TW201927525A - 用於接合複合結構之方法與系統 - Google Patents

用於接合複合結構之方法與系統 Download PDF

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TW201927525A
TW201927525A TW107136029A TW107136029A TW201927525A TW 201927525 A TW201927525 A TW 201927525A TW 107136029 A TW107136029 A TW 107136029A TW 107136029 A TW107136029 A TW 107136029A TW 201927525 A TW201927525 A TW 201927525A
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vacuum bag
vacuum
bag
mechanical force
volume
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TW107136029A
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TWI797173B (zh
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史蒂芬 唐納德 布蘭查德
蓋瑞Ｄ 奧克斯
阿爾內Ｋ 路易斯
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美商波音公司
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1018—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using only vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/40—Maintaining or repairing aircraft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/544—Details of vacuum bags, e.g. materials or shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81459—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a filled deformable bladder, e.g. bladder filled with oil, with granules or with a meltable solid material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一種用於接合複合結構的方法，其包括將第二結構定位在第一結構上之接合位點處，及將第一真空袋耦接至該第一結構使得該第一真空袋覆蓋該接合位點。該方法亦包括將真空施加至該第一真空袋以經由該第一真空袋向該第二結構施用第一機械力。第二真空袋係耦接至該第一結構，使得該第二真空袋覆蓋該第二結構，及該第一真空袋之至少一部分。該方法進一步包括將真空施加至該第二真空袋以經由該第二真空袋向該第二結構施用第二機械力。

Description

用於接合複合結構之方法與系統
本發明之領域係關於用於接合由複合材料構成之結構之系統及方法，且詳言之，係關於用於在高壓釜外部執行此類接合之方法及系統。
