 and / or 144 may apply a vacuum from the vacuum source 150 to the vacuum distribution manifolds 140 and / or 144. , A vacuum control structure 148 such as a valve that may be configured to selectively add to the exhaust path 122, the retention path 126, and / or the enclosed space 250. If the vacuum distribution manifold 140 and / or 144 includes a vacuum control structure 148, it is within the scope of the present invention that the vacuum control structure 148 can be operated in any suitable manner. As an illustrative example (but not limited to), the vacuum control structure 148 can be manually activated. As another illustrative example (but not limited to), the vacuum control structure 148 may be automatically used, for example, via the control system 198 and / or using the method 400 described herein. Can be operated.

  The seal structure 170 may comprise any suitable structure that can form a fluid seal between the barrier structure 110 and the support surface 200 when the vacuum compression apparatus 100 is disposed on the support surface 200. it can. As an illustrative example (but not limited to), seal structure 170 may be an elastic material, a polymer material, latex, and / or urethane illustrative example (but not limited to). May include and / or may be a compression seal, an elastic seal, and / or a tubular elastic seal that may be formed from any suitable material. This can include materials that do not adhere to the support surface 200, do not chemically react with the support surface 200, and / or do not move contaminants to the support surface 200.

  Further, the seal structure 170 can be arranged and / or configured in any suitable manner that can allow the formation of a fluid seal in the vacuum compression apparatus 100. As an illustrative example (but not limited to), the seal structure 170 can be disposed between the barrier structure 110 and the support surface 200. As another illustrative example (but not limited to), the seal structure 170 can be disposed and / or operatively attached to the first surface 114 of the barrier structure 110.

  It is contemplated that the seal structure 170 can be configured to reversibly compress and / or deform when forming a fluidic seal between the barrier structure 110 and the support surface 200. Included in the technical scope. Accordingly, the seal structure 170 can include and / or define a pre-deformation thickness 172 when the vacuum compression apparatus 100 is in the pre-deformation configuration 104 (as shown in FIG. 5). When the vacuum compression apparatus 100 is in the deformed configuration 108 (as shown in FIG. 6), a deformed thickness 174 can be provided and / or defined. As further illustrated in FIGS. 5 and 6, the deformed thickness 174 may be less than the undeformed thickness 172. This deformation of the seal structure 170 when compressed between the barrier structure 110 and the support surface 200 (such as when the pressure in the enclosed space 250 is reduced) is between the barrier structure 110 and the support surface 200. Fluid sealing can be improved, provided, and / or formable.

  As shown in FIGS. 5 and 6, the enclosed space 250 can be bounded and / or defined by the support surface 200 and the first surface 114 of the barrier structure 110. Further, as also illustrated, the seal structure 170 can bound, define and / or form the outer edge of the enclosed space 250. This can be achieved by surrounding the enclosed space 250 with a continuous length seal structure 170, as shown in FIG.

  The support surface 200 can include any suitable surface that can receive the composite load 810 and / or can define at least a portion of the enclosed space 250. As an illustrative example (but not limited to), the support surface 200 is an inner mold line configured to define the shape, profile, and / or profile of the composite structure 800 that can be formed from the load 810. A layup mandrel 202 such as an (inner mold line) layup mandrel and / or an outer mold line layup mandrel may be included. Accordingly, the seal structure 170 can be configured to form a fluidic seal between the layup mandrel 202 and the barrier structure 110.

  As another illustrative example (but not limited to), the formation of composite structure 800 may be performed on composite material on layup mandrel 202 prior to compression of a given composite charge 810. Compressing a plurality of charges 810 to produce a plurality of compressed charges 812 of a composite material (sometimes referred to herein as previously compressed charges 812). Can do. It is within the scope of the present invention that a given charge of composite material 810 can be compressed at a location away from a plurality of previously compressed charges 812. Under such circumstances, the support surface 200 for a given load of composite material 810 may be a layup mandrel 202, and a given load may be compressed into the layup mandrel 202, And / or a seal structure 170 may form a fluid seal between the layup mandrel 202 and the barrier structure 110.

  Additionally or alternatively, a given charge of composite material 810 is adjacent and / or adjacent to at least one of the plurality of previously compressed charges 812 and / or a plurality of charges. It is within the scope of the present invention that it can be compressed at locations including at least one of the previously compressed charges 812. This can occur when a given load 810 is configured to abut, abut and / or overlap at least one of the plurality of previously compressed loads 812. Under such circumstances, the support surface 200 can further include one or more pre-compressed loads 812 and / or one or more pre-compressed loads 812, Often, at least a portion of a given charge 810 can be compressed into one or more pre-compressed charges 812 and / or the seal structure 170 can be a pre-compressed charge of composite material. It can be configured to form a fluid seal between the object 812 and the barrier structure 110.

  As described above, the composite load 810 can be compressed on the support surface 200 to form at least a portion of the composite structure 800. Illustrative examples of composite structure 800 in accordance with the present invention include, but are not limited to, any suitable aircraft 700, a portion of aircraft 700, fuselage 710, fuselage 720, fuselage fuselage 730, wing 740, And / or a stabilizer 750. As an illustrative example of but not limited to a load 810, any suitable filler 760, stringer 770, and / or skin portion 790 that can form part of the composite structure 800 include Can be mentioned.

  The composite load 810 may be referred to herein as a composite mass 810, a composite volume 810, and / or a composite patch 810, and may comprise any suitable structure. it can. As an illustrative example (but not limited to), the load 810 can include at least one ply of composite material. As another illustrative example (but not limited to), the load 810 is a stack of at least 2, at least 3, at least 4, at least 5, at least 10, at least 15, or at least 20 of composite material. Of plies. As yet another illustrative example (but not limited to), the load 810 is less than 80, less than 70, less than 60, less than 50, less than 45, less than 40, less than 35, 30 of the composite material. Less, less than 25, less than 20, less than 15, or less than 10 stacked plies may be included.

  The charge 810 can be formed from any suitable composite material and / or the load 810 can include any suitable composite material. As an illustrative example (but not limited to), the load 810 can include a pre-impregnated composite material. As another illustrative example (but not limited to), the load 810 can include a plurality of fibers and / or resin materials. Illustrative examples of fibers include (but are not limited to) carbon fibers, polymer fibers, metal fibers, and / or glass fibers. Illustrative examples of resin materials include (but are not limited to) epoxies, adhesives, and / or polymer resins. As a further illustrative example (but not limited to), the load 810 can include a metal ply, a metal film, a metal layer, and / or any suitable combination of the above materials. .