使用由複合材料所構成之結構越來越普及，尤其在如飛行器機身之此類應用中，其中益處包括強度及剛度增強、重量減少且部件數量減少。然而，複合結構在受到到損壞時常常需要大量的修復工作才能使得飛行器著地，藉此增加了飛行器之支援成本。當前維護過程頻繁地需要在飛行器可恢復飛行之前移除且替換受到損壞的組件。
至少一些已知的修復及接合方法係使用施加大氣壓力之真空袋以在固化製程期間提供緊密的接觸。當複合層之間的環氧樹脂固化時，環氧樹脂會排出揮發性有機化合物。在真空下，歸因於真空袋下之低蒸汽壓，此釋氣會增加。另外，母體複合結構(飛行器)中之任何駐留濕氣亦會蒸發。此類釋氣可能會導致固化複合層及/或黏接線中存在不可接受的孔隙度水平。若出現過高孔隙度，則固化的複合物在結構上可能不可接受。修復技術員接著必須藉由將所有受影響的層研磨掉且從頭開始接合製程而以物理方式移除所有受影響的層。此操作可能需要幾小時或幾天，此取決於部件之複雜度及大小。
至少一些已知的修復及接合方法會在高壓釜中在壓力下固化部 件，以在固化環氧樹脂期間將揮發物保持呈溶液狀態且因此防止複合部件中出現孔隙。然而，高壓釜購買及操作起來昂貴，且其大小有限。類似地，高壓釜很少用於對複合結構或部件執行接合修復。
在一個態樣中，提供一種接合一結構之方法。該方法包括將第二結構定位在第一結構上之接合位點處且將第一真空袋耦接至該第一結構，使得該第一真空袋覆蓋該接合位點。該方法亦包括將真空施加至該第一真空袋以經由該第一真空袋向該第二結構施用第一機械力。第二真空袋耦接至該第一結構，使得該第二真空袋覆蓋該第二結構，及該第一真空袋之至少一部分。該方法進一步包括將真空施加至該第二真空袋以經由該第二真空袋向該第二結構施用第二機械力。
在另一態樣中，提供一種複合結構接合系統。該複合結構接合系統包括：第一結構，其包括接合位點；及第二結構，其經建構以在該接合位點處耦接至該第一結構。該複合結構接合系統亦包括耦接至該第一結構之第一真空袋。該第一真空袋經建構以當將真空施加於該第一真空袋時將第一機械力施加於該第二結構。該複合結構接合系統進一步包括第二真空袋，該第二真空袋係耦接至該第一結構使得該第二真空袋覆蓋該第二結構。該第二真空袋經建構以當將真空施加於該第二真空袋時將第二機械力施加於該第二結構。
已經論述之特徵、功能及優點可在各種實施方式中獨立地實現，或可在另外的其他實施方式中組合，其另外細節可參考以下描述及圖式看出。
100‧‧‧複合結構接合系統
102‧‧‧第一結構
104‧‧‧第二結構
106‧‧‧第一真空袋
108‧‧‧第二真空袋
110‧‧‧接合位點
112‧‧‧第一體積
114‧‧‧第一密封機構
116‧‧‧第一探測器
118‧‧‧真空源
120‧‧‧軟管
122‧‧‧第二體積
124‧‧‧第二密封機構
126‧‧‧第二探測器
128‧‧‧加熱毯
200‧‧‧方法
202‧‧‧定位步驟
204‧‧‧耦接步驟
206‧‧‧施加步驟
208‧‧‧耦接步驟
210‧‧‧施加步驟
212‧‧‧通氣步驟
214‧‧‧維持步驟
F1‧‧‧第一機械力
F2‧‧‧第二機械力
圖1為例示性複合結構接合系統之俯視圖，該複合結構接合系統說明第一結構、第二結構及第一真空袋；圖2為圖1中所展示之進一步說明第二真空袋之複合結構接合系統的俯視圖；圖3為圖2中所展示之複合結構接合系統之橫截面側視圖；且圖4說明使用圖2及圖3中所展示之複合結構接合系統來接合複合結構的方法。
本文中所描述之實施包括用於結合複合結構之方法及系統。該方法包括將第二結構定位在第一結構上之接合位點處且將第一真空袋耦接至第一結構，使得第一真空袋覆蓋接合位點。該方法亦包括將真空施加至第一真空袋以經由第一真空袋向第二結構施用第一機械力。第二真空袋耦接至第一結構，使得第二真空袋覆蓋第二結構，及第一真空袋之至少一部分。該方法進一步包括將真空施加至第二真空袋以經由第二真空袋向第二結構施用第二機械力。在將兩個機械力同時施加至第二結構之後，至少部分地使第一真空袋通氣以移除或減少作用於第二結構之來自第一真空袋的第一機械力且將第二結構曝露於大氣壓力。第二真空袋維持真空以維持作用於第二結構之第二機械力，同時仍將第二結構曝露於第一體積內之基本大氣壓力。藉由在固化期間將第二結構曝露於大氣壓力且維持由第二真空袋提供之壓實力，在固化期間形成在至少第二結構內之揮發性有機化合物保持呈溶液狀態且能夠在不蒸發之情況下自第二結構移除，因此防止第二結構內出現孔隙。
本文中所描述之複合結構接合系統用於修復受損壞的結構或在 二次接合製程中將兩個複合結構結合在一起。該系統允許使用大氣壓實壓力，且無與傳統真空袋固化中之低蒸汽壓相關聯的問題。更特定言之，本文中所描述之複合結構接合系統允許將機械壓力施加於複合結構且不將其曝露於低蒸汽壓。
因而，顯著地減少或防止複合結構內之孔隙，因此增加或維持了複合結構之結構完整性。另外，本文中所描述之複合結構接合系統設計成在不使用高壓釜之情況下在第一結構上產生部分地固化或完全固化之高壓釜品質的熱接合複合物修復。因而，相較於已知的方法，本文中所描述之複合結構接合系統使得在縮短的時間間隔和降低的成本下結合具有任何大小及形狀之複合結構。
圖1為例示性複合結構接合系統100之俯視圖，該複合結構接合系統說明母體結構或第一結構102、修復結構或第二結構104及第一真空袋106。圖2為進一步說明第二真空袋108之複合結構接合系統100之俯視圖。圖3為複合結構接合系統100之橫截面側視圖。
在例示性實施方式中，第一結構102為飛行器之組件。舉例而言，第一結構102為飛行器機身、機翼或尾翼中之任一者。此外，在例示性實施方式中，第一結構102由複合材料(例如嵌入於環氧樹脂中之碳或硼纖維)形成且包括需要修復之接合位點110，該複合材料具有複數個層。如本文中所描述，將使用在第一結構102上定位於接合位點110處之第二結構104進行修復。類似於第一結構102，第二結構104亦由複合材料形成，該複合材料將就地被壓實、縮減體積且完全固化。如本文中所描述，複合結構接合系統100可用作用於修復受損壞的複合結構之修復系統。另外，複合結構接合系統100可用於二次接合兩個預固化的複合結構。
參考圖1至圖3，複合結構接合系統100包括第一真空袋106，該 第一真空帶耦接至第一結構102使得第一真空袋106覆蓋整個第二結構104及整個接合位點110。更特定言之，第一真空袋106耦接至第一結構102，使得第一體積112(圖3中展示)由第一真空袋106及第一結構102限定。如本文中所描述，第一體積112內含有第二結構104。第一真空袋106之周邊藉由第一密封機構114密封至第一結構102，該第一密封機構環繞第二結構104及接合位點110。此外，在例示性實施方式中，複合結構接合系統100包括耦接至第一真空袋106之第一探測器116。第一探測器116穿過第一真空袋106中之開口，且選擇性地耦接第一真空袋106之第一體積112，該第一真空袋經由軟管120與真空源118流動連通。
在例示性實施方式中，複合結構接合系統100亦包括第二真空袋108，該第二真空袋耦接至第一結構102使得第二真空袋108覆蓋整個第二結構104及整個接合位點110以及第一真空袋106之至少一部分。更特定言之，第二真空袋108耦接至第一結構102，使得第二體積122(圖3中展示)由第二真空袋108、第一結構102及第一真空袋106限定。如本文中所描述，第二真空袋108且因此第二體積122覆蓋整個第二結構。然而，當第二體積122與第二結構104重疊時，第二結構104定位在第一真空袋106與第一結構102之間的第二體積122外部。更特定言之，第二結構104藉由第一真空袋106與第二體積122分離。
第二真空袋108之周邊藉由第二密封機構124密封至第一結構102，該第二密封機構環繞第二結構104及接合位點110。如圖2及圖3中最佳展示，第二密封機構124橫跨第一真空袋106部分地延伸，使得第一真空袋106之一部分未被第二真空袋108覆蓋。更特定言之，未被第二真空袋108覆蓋之第一真空袋106的部分包括第一探測器116，使得當第二真空袋108耦接至第一結構102及第一真空袋106時，第一探測器116定位在第二體積122外部。