  As described above, the vacuum compression apparatus 100 defines at least the configuration 104 before deformation and the configuration 108 after deformation. As also described above, when the vacuum compression apparatus 100 moves from the configuration 104 before deformation to the configuration 108 after deformation, the seal structure 170 shifts from the thickness 172 before deformation to the thickness 174 after deformation. Can do. In addition to or instead of this, it is also included in the technical scope of the present invention that the shape, contour, and / or outer shape of the barrier structure 110 may vary depending on the configuration of the vacuum compression device 100. . As an illustrative example (but not limited to this), when the vacuum compression apparatus 100 is in the pre-deformation configuration 104, the barrier structure 110 has a planar or at least substantially planar shape, contour. And / or can have and / or be defined. As another illustrative example (but not limited to), the shape, contour, and / or contour (barrier structure 110) of the barrier structure 110 when the vacuum compression apparatus 100 is in the configuration 108 after deformation. Of the first surface 114 and / or the second surface 116 of the first surface 114 and / or the second surface 116 may match or at least partially match the shape, contour, and / or shape of the support surface 200. it can. This is illustrated in FIGS. 8-10, which shows a schematic cross-sectional view of a vacuum compression apparatus 100 according to the present invention for compressing a composite charge 810 on a non-planar support surface 200. FIG.

  As shown in FIG. 8, the support surface 200 can include a convex support surface, and can be a convex support surface and / or define a convex shape, contour, and / or profile. be able to. In these situations, when the vacuum compression apparatus 100 is placed on the support surface 200 and in the deformed configuration 108, the barrier structure 110 can also define a convex shape, contour, and / or contour.

  In addition or alternatively, as shown in FIG. 9, the support surface 200 can include a concave support surface, and can be a concave support surface and / or a concave shape, A contour and / or contour can be defined. In these situations, when the vacuum compression apparatus 100 is placed on the support surface 200 and in the deformed configuration 108, the barrier structure 110 can also define a convex shape, contour, and / or contour.

  As shown in FIG. 10, the support surface 200 can include and / or define a discontinuous and / or stepped shape, contour, and / or profile. In FIG. 10, the support surface 200 is defined by a layup mandrel 202 and a composite stuffed load 812. Further, the enclosed space 250 is evacuated, and the vacuum compression apparatus 100 is in the modified configuration 108. In FIG. 10, the seal structure 170 forms part of the fluid seal between the layup mandrel 202 and the barrier structure 110 as indicated by reference numeral 176, and is preceded by reference numeral 178. Forming a portion of the fluid seal between the compressed charge 812 and the barrier structure 110. As shown, the barrier structure 110 has been deformed from a planar shape, contour, and / or contour due to the application of a vacuum to the enclosed space 250. However, as described above, the barrier structure 110 can return to a planar outline when pressure is applied to the enclosed space 250 and / or the vacuum is removed from the enclosed space 250.

  FIG. 11 illustrates (but is not limited to) examples of barrier structures 110 according to the present invention that are somewhat detailed but are still illustrative. The barrier structure 110 of FIG. 11 may be utilized in any of the vacuum compression apparatus 100 disclosed herein and / or is described herein in connection with any of FIGS. 3-12. Any of the barrier structures 110 disclosed herein may be formed and / or any of the barrier structures 110 disclosed herein in connection with any of FIGS. 3-12. It is included in the technical scope of the present invention.

  The barrier structure 110 of FIG. 11 includes a first planar wall 130, a second opposing planar wall 132, and between the first planar wall 130 and the second planar wall 132. A plurality of elongate webs 134 extending in the direction. Such a barrier structure 110 is sometimes referred to herein as a panel 112 and / or a double wall panel 112. Planar walls 130 and 132 cooperate with a plurality of elongate webs 134 to define a plurality of elongate channels 136 that extend through barrier structure 110. The channel 136 may extend along a longitudinal axis parallel to the first planar wall 130 and / or the second planar wall 132, may extend from the edge 138 of the barrier structure 110, It is within the scope of the present invention that it may extend from the first edge to the second edge of the barrier structure 110 and / or extend between two opposite edges of the barrier structure 110. .

  The first planar wall 130 can define the first surface 114 of the barrier structure 110 and the second planar wall 132 can define the second surface 118 of the barrier structure 110. In addition, the first planar wall 130 may define at least a portion of the exhaust path 122 and / or the retention path 126 as shown. The exhaust path 122, sometimes referred to herein as the exhaust channel 124, can be in communication with one or more selected elongated channels 136 that can form part of the vacuum distribution manifold 140. Accordingly, the vacuum source 150 can selectively evacuate the exhaust channel 124 (or provide a vacuum to the exhaust channel 124), as indicated by the dashed arrow 125 in FIG. When the barrier structure 110 of FIG. 11 forms part of the vacuum compression apparatus 100 and is disposed on the support surface 200, this vacuum causes the pressure of the enclosed space 250 as described herein. Can be utilized to lower.

  Similarly, the retention path 126, sometimes referred to herein as a retention channel 128, is connected to one or more selected elongated channels 136 that can form part of the second vacuum distribution manifold 144. Can communicate. Accordingly, the vacuum source 150 can selectively evacuate the retention channel 128 (or provide a vacuum to the retention channel 128), as indicated by the dashed arrow 129 in FIG. When the composite charge 810 is located on the first surface 114 of the barrier structure 110, the vacuum causes the composite charge 810 to be applied to the first surface 114 of the barrier structure 110 as described herein. Can be used to hold.

  FIG. 12 is a flow diagram illustrating a method 400 according to the present invention for compressing a composite charge on a support surface. In FIG. 12, some steps are indicated by a dashed box indicating that such steps may be optional or that they may correspond to an optional variant of the method according to the invention. . However, it is not necessary for all methods according to the present invention to include the steps indicated by the solid box. Further, the method and steps shown in FIG. 12 are not intended to limit the present invention, as will be understood from considerations herein, such as methods having more or fewer steps than illustrated. These methods and steps are also included in the technical scope of the present invention.

  With this in mind, the method 400 can include a step 410 of placing a composite charge between the vacuum compression device and the support surface, wherein the vacuum compression device is placed on the support surface to define an enclosed space. And step 430 for reducing the pressure in the enclosed space. Further, the method 400 can include a step 440 of compressing the composite load on the support surface and a step 450 of increasing the pressure of the enclosed space and repeating the method 460.

  Placing the composite charge between the vacuum compression apparatus and the support surface 410 may include placing the composite charge prior to placing 420. It is within the scope of the present invention that placing step 410 may include placing a single charge of composite material or multiple charges of composite material. If the placing step 410 includes placing a plurality of composite material loads, the placing step 420 places the vacuum compression device such that the enclosed composite space contains the plurality of composite material loads. It is within the scope of the present invention that compressing step 440 can include simultaneously compressing multiple loads of composite material.

  It is within the scope of the present invention that the placing step 410 may further comprise placing a composite load on the support surface. This can include aligning the composite load to the support surface, for example by using any suitable laser projection system and / or alignment tool. In addition, the placing step 410 may alternatively include forming a composite load on the support surface. As an illustrative example (but not limited to), the forming step may include the step of overlaying a plurality of plies of composite material on a support surface to form a composite load. it can. Placing on the support surface and / or forming on the support surface further includes holding the composite load on the support surface after placement and / or formation, for example by using an adhesive. be able to.

  It is within the scope of the present invention that placing step 410 may include placing a composite charge on a vacuum compression apparatus. As an illustrative example (but not limited to), the vacuum compression apparatus can include a barrier structure, and the placing step includes aligning the composite charge on the barrier structure. Can do. Additionally or alternatively, the placing step 410 may include forming a composite charge on the vacuum compression apparatus. As an illustrative example (but not limited to), the forming step may include overlaying a plurality of composite plies on the barrier structure to form a composite load. it can. Placing on the vacuum compression device and / or forming on the vacuum compression device may further include holding the composite charge on the vacuum compression device after placement and / or formation. As an illustrative example (but not limited to), the holding step may include applying a vacuum to a plurality of holding paths defined by the barrier structure, as described herein. it can.

  Arranging the vacuum compression device 420 on the support surface to define an enclosed space may include defining an enclosed space that includes and / or contains a composite loading. It is within the scope of the present invention that the placing step 420 may further comprise the step 422 of aligning the vacuum compression device with the support surface. This aligns the vacuum compression device so that the enclosed space is defined by the desired portion of the support surface and / or the composite load is compressed at the desired location on the support surface; Locating, installing, and / or arranging in other ways may be included. As an illustrative example (but not limited to), the vacuum compression device can include and / or define an indexing structure, and the support surface can include and / or define a mating indexing structure. . In these situations, the aligning step 422 includes aligning the indexing structure with the counterpart indexing structure to achieve alignment and / or receiving one of the indexing structure and the counterpart indexing structure into the other of the indexing structure and the counterpart indexing structure. Can be included.

  Additionally or alternatively, the vacuum compression apparatus further comprises a seal structure configured to form a fluid seal between the vacuum compression apparatus or the barrier structure of the vacuum compression apparatus and the support surface. Can do. Under these circumstances, the placing step 420 can further include a step 424 of bringing the seal structure into contact with the support surface. As an illustrative example (but not limited to), as described above, the support surface can include a lay-up mandrel and / or a pre-compressed load of composite material, and / or Or the contact of the layup mandrel and / or composite material previously compressed, the contacting step contacting the layup mandrel and / or composite material previously compressed charge to the seal structure. Can be included. In addition or alternatively, the support surface may define a stepped profile defined by both the lay-up mandrel and the composite material's pre-compressed loading, and the contacting step 424 is a seal step. Contacting the first portion of the structure with the layup mandrel and contacting the second portion of the seal structure with the previously compressed charge of the composite material may be included.

  The step 430 of reducing the pressure in the enclosed space is a step of reducing the pressure after the placing step 420 and / or moving the vacuum compression device from a pre-deformation configuration to a post-deformation configuration different from the pre-deformation configuration. The step of reducing the pressure can be included. As an illustrative example (but not limited to), the step of reducing the pressure includes, for example, reducing the pressure of the enclosed space and / or at least partially evacuating the enclosed space, for example Applying a vacuum to the enclosed space via any suitable vacuum distribution manifold and / or from any suitable vacuum source may be included.

  It is within the scope of the present invention that the step of reducing pressure 430 may further include a step 432 of at least partially matching the barrier structure to the shape, shape, or contour of the support surface. As an illustrative example (but not limited to), when the vacuum compression device is in a pre-deformation configuration, the barrier structure may be planar or at least substantially planar in shape, outline, or contour. And / or can be defined. However, when the vacuum compression device is in a modified configuration that can occur, for example, during step 430 of reducing the pressure, the barrier structure may be similar to the outer shape of the support surface, or It can be deformed into a non-planar, concave and / or convex profile that can depend at least in part.

  It is also within the scope of the present invention that the pressure reducing step 430 may include a step 434 of compressing the seal structure. As an illustrative example (but not limited to), as described above, the seal structure can be positioned between the barrier structure and the support surface and / or the barrier facing the support surface. The first surface of the structure can be operably attached. Under such circumstances, the compressing step 434 can include transitioning the seal structure from a pre-compression configuration to a post-compression configuration, wherein the seal is oriented in a direction perpendicular to the first surface of the barrier structure. The thickness of the structure may be greater when the seal structure is in the pre-compression configuration than when the seal structure is in the post-compression configuration.

  The step 440 of compressing the composite charge on the support surface is performed between the vacuum compression device and the support surface to produce, produce, and / or form a composite charge on the support surface. Compressing and / or compressing the composite charge. The step of compressing 440 may be performed at least partially simultaneously with the step of reducing pressure 430.

  It is within the scope of the present invention that compressing step 440 may include the step of compressing the composite charge without “bagging” the composite charge. An illustrative example of (but not limited to) is described herein. In addition, or alternatively, the compressing step 440 may include compressing the composite charge without forming an adhesive bond between the vacuum compression device and the support surface. Are included in the technical scope of the present invention.

  The step 450 of increasing the pressure in the enclosed space includes the step of increasing the pressure to move the vacuum compression device from the post-deformation configuration to the pre-deformation configuration and / or to return the vacuum compression device to the pre-deformation configuration. Can be included. As an illustrative example (but not limited to), the step of increasing pressure 450 removes and / or isolates the vacuum from the enclosed space and / or increases the pressure of the enclosed space. Supplying a flow of bleed gas to the enclosed space. As a further illustrative example (but not limited to), the step 450 of increasing pressure returns the barrier structure to the pre-deformation step 452 and / or returns the seal structure to the pre-compression configuration. Step 454 may be included. The returning step 450 may be followed by a step 430 of reducing pressure and / or a step 440 of compressing.

  Repeating the method 460 may include repeating any suitable portion of the method 400 based on any suitable criteria. As an illustrative example (but not limited to), the composite charge may include a first charge of the composite material and / or be the first charge of the composite material. Repeating step 460 may include at least placing step 420, reducing pressure step 430, compressing step 440, to compress the next charge of composite material or multiple charges of composite material on the support surface, And repeating step 450 of increasing pressure. This may be used to form a completed or at least partially completed composite structure for a composite structure whose illustrative examples (but not limited to) are described in more detail herein. Repeating steps can be included.