此外，在例示性實施方式中，複合結構接合系統100包括第二探 測器126，該第二探測器耦接至第二真空袋108。第二探測器126穿過第二真空袋108中之開口且選擇性地耦接第二真空袋108之第二體積122，該第二真空袋經由軟管120與真空源118流動連通。視情況，加熱毯128定位於第一真空袋106與第二結構104之間以在固化期間將熱提供至第一結構102及第二結構104。在於二次接合製程期間使用複合結構接合系統100之情形中，結構102及104以及真空袋106及108可定位於提供加熱的烘箱內部。
在操作中，第一探測器116耦接至真空源118，且便於將真空施加於第一真空袋106以自第一體積112移除空氣。在此組態中，當將真空施加於第一真空袋106時，第一真空袋106在第二結構104上施用第一機械力F1。更特定言之，因為第一真空袋106完全覆蓋第二結構104，所以第一真空袋106將第一機械力F1施加於第二結構104之整個區域，亦即，第一真空袋106貼合第二結構104之形狀，從而將第一機械力F1施加於第二結構104之整個區域。在例示性實施方式中，第一機械力F1為壓縮或壓實力，該壓縮或壓實力將第二結構104向下按壓至第一結構102上以防止第二結構104出現孔隙，且因此防止其膨脹。儘管圖3說明了第一真空袋106與第二結構104之間的間隙，但此僅出於說明之目的，且在操作中，第一真空袋106直接接觸第二結構106(或間接經由視情況選用的加熱毯128)以施加第一機械力F1。
類似地，第二探測器126耦接至真空源118且便於將真空施加於第二真空袋108以自第二體積122移除空氣。如本文中所描述，將真空施加於第二真空袋108，同時第一真空袋106亦在真空下。在此組態中，當將真空施加於第二真空袋108時，第二真空袋108在第二結構104上施用第二機械力F2。更特定言之，因為第二真空袋108完全覆蓋第二結構104且覆蓋第一真空袋106之大部分，所以第二真空袋108將第二機械力F2施加於第一真空袋106，及第二結構104之整個區域，亦即，第二真空袋108貼合第二結構104之形狀，從而將第二 機械力F2施加於第二結構104之整個區域。類似於第一機械力F1，第二機械力F2為壓縮或壓實力，該壓縮或壓實力與第一機械力F1在相同方向上起作用以將第二結構104向下按壓至第一結構102上，從而防止第二結構104出現孔隙，且因此防止其膨脹。儘管圖3說明了第二真空袋108與第一真空袋106之間的間隙，但此僅出於說明之目的，且在操作中，第二真空袋108直接接觸第一真空袋106以將第二機械力F2施加於第二結構。
在例示性實施方式中，第一真空袋106及第二真空袋108同時將第一機械力F1及第二機械力F2分別施加於第二結構104並維持預定時間量。在已過去持續時間之後，至少部分地移除施加於第一真空袋106之真空以使第一體積112通氣，使得第一體積112及第二結構104曝露於大氣壓力。因而，第一機械力F1至少部分地自第二結構104移除。在一些實施方式中，使第一真空袋106完全通氣至大氣壓力。在其他實施方式中，將減少的真空施加於第一真空袋106以便於自第二結構104移除複數種揮發性有機化合物。
在移除施加於第一真空袋106之真空之後，維持施加於第二真空袋108之真空。在此組態中，維持第二真空袋108之真空會維持作用於第二結構104之第二機械力F2，同時仍將第二結構104曝露於第一體積112內之大氣壓力。因此，第二真空袋108施加壓實壓力以防止第二結構104中出現孔隙。更特定言之，藉由在固化期間將第二結構104曝露於大氣壓力且維持由第二真空袋108提供之壓實力，在固化期間形成在至少第二結構104內之揮發性有機化合物保持呈溶液狀態且能夠在不蒸發之情況下自第二結構104移除，因此防止第二結構104內出現孔隙。