  Repeating step 460 may include moving the vacuum compression device from the pre-deformation configuration to the post-deformation configuration and then returning the vacuum compression device to the pre-deformation configuration multiple times (i.e., multiple composite materials Reusing the vacuum compression apparatus to compress the charge) is within the scope of the present invention. In addition or alternatively, the repeating step 460 may be performed without damaging the vacuum compression apparatus, without “bagging” each of the plurality of loads of the composite material, and / or Alternatively, it is within the scope of the present invention to include the step of repeating the vacuum compression device without attaching it to the support surface.

  Referring now to FIGS. 13 and 14, embodiments of the present invention may be described in the context of an aircraft manufacturing and service method 900 as shown in FIG. 13 and an aircraft 700 as shown in FIG. it can. In a pre-manufacturing stage, an exemplary method 900 may include aircraft 700 specifications and design 905 and material procurement 910. In manufacturing, component and subassembly manufacturing 915 and system integration 920 of aircraft 700 takes place. Thereafter, the aircraft 700 can be put into service 930 via authentication and transport 925. During service by the customer, regular maintenance and maintenance inspection 935 (which may include improvements, setting changes, modifications, etc.) is planned for aircraft 700.

  Each process of method 900 may be performed or performed by a system integrator, a third party, and / or an operator (eg, a customer). For purposes of this description, system integrators may include, but are not limited to, any number of aircraft manufacturers and major system subcontractors, and third parties are not limited to these. May include any number of manufacturers, subcontractors, and suppliers, and operators may be airlines, leasing companies, military, service organizations, and so on.

  As shown in FIG. 14, an aircraft 700 manufactured by the exemplary method 900 can include a fuselage 710 having a plurality of systems 712 and an interior 714. Examples of advanced system 712 include one or more of propulsion system 715, electrical system 716, hydraulic system 717, and environmental system 718. Any number of other systems may also be included. Although an aerospace example is shown, the principles of the present invention are applicable to other industries such as the automotive industry.

  The apparatus and methods embodied herein may be used in any one or more of the stages of manufacturing and service method 900. For example, the component or subassembly corresponding to the component and subassembly manufacturing process 915 is manufactured or manufactured in a manner similar to the component and subassembly manufactured when the aircraft 700 is in service. Can. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may provide for a stage of manufacturing 915, such as by greatly facilitating assembly of the aircraft 700 or significantly reducing the cost of the aircraft 700. And 920. Similarly, one or more of the apparatus embodiments, method embodiments, or combinations thereof may be utilized when the aircraft 700 is in service, such as, but not limited to, maintenance and service inspection 935. Can.

  Illustrative examples (but not limited to) of the inventive subject matter according to the present invention are described in the enumerated paragraphs below.

A1. A vacuum compression apparatus for compressing a composite material charge on a support surface, the vacuum compression apparatus being disposed on the support surface and configured to define an enclosed space, the vacuum compression apparatus The device
A barrier structure comprising a first surface and a second surface opposite the first surface;
A seal structure configured to form a fluid seal between the support surface and the barrier structure when compressed between the support surface and the barrier structure;
An apparatus comprising: a vacuum distribution manifold in communication with the enclosed space, the vacuum distribution manifold configured to selectively apply a vacuum to the enclosed space.

  A2. The apparatus of paragraph A1, wherein the barrier structure is at least a substantially planar and optionally a planar barrier structure.

  A3. The apparatus of paragraph A1 or A2, wherein the barrier structure is formed from a flexible material.

  A4. The apparatus of any of paragraphs A1 through A3, wherein the barrier structure is formed from at least one of an optically transmissive material, an optically translucent material, and an optically translucent material. .

  A5. The apparatus of any of paragraphs A1 through A4, wherein the barrier structure is formed from at least one of a polymeric material and polycarbonate.

  A6. The barrier structure further comprises a release surface defining the first surface of the barrier structure, optionally, the material selected such that the release surface does not adhere to the composite material load; The apparatus of any of paragraphs A1 through A5, comprising at least one of a material selected so as not to react with the composite charge and a fluoropolymer.

  A7. The apparatus according to any of paragraphs A1 to A6, wherein the first surface of the barrier structure further defines a plurality of holding paths communicating with the enclosed space.

  A8. The vacuum distribution manifold is a first vacuum distribution manifold, the vacuum is a first vacuum, and the apparatus is a second vacuum distribution manifold that communicates with the plurality of holding paths, the plurality of holding The apparatus of paragraph A7, comprising a second vacuum distribution manifold configured to selectively apply a second vacuum to the path.

  A9. The vacuum compression apparatus may include the composite material charge when the composite material charge is disposed on the first surface and the second vacuum is applied to the plurality of holding channels. The apparatus of paragraph A8, configured to be held on one side.

  A10. The barrier structure includes a first planar wall, a second planar wall, and a plurality of elongated webs extending between the first planar wall and the second planar wall. The apparatus of any of paragraphs A1 through A9, wherein, optionally, the barrier structure is a panel, and optionally the barrier structure is a double-walled panel.

  A11. The first planar wall, the second planar wall, and the plurality of elongated webs optionally include a plurality of elongated channels extending from an edge of the barrier structure, and optionally, the barrier structure. The apparatus of Paragraph A10, defining a plurality of elongated channels extending between a first edge of the barrier and a second edge of the barrier structure.

  A12. The barrier structure optionally extends from a plurality of elongated channels extending from an edge of the barrier structure, and optionally extends between a first edge of the barrier structure and a second edge of the barrier structure. The apparatus of any of paragraphs A1 through A10, wherein a plurality of elongated channels are defined.

  A13. The barrier structure defines a plurality of exhaust passages, the plurality of exhaust passages including one or more selected exhaust channels of the plurality of elongated channels and the first surface of the barrier structure. The apparatus of paragraph A11 or A12, extending between and providing communication between the vacuum distribution manifold and the enclosed space.

  A14. The barrier structure defines a retention path / the plurality of retention paths, the retention path including one or more selected retention channels of the plurality of elongated channels and the first surface of the barrier structure. The apparatus of any of paragraphs A11 to A13, extending between and providing communication between a second vacuum distribution manifold / second vacuum distribution manifold and the enclosed space.

  A15. The apparatus of any of paragraphs A11 through A14, wherein the plurality of elongated channels define at least a portion of the vacuum distribution manifold.

  A16. The apparatus of any of paragraphs A1 through A15, wherein the vacuum distribution manifold further comprises a bleed valve configured to selectively supply a flow of bleed gas to the enclosed space.

  A17. The apparatus of any of paragraphs A1 through A16, wherein the vacuum distribution manifold further comprises a pressure detector configured to detect pressure in the vacuum distribution manifold.

  A18. The vacuum distribution mechanism further comprises a vacuum control structure that is selectively actuated to apply a vacuum to the enclosed space, optionally wherein the vacuum control structure is manually actuated. Or the apparatus of any of paragraphs A1 to A17, configured to be at least one of automatically activated.

  A19. The apparatus according to any one of paragraphs A1 to A18, wherein the seal structure defines an outer periphery of the enclosed space.

  A20. The device according to any one of paragraphs A1 to A19, wherein the seal structure is located between the barrier structure and the support surface when the vacuum compression device is disposed on the support surface.

  A21. The apparatus of any of paragraphs A1 through A20, wherein the seal structure is operatively attached to the first surface of the barrier structure.

  A22. Paragraphs A1 to A21, wherein the seal structure is selected to be at least one of non-adhering to the support surface, not chemically reacting with the support surface, and not moving contaminants to the support surface. Any device.

  A23. The apparatus according to any one of paragraphs A1 to A22, wherein the seal structure includes at least one of a compression seal, an elastic seal, and a tubular elastic seal.

  A24. The apparatus according to any one of paragraphs A1 to A23, wherein the seal structure is formed of at least one of an elastic material, a polymer material, latex, and urethane.

  A25. At least a portion of the enclosed space is as defined in paragraphs A1 through A24, wherein the device is bounded by or defined by the support surface when the device is disposed on the support surface. Any device.

  A26. Any of paragraphs A1 through A25, wherein at least a portion of the enclosed space is bounded by the first surface of the barrier structure or defined by the first surface of the barrier structure. Equipment.

  A27. Any of paragraphs A1 to A26, wherein at least a portion of the enclosed space, optionally an outer periphery of the enclosed space, is bounded by the seal structure or defined by the seal structure. Equipment.

  A28. The support surface includes at least one, optionally at least two of a layup mandrel, a pre-compressed composite material charge, a portion of the composite structure, and a portion of the composite structure supported by the layup mandrel. The apparatus of any of paragraphs A1 through A27, optionally including at least three, and optionally including all.

  A29. The support surface includes a pre-compressed composite charge, and further when the seal structure is compressed between the pre-compressed composite charge and the barrier structure. The apparatus of any of paragraphs A1 through A27, configured to form a fluidic seal between the previously compressed composite load and the barrier structure.

  A30. The apparatus of any of paragraphs A1 through A29, wherein the vacuum compression apparatus further comprises a vacuum source configured to generate a vacuum, and optionally the vacuum source is a high flow vacuum source.

  A31. The vacuum compression device further comprises an indexing structure configured to align the device on a support surface, and optionally the support surface when the device is aligned on the support surface. The apparatus of any of paragraphs A1 to A30, comprising a counterpart indexing structure configured to pair with the other party.

  A32. Paragraph A1 wherein the composite material charge forms part of at least one of a composite structure, airframe, aircraft fuselage, aircraft fuselage fuselage, aircraft wing, aircraft stabilizer, filler, hull, and longitudinal. To A31.

A33. The composite material charge is:
(I) at least one ply of composite material;
(Ii) at least two, at least 3, at least 4, at least 5, at least 10, at least 15, or at least 20 plies stacked of composite materials, and (iii) less than 80 stacked composite materials, Any of paragraphs A1 through A32 comprising at least one of less than 70, less than 60, less than 50, less than 45, less than 40, less than 35, less than 30, less than 25, less than 20, less than 15, or less than 10 plies Equipment.

  A34. The composite material includes a plurality of fibers and a resin material, and optionally the plurality of fibers includes at least one of a plurality of carbon fibers, a plurality of polymer fibers, and a plurality of glass fibers; The apparatus of Paragraph A33, wherein optionally the resin material comprises at least one of an epoxy, an adhesive, and a polymer resin.

  A35. The apparatus of paragraph A33 or A34, wherein the composite material comprises a pre-impregnated composite material.

  A36. The vacuum compression device is not disposed on the support surface, and the structure before deformation when no vacuum is applied to the enclosed space, and the enclosed space is disposed on the support surface. The apparatus according to any one of paragraphs A1 to A35, comprising: a configuration after deformation when a vacuum is applied to

  A37. The barrier structure is planar when the device is in the pre-deformation configuration, and further the barrier structure is at least partially in the outer shape of the support surface when the device is in the post-deformation configuration. The apparatus of Paragraph A36, wherein the contours of the support surfaces are identical and optionally include at least one of a non-planar contour, a concave contour, and a convex contour.

  A38. The seal structure defines a thickness measured in a direction perpendicular to the first surface of the barrier structure, the thickness being a thickness before deformation when the device is in a pre-deformation configuration; The device according to paragraph A36 or A37, further comprising a post-deformation thickness when the device has a post-deformation configuration, wherein the post-deformation thickness is smaller than the pre-deformation thickness.

  A39. The vacuum compressing device is a reusable vacuum compressing device, and optionally the reusable vacuum compressing device is optionally free of composite material on the support surface without causing damage to the vacuum compressing device. The apparatus of any of paragraphs A1 through A38, configured to compress a plurality of charges.

A40. Multiple loads of composite material; and
A supporting surface;
A vacuum compression apparatus according to any one of paragraphs A1 to A39;
A composite structure manufacturing assembly comprising:

  A41. A layup mandrel forms at least a portion of the support surface, and optionally the assembly has an automatic placement structure programmed to place each of the plurality of loads of the composite material on the layup mandrel. The assembly of paragraph A40, further comprising:

  A42. The assembly of paragraph A41, wherein the automatic placement structure includes an assembly robot.

  A43. The assembly of A41 or A42, wherein the automatic placement structure is programmed to place each of a plurality of loads of the composite material on the layup mandrel using the method of any of paragraphs B1-B23.

  A44. The vacuum compression device is disposed on the support surface to define the enclosed space, the composite material charge is disposed in the enclosed space, and the vacuum is applied to the enclosed space. And the outer shape of the first surface of the barrier structure corresponds to the outer shape of the support surface, and optionally the outer shape of the support surface is a non-planar outer shape, a concave outer shape, and a convex shape. The assembly of any of paragraphs A40 through A43, which is at least one of an outline.

  A45. The assembly of paragraph A44, wherein the support surface is further defined by a pre-compressed composite load.

  A46. The assembly of paragraph A45, wherein the support surface defines a stepped profile.

  A47. The assembly of any of paragraphs A44 through A46, wherein the assembly further includes an adhesive positioned between the composite load and the support surface.

B1. A method of compressing a composite charge on a support surface, comprising:
Placing a vacuum compression device on the support surface to define an enclosed space for containing the composite material charge;
Reducing the pressure in the enclosed space in order to shift the vacuum compression device from a configuration before deformation to a configuration after deformation different from the configuration before deformation;
Compressing the composite charge between the vacuum compression apparatus and the support surface;
Increasing the pressure of the enclosed space to return the vacuum compression device to the configuration prior to the deformation;
Including methods.