圖4說明用於使用複合結構接合系統100(圖2及圖3中展示)接合諸如第一結構102之複合結構的方法200。方法200包括定位202，將諸如第二結構104之第二結構定位在諸如第一結構102之第一結構上的諸如接合位點110 之接合位點處。方法200亦包括將諸如第一真空袋106之第一真空袋耦接204至第一結構，使得第一真空袋覆蓋接合位點。耦接步驟204包括運用諸如第一密封機構114之第一密封機構將第一真空袋密封至第一結構。因而，第一真空袋及第一結構組合以限定第一體積，諸如第一體積112，該第一體積含有第二結構使得第一真空袋覆蓋第二結構。
在例示性實施方式中，一旦第一真空袋耦接204至第一結構，即將真空施加206於第一真空袋以經由第一真空袋向第二結構施用諸如第一機械力F1之第一機械力。如本文中所描述，第一機械力為壓實力，該壓實力將第二結構壓縮至第一結構中或朝向第一結構壓縮第二結構。真空施加步驟206包括耦接諸如源118之真空源，該真空源與諸如第一探測器116之第一探測器流動連通。第一探測器耦接與真空源流動連通之第一體積以便於自第一體積內移除空氣且向第二結構施用第一機械力。
方法200亦包括將諸如第二真空袋108之第二真空袋耦接208至第一結構，及第一真空袋之一部分，使得第二真空袋覆蓋第二結構，及第一真空袋之至少一部分。耦接步驟208包括運用諸如第二密封機構124之第二密封機構將第二真空袋密封至第一結構。此外，耦接步驟208包括將第二真空袋耦接208至第一真空袋，使得第一真空袋上之第一探測器未被第二真空袋覆蓋且保持曝露。因而，第二真空袋、第一結構及第一真空袋組合以限定諸如第二體積122之第二體積。如本文中所描述，第二真空袋覆蓋整個第二結構。然而，第二結構位於第二體積外部。更特定言之，第二結構藉由第一真空袋與第二體積分離。在例示性實施方式中，將第二真空袋耦接208至第一結構及將真空施加206於第一真空袋之次序係可互換的。
在例示性實施方式中，一旦第二真空袋耦接208至第一結構，即將真空施加210於第二真空袋以經由第二真空袋將諸如第二機械力F2之第二機 械力施用於第二結構。如本文中所描述，第二機械力為壓實力，該壓實力將第二結構壓縮至第一結構中或朝向第一結構壓縮第二結構。真空施加步驟210包括耦接諸如源118之真空源，該真空源與諸如第二探測器126之第二探測器流動連通。第二探測器耦接與真空源流動連通之第二體積以便於自第二體積內移除空氣且向第二結構施用第二機械力。
如本文中所描述，因為第二真空袋覆蓋第一真空袋以及第二結構，所以亦將第二機械力施加於第一真空袋。另外，僅在將真空施加206於第一真空袋之後執行真空施加步驟210，使得將真空同時施加於兩個真空袋，從而將兩個機械力同時施加於第二結構並維持預定時間量。
方法200亦包括使第一真空袋至少部分地通氣212以移除或撤銷作用於第二結構之來自第一真空袋的第一機械力。通氣步驟212使得允許空氣進入第一真空袋之第一體積中以將第二結構曝露於大氣壓力，從而便於在揮發物呈溶液狀態時自第二結構移除複數種揮發性有機化合物。此外，僅在將真空施加210於第二真空袋之後執行通氣步驟212。方法200亦包括在使第一真空袋至少部分地通氣之後維持214第二真空袋之真空，以維持作用於第二結構之第二機械力。因而，當使第一真空袋至少部分地通氣212時，自第二結構移除第一機械力。然而，在移除施加於第一真空袋之真空之後維持214第二真空袋之真空使得會維持作用於第二結構之第二機械力，同時仍將第二結構曝露於第一體積內之大氣壓力。藉由在固化期間將第二結構曝露212於大氣壓力且維持214由第二袋提供之壓實力，在固化期間形成在至少第二結構內之揮發性有機化合物保持呈溶液狀態且在不蒸發之情況下自第二結構移除，因此防止第二結構內出現孔隙。
視情況，方法200亦可包括將諸如加熱毯128之加熱毯定位在第一真空袋下方以覆蓋第二結構。
另外，方法200亦可包括出於清楚起見此處未明確描述之其他步驟。舉例而言，此類步驟可包括在定位第二結構之前製備接合位點、在預定溫度下固化接合位點處之第二結構及第一結構並維持預定時間段，及視需要在接合位點處執行任何表面修整。此外，定位202、耦接204、施加206、耦接208、施加210、通氣212及維持214步驟中之每一者係在高壓釜外部執行，且能夠直接對航線上之飛行器執行。