  B2. The vacuum compression apparatus includes a barrier structure including a first surface and a second surface opposite to the first surface, and after the arranging step, the enclosed space is formed with the first surface of the barrier structure. The method of paragraph B1, defined between said support surface.

  B3. The barrier structure is at least substantially planar when the vacuum compression apparatus is in the pre-deformation configuration, and the step of lowering the pressure further at least partially in the contour of the support surface. Matching, optionally wherein the outer shape of the support surface includes at least one of a non-planar shape, a concave shape, and a convex shape, and optionally the matching step comprises: The method of paragraph B2, which occurs at least partially simultaneously with at least one of the step of reducing the pressure and the step of compressing.

  B4. The method of paragraph B2 or B3, wherein the vacuum compression apparatus further comprises a seal structure operably attached to the first surface of the barrier structure.

  B5. The step of reducing the pressure compresses the seal structure between the barrier structure and the support surface so as to shift the seal structure from a pre-compression configuration to a post-compression configuration different from the pre-compression configuration. The method of paragraph B4, further comprising the step of: further increasing the pressure includes returning the seal structure to the pre-compression configuration.

  B6. The method of paragraph B4 or B5, wherein the placing step comprises bringing the seal structure into contact with the support surface.

  B7. The method of Paragraph B6, wherein a portion of the support surface is defined by a layup mandrel, and wherein the placing step further comprises contacting the seal structure with the layup mandrel.

  B8. A portion of the support surface is defined by a pre-compressed composite material charge, and the placing step further comprises contacting the seal surface with the pre-compressed composite material charge. The method of B6 or B7.

  B9. The support surface defines a stepped contour defined by a layup mandrel / the layup mandrel and / or a previously compressed composite material charge / the previously compressed composite material charge; The method of any of paragraphs B6 through B8, wherein the placing step further comprises contacting the sealing surface with the layup mandrel and the previously compressed composite material charge.

  B10. The step of reducing the pressure includes compressing a first portion of the seal structure between the barrier structure and the mandrel, and compressing a second portion of the seal structure to the barrier structure and the previously compressed composite material. The method of paragraph B9, comprising the step of compressing between the first charge.

  B11. The method of any of paragraphs B1 through B10, wherein the method further includes the step of positioning the composite material charge between the vacuum compression apparatus and the support surface prior to the placing step.

  B12. The charge of the composite material is a first charge of the composite material, and the step of positioning includes positioning a plurality of charges of the composite material, and the placing step includes a plurality of the charge of the composite material. The method of Paragraph B11, including the step of positioning the charge so that it is received in the enclosed space, and wherein the step of compressing includes simultaneously compressing the plurality of charges of the composite material.

  B13. The positioning step includes placing the composite material charge on the support surface, and optionally the placing step includes aligning the composite material charge on the support surface. Optionally, the step of aligning includes aligning to an alignment jig, and optionally the step of placing includes holding the composite load on the support surface with an adhesive. The method of paragraph B11 or B12.

  B14. The positioning step includes forming a composite material charge on the support surface, and optionally forming the composite material on the support surface to form the composite material charge. The method of paragraphs B11 or B12, including the step of overlaying a plurality of plies of material, and optionally the step of forming includes holding the composite material charge on the support surface with an adhesive.

  B15. The positioning step includes placing the composite material charge on the vacuum compression device, and optionally placing the barrier structure of the vacuum compression device / the composite material on the barrier structure. Aligning the charge of the substrate, and optionally placing the load, wherein the composite load is retained on the barrier structure by applying a vacuum to a plurality of retention paths defined by the barrier structure. The method of paragraph B11 or B12, including the step of:

  B16. The positioning step includes forming the composite material charge on the vacuum compression device, and optionally forming the forming step of the vacuum compression device to form the composite material charge. A step of overlaying a plurality of plies of composite material on the barrier structure / barrier structure, and optionally the forming step comprises applying the vacuum to a plurality of retention paths defined by the barrier structure. The method of paragraph B11 or B12, comprising the step of holding a charge of material on the barrier structure.

  B17. The method of any of paragraphs B1 through B16, wherein the vacuum compression apparatus comprises an indexing structure, the support surface comprises a mating indexing structure, and the placing step further comprises aligning the indexing structure with the mating indexing structure.

  B18. The method of any of paragraphs B1 through B17, wherein the method includes the step of compressing the composite material charge without bagging the composite material charge.

  B19. The method of any of paragraphs B1 through B18, wherein the method does not include forming an adhesive bond between the vacuum compression apparatus and the support surface.

  B20. The method of any one of paragraphs B1 to B19, wherein the step of reducing the pressure is performed following the step of arranging.

  B21. The method of any of paragraphs B1 to B20, wherein the compressing step is simultaneous with the step of reducing the pressure.

  B22. The method of any one of paragraphs B1 to B21, wherein the step of increasing the pressure is performed following the step of decreasing the pressure and the step of compressing.

  B23. The composite charge is a first charge of a composite material, and the method further includes the step of repeating the method to compress a plurality of composite charge on the support surface. One of the methods of B22.

  B24. The method of paragraph B23, wherein the repeating step includes a step of moving the vacuum compression device from the pre-deformation configuration to the post-deformation configuration and then returning the vacuum compression device to the pre-deformation configuration multiple times.

  B25. The method of paragraph B23 or B24, wherein the step of repeating includes the step of repeating without damaging the vacuum compression apparatus.

  B26. The method of any one of paragraphs B1 to B25, wherein the vacuum compression device includes the vacuum compression device of any of paragraphs A1 to A38.

  C1. Use of any of the devices of any of paragraphs A1 to A39 or any of the assemblies of any of paragraphs A40 to A47 by any of the methods of paragraphs B1 to B26.

  C2. Use of any of the methods of paragraphs B1 to B26 in any of the apparatus of any of paragraphs A1 to A39 or any of the assemblies of any of paragraphs A40 to A47.

  C3. Any of the apparatus of any of paragraphs A1 to A39, any of the assemblies of any of paragraphs A40 to A47, or any of the methods of any of paragraphs B1 to B26 for compressing a composite charge. use.

  C4. Any of the apparatus of any of paragraphs A1 to A39, any of the assemblies of any of paragraphs A40 to A47, or any of the methods of any of paragraphs B1 to B26 to form part of the composite structure. use.

  C5. The apparatus of any of paragraphs A1-A39 to form a portion of at least one of an airframe, an aircraft fuselage, an aircraft fuselage fuselage, an aircraft wing, an aircraft stabilizer, a filler, a hull, and a longitudinal member. Any use of any of the assemblies of paragraphs A40 to A47 or any of the methods of paragraphs B1 to B26.

  C6. Use of a reusable vacuum compression device to compress composite charge.

D1. A vacuum compression apparatus for compressing a composite load on a support surface, wherein the vacuum compression apparatus is disposed on the support surface and is configured to define an enclosed space, the vacuum compression apparatus comprising: ,
A barrier structure comprising a first surface and a second surface opposite the first surface;
A seal structure configured to form a fluid seal between the support surface and the barrier structure when compressed between the support surface and the barrier structure;
A vacuum distribution manifold in communication with the enclosed space, the vacuum distribution manifold configured to selectively apply a vacuum to the enclosed space;
A device comprising:

  D2. The barrier structure further comprising a release surface defining the first surface of the barrier structure, the material selected such that the release surface does not adhere to the composite material load; The apparatus of paragraph D1, comprising at least one of a material selected so as not to react with a charge and a fluoropolymer.

  D3. The apparatus of paragraph D1, wherein the first surface of the barrier structure further defines a plurality of retention paths communicating with the enclosed space.

  D4. The vacuum distribution manifold is a first vacuum distribution manifold, the vacuum is a first vacuum, the apparatus communicates with the plurality of holding paths, and a second vacuum is connected to the plurality of holding paths. The apparatus of Paragraph D3, comprising a second vacuum distribution manifold configured to selectively apply.

  D5. The barrier structure includes a first planar wall, a second planar wall, and a plurality of elongated webs extending between the first planar wall and the second planar wall; The first planar wall, the second planar wall, and the plurality of elongated webs define a plurality of elongated channels, and the plurality of elongated channels further includes the vacuum distribution The apparatus of paragraph D1, defining at least a portion of the manifold.

  D6. The apparatus of Paragraph D1, wherein the seal structure is located between the barrier structure and the support surface when the vacuum compression device is disposed on the support surface.

  D7. At least one of the seal structure not adhering to the composite material charge, not chemically reacting with the composite material charge, and not transferring contaminants to the composite material charge. The device of Paragraph D1, which is selected to be one.

  D8. The apparatus of Paragraph D1, wherein the seal structure includes at least one of a compression seal, an elastic seal, and a tubular elastic seal.

  D9. The structure before the deformation when the vacuum is not applied to the enclosed space that is not arranged on the support surface, and the vacuum is applied to the enclosed space arranged on the support surface. The apparatus of Paragraph D1, comprising the modified structure at the time.

  D10. The barrier structure is planar when the device is in the pre-deformation configuration, and further, the barrier structure is at least partially in the outer shape of the support surface when the device is in the post-deformation configuration. The apparatus of Paragraph D9, wherein the contour of the support surface includes at least a non-planar contour.

  D11. The seal structure defines a thickness measured in a direction perpendicular to the first surface of the barrier structure, the thickness being a pre-deformation thickness when the device is in a pre-deformation configuration; The device of Paragraph D9, further comprising a post-deformation thickness when the device has a configuration after deformation, wherein the post-deformation thickness is smaller than the pre-deformation thickness.

  D12. The apparatus of paragraph D1, wherein the vacuum compression apparatus is a reusable vacuum compression apparatus configured to compress a plurality of composite loads on the support surface without causing damage to the vacuum compression apparatus.

D13. Multiple loads of composite material; and
A supporting surface;
The vacuum compression apparatus of paragraph D1,
A composite structure manufacturing assembly comprising:

  D14. The vacuum compression device is disposed on the support surface to define the enclosed space, the composite material charge is disposed in the enclosed space, and the vacuum is contained in the enclosed space. And the assembly of paragraph D13, wherein the outer shape of the first surface of the barrier structure corresponds to the outer shape of the support surface.

  D15. The apparatus of paragraph D14, wherein at least a portion of the enclosed space is at least one of bounded by the seal structure or defined by the seal structure.

  D16. The apparatus of Paragraph D14, wherein the support surface includes at least one of a layup mandrel, a pre-compressed composite material charge, a portion of the composite structure, and a portion of the composite structure supported by the layup mandrel.

  D17. The support surface includes a pre-compressed composite charge, and the seal structure is compressed between the pre-compressed composite charge and the barrier structure to seal the fluid. The apparatus of Paragraph D14, which forms

  D18. The plurality of loads of the composite material form a portion of at least one of a composite structure, airframe, aircraft fuselage, aircraft fuselage fuselage, aircraft wing, aircraft stabilizer, filler, hull, and longitudinal. The apparatus of paragraph D13.

D19. A method of compressing a composite charge on a support surface, comprising:
Placing a vacuum compression device on the support surface to define an enclosed space for containing the composite material charge;
Reducing the pressure in the enclosed space in order to shift the vacuum compression device from a configuration before deformation to a configuration after deformation different from the configuration before deformation;
Compressing the composite charge between the vacuum compression apparatus and the support surface;
Increasing the pressure in the enclosed space to return the vacuum compression device to the pre-deformation configuration.

  D20. The vacuum compression apparatus further includes a seal structure operably attached to the first surface of the barrier structure, and the step of reducing the pressure is different from a configuration before compression of the seal structure from a configuration before compression. Compressing the seal structure between the barrier structure and the support surface to transition to a post-compression configuration, wherein the step of increasing the pressure further returns the seal structure to the pre-compression configuration. The method of D19, comprising:

  D21. The placing step comprises contacting a sealing structure of the vacuum compression device with the support surface, wherein a portion of the support surface is defined by a pre-compressed composite load; The method of Paragraph D19, wherein the step of contacting includes bringing the seal structure into contact with the previously compressed composite material charge.

  D22. The composite material charge is a first composite material charge, and the method further comprises the step of repeating the method to compress a plurality of composite material charges on the support surface; The step of repeating damages the vacuum compression device, the step of moving the vacuum compression device from the pre-deformation configuration to the post-deformation configuration and then returning the vacuum compression device to the pre-deformation configuration. The method of paragraph D19, including multiple times without any.

  As used herein, the terms “selective” and “selectively” refer to specific terms when modifying the action, operation, configuration, or other function of one or more components or features of a device. Meaning, action, operation, configuration, or other function is meant to be a direct or indirect result of a user operation of one aspect or one or more components of the device.

  As used herein, the terms “configured” and “configured” mean that a component, component, or other subject matter is designed and / or intended to perform a given function. Means. Thus, the use of the terms “configured” and “configured” should not be interpreted to mean that a given component, component, or other subject matter simply “can” perform a given function; That its components, components, and / or other subjects are specifically selected, generated, implemented, utilized, programmed, and / or designed for the purpose of performing the function. Should be interpreted as meaning. Also, a component, component, and / or other subject matter described to be configured to perform a particular function may be configured to perform that function in addition to or instead of this. It is possible to express the above and vice versa, and it is also included in the technical scope of the present invention. Similarly, the subject matter stated to be configured to perform a particular function can be expressed as being able to act to perform that function in addition or instead. is there.