本文中所描述之複合結構接合系統允許使用大氣壓實壓力且無與傳統真空袋固化中之低蒸汽壓相關聯的問題。更特定言之，本文中所描述之複合結構接合系統允許將機械壓力施加於第二及第一結構且不將其曝露於低蒸汽壓。因而，顯著地減少或防止複合結構內之孔隙，因此增加或維持了複合結構之結構完整性。更特定言之，藉由在固化期間將第二結構曝露於大氣壓力且維持由第二袋提供之壓實力，在固化期間形成在至少第二結構內之揮發性有機化合物保持呈溶液狀態且能夠在不蒸發之情況下自第二結構移除，因此防止第二結構內出現孔隙。
另外，本文中所描述之複合結構接合系統設計成在不使用高壓釜之情況下在第一結構上產生部分地固化或完全固化之高壓釜品質的熱接合複合物修復。因而，相較於已知的方法，本文中所描述之複合結構接合系統使得在縮短的時間間隔和降低的成本下接合具有任何大小及形狀之複合結構。
儘管本發明的各種實施方式之特定的特徵可在一些圖式中展示且在其他圖式中未展示，但此僅出於方便起見。根據本發明之原理，圖式之任何特徵可結合任何其他圖式之任何特徵加以提及及/或主張。
此書面描述使用實例以揭示包括最佳模式之各種實施方式，以使得熟習此項技術者能夠實踐彼等實施方式，包括製造及使用任何器件或系統及執行任何所併入的方法。可獲專利的範圍係由申請專利範圍限定，且可包括 熟習此項技術者能想到的其他實例。若此類其他實例具有並非不同於申請專利範圍字面語言之結構元件，或若該等其他實例包括與申請專利範圍字面語言無實質差異之等效結構元件，則該等實例意欲在申請專利範圍之範圍內。

Claims (20)

  1. 一種接合複合結構之方法(200)，該方法包含：將第二結構(104)定位(202)在第一結構(102)上之接合位點(110)處；將第一真空袋(106)耦接(204)至該第一結構(102)，使得該第一真空袋(106)覆蓋該接合位點(110)；將真空施加(206)於該第一真空袋(106)以經由該第一真空袋(106)向該第二結構(104)施用第一機械力(F1)；將第二真空袋(108)耦接(208)至該第一結構(102)，使得該第二真空袋(108)覆蓋該第二結構(104)，及該第一真空袋(106)之至少一部分；及將真空施加(210)於該第二真空袋(108)以經由該第二真空袋(108)向該第二結構(104)施用第二機械力(F2)。
  2. 如請求項1所述之方法(200)，其進一步包含使該第一真空袋(106)至少部分地通氣(212)，以移除作用於該第二結構(104)之該第一機械力(F1)的至少一部分。
  3. 如請求項2所述之方法(200)，其中使該第一真空袋(106)至少部分地通氣(212)包含在將該真空施加(210)於該第二真空袋(108)之後使該第一真空袋(106)至少部分地通氣。
  4. 如請求項2所述之方法(200)，其中使該第一真空袋(106)至少部分地通氣(212)包含將該第二結構(104)曝露於大氣壓力。
  5. 如請求項2所述之方法(200)，其進一步包含在使該第一真空袋(106)至少部分地通氣(212)之後維持(214)該第二真空袋(108)之該真空，以維持作用於該第二結構(104)之該第二機械力(F2)。
  6. 如請求項5所述之方法(200)，其中維持(214)該第二真空袋(108)之該真空以維持該第二機械力(F2)包含維持該第二真空袋(108)之該真空以維持 作用於該第一真空袋(106)及該第二結構(104)之壓實力，且其中使該第一真空袋(106)至少部分地通氣(212)包含將該第二結構(104)曝露於大氣壓力以便於自該第二結構(104)移除複數種揮發性有機化合物。