  The various components and steps disclosed for the devices and methods disclosed herein are not necessarily required for all devices and methods according to the present invention, and the present invention is not limited to the various components and methods disclosed herein. Includes all new and non-obvious combinations and subcombinations of components and steps. Further, one or more of the various components and steps disclosed herein may define an independent inventive subject matter separate from the entirety of the disclosed apparatus or method. Accordingly, such inventive subject matter need not necessarily be related to the specific apparatus and methods explicitly disclosed herein, but such inventive subject matter is explicitly disclosed herein. Usefulness can be found in devices and / or methods that have not been done.

20 Composite structure manufacturing assembly 100 Vacuum compression device 104 Configuration before deformation 108 Configuration after deformation 110 Barrier structure 114 First surface 118 Second surface 122 Exhaust path 124 Exhaust channel 126 Holding path 128 Holding channel 130 Wall 132 second planar wall 134 elongate web 136 channel 138 edge 140 vacuum distribution manifold (exhaust manifold)
144 Second vacuum distribution manifold (holding manifold)
148 Vacuum control structure 150 Vacuum source 152 Vacuum 160 Bleed valve 162 Flow of bleed gas 170 Seal structure 172 Thickness before deformation 174 Thickness after deformation 180 Indexing structure 190 Automatic arrangement structure 198 Control system 200 Support surface 202 Lay-up mandrel 210 Counterpart indexing structure 214 Alignment jig 250 Surrounded space 700 Aircraft 710 Airframe 720 Body 730 Body 740 Wings 750 Stabilizer 760 Filler 770 Vertical member 780 Frame 790 Outer skin portion 800 Composite structure 810 Loading 812 Packing 8 Agent

Claims (13)

A vacuum compression device (100) for compressing a composite charge (810) on a support surface (200), comprising:
The vacuum compression device (100) is disposed on the support surface (200) and is configured to define an enclosed space;
The vacuum compression apparatus (100)
A barrier structure (110) comprising a first surface and an opposite second surface;
It is configured to form a fluid seal between the support surface (200) and the barrier structure (110) when compressed between the support surface (200) and the barrier structure (110). Sealing structure (170),
A vacuum distribution manifold (140) in communication with the enclosed space, the vacuum distribution manifold (140) configured to selectively apply a vacuum to the enclosed space;
Equipped with a,
The barrier structure (110) includes a first planar wall (130), a second planar wall (132), the first planar wall, and the second planar wall. Defined by a plurality of elongated webs (134) extending between
The first planar wall, the second planar wall, and the plurality of elongated webs define a plurality of elongated channels (136), and the plurality of elongated channels further includes the vacuum distribution manifold. An apparatus defining at least a portion of (140) . The barrier structure (110) further comprises a release surface (116) defining the first surface of the barrier structure (110);
The release surface (116) is selected so that it does not react with the composite material charge (810), the material selected such that it does not adhere to the composite charge (810). The apparatus of claim 1, comprising at least one of a material and a fluoropolymer.   The apparatus of claim 1, wherein the first surface of the barrier structure (110) further defines a plurality of retaining channels (126) in communication with the enclosed space.   The seal structure (170) is located between the barrier structure (110) and the support surface (200) when the vacuum compression device (100) is disposed on the support surface (200). Item 2. The apparatus according to Item 1.   The apparatus of claim 1, wherein the seal structure (170) comprises at least one of a compression seal, an elastic seal, and a tubular elastic seal.   The structure before deformation when the vacuum is not applied to the enclosed space that is not arranged on the support surface (200), and the enclosed space arranged on the support surface (200) The apparatus according to claim 1, comprising: a configuration after deformation when a vacuum is applied to the apparatus. The barrier structure (110) is planar when the device is in the pre-deformation configuration;
Furthermore, the barrier structure (110) at least partially matches the outer shape of the support surface (200) when the device is in the deformed configuration,
The apparatus of claim 6 , wherein the contour of the support surface (200) comprises at least a non-planar contour. The seal structure (170) defines a thickness measured in a direction perpendicular to the first surface of the barrier structure (110);
The thickness comprises a thickness before deformation when the device is a configuration before the deformation, and a thickness after deformation when the device is a configuration after the deformation,
The device according to claim 6 or 7 , wherein the post-deformation thickness is smaller than the pre-deformation thickness.   Reuse configured such that the vacuum compression device (100) compresses a plurality of composite loads (810) on the support surface (200) without causing damage to the vacuum compression device (100). The device of claim 1, which is a possible vacuum compression device. A method of compressing a composite charge (810) on a support surface (200) comprising:
Placing a vacuum compression device (100) on a support surface (200) so as to define an enclosed space containing said composite material charge (810);
Reducing the pressure in the enclosed space (430) in order to shift the vacuum compression device (100) from a configuration before deformation to a configuration after deformation different from the configuration before deformation;
Compressing (440) the composite charge (810) between the vacuum compression apparatus (100) and the support surface (200);
Increasing the pressure in the enclosed space to return the vacuum compression apparatus (100) to the configuration prior to the deformation (450);
Only including,
The vacuum compression apparatus (100) further includes a barrier structure (110), the barrier structure (110) comprising a first planar wall (130), a second planar wall (132), and the Defined by a plurality of elongated webs (134) extending between a first planar wall and the second planar wall;
The first planar wall, the second planar wall, and the plurality of elongated webs define a plurality of elongated channels (136), and the plurality of elongated channels are further defined in a vacuum distribution manifold ( 140) defining at least a portion of 140) . The vacuum compression apparatus (100) further comprises a seal structure (170) operably attached to the first surface of the barrier structure (110),
The step of lowering the pressure (430) moves the seal structure (170) to the barrier structure (170) so as to shift the seal structure (170) from a pre-compression configuration to a post-compression configuration different from the pre-compression configuration. 110) and the support surface (200),
The method of claim 10 , wherein the step of further increasing the pressure (450) comprises returning the seal structure (170) to the pre-compression configuration. The placing step (420) comprises bringing a sealing structure (170) of the vacuum compression device (100) into contact with the support surface (200);
A portion of the support surface (200) is defined by a composite material charge (812) previously compressed;
12. The method of claim 10 or 11 , further comprising the step of placing (420) contacting the seal structure (170) to the previously compressed composite material charge (812). The composite charge (810) is the first charge of the composite;
The method further includes repeating (460) the method to compress a plurality of composite loads (810) on the support surface (200);
The step of repeating (460) is a step of moving the vacuum compression device (100) from the pre-deformation configuration to the post-deformation configuration and then returning the vacuum compression device (100) to the pre-deformation configuration. 13. The method according to any one of claims 10 to 12, comprising a plurality of times without damaging the vacuum compression device (100).

Images