  7. 如請求項1所述之方法(200)，其中將該第一真空袋(106)耦接(204)至該第一結構(102)包含運用第一密封機構(114)將該第一真空袋(106)密封至該第一結構(102)，且其中將該第二真空袋(108)耦接(208)至該第一結構(102)包含運用第二密封機構(124)將該第二真空袋(108)密封至該第一結構(102)。
  8. 如請求項1所述之方法(200)，其中耦接(208)該第二真空袋(108)以覆蓋該第一真空袋(106)之至少一部分包含將該第二真空袋(108)耦接至該第一真空袋(106)，使得該第一真空袋(106)上之第一探測器(116)未被該第二真空袋(108)覆蓋。
  9. 如請求項1所述之方法(200)，其進一步包含將加熱毯(128)定位在該第一真空袋(106)與該第二結構(104)之間。
  10. 如請求項1所述之方法(200)，其中將真空施加(210)於該第二真空袋(108)包含在高壓釜外部將該真空施加於該第二真空袋(108)。
  11. 一種複合結構接合系統(100)，其包含：第一結構(102)，其包含接合位點(110)；第二結構(104)，其經建構以在該接合位點(110)處耦接至該第一結構(102)；第一真空袋(106)，其耦接至該第一結構(102)，其中該第一真空袋(106)經建構以在將一真空施加於該第一真空袋(106)時將第一機械力(F1)施加於該第二結構(104)；及第二真空袋(108)，其耦接至該第一結構(102)，使得該第二真空袋(108)覆蓋該第二結構(104)，其中該第二真空袋(108)經建構以在將一真空施加於該第二 真空袋(108)時將第二機械力(F2)施加於該第二結構(104)。
  12. 如請求項11所述之複合結構接合系統(100)，該第一真空袋(106)及該第二真空袋(108)經建構以同時施加該第一機械力(F1)及該第二機械力(F2)。
  13. 如請求項11所述之複合結構接合系統(100)，其中該第二真空袋(108)經建構以在將該第一真空袋(106)至少部分地通氣至大氣壓之後維持作用於該第二結構(104)及該第一真空袋(106)之該第二機械力(F2)。
  14. 如請求項11所述之複合結構接合系統(100)，其中該第二真空袋(108)經建構以接觸在該第二結構(104)之整個區域上方的該第一真空袋(106)，使得將該第二機械力(F2)施加於該第一真空袋(106)及該第二結構(104)。
  15. 如請求項11所述之複合結構接合系統(100)，其進一步包含加熱毯(128)，該加熱毯(128)定位於該第一真空袋(106)與該第二結構(104)之間。
  16. 如請求項11所述之複合結構接合系統(100)，其中該第一真空袋(106)在該第一真空袋(106)與該第一結構(102)之間限定第一體積(112)，其中該第二結構(104)定位在該第一體積(112)內。
  17. 如請求項16所述之複合結構接合系統(100)，其進一步包含耦接至該第一真空袋(106)之第一探測器(116)，其中該第一探測器(116)選擇性地耦接該第一體積(112)，該第一體積(112)與真空源(118)流動連通。
  18. 如請求項17所述之複合結構接合系統(100)，其中該第二真空袋(108)在該第二真空袋(108)、該第一結構(102)與該第一真空袋(106)之間限定第二體積(122)，其中該第二結構(104)定位在該第一真空袋(106)與該第一結構(102)之間的該第二體積(122)的外部。
  19. 如請求項18所述之複合結構接合系統(100)，其中當該第二真空袋(108)耦接至該第一真空袋(106)時，該第一探測器(116)定位在該第二體積 (122)的外部。
  20. 如請求項18所述之複合結構接合系統(100)，其進一步包含耦接至該第二真空袋(108)之第二探測器(126)，其中該第二探測器(126)選擇性地耦接該第二體積(122)，該第二體積(122)與該真空源(118)流動連通。
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