Enhanced systems that facilitate vacuum bag curing of composite parts

Patent metadata

Field	Value
Publication number	US-10974467-B2
Application number	US-201615043358-A
Country	US
Kind code	B2
Filing date	Feb 12, 2016
Priority date	Feb 12, 2016
Publication date	Apr 13, 2021
Grant date	Apr 13, 2021

Abstract

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.

First claim

The invention claimed is:

1. A method comprising:
integrating traces and an integral amplifier into a forming tool during fabrication of the forming tool, including printing a solid-state capacitor into the forming tool;
initiating curing of a composite part in a vacuum bag sealed to the forming tool holding the composite part in a defined shape;
detecting a temperature of the composite part during curing via a thermocouple integrated into the tool, by operating the amplifier to amplify signal output from the thermocouple; and
adjusting heat applied to the composite part in response to the detected temperature.

2. The method of claim 1 wherein:
integrating comprises performing additive manufacturing.

3. The method of claim 1 wherein:
adjusting the heat comprises altering an amount of electromagnetic energy applied to a susceptor that is integrated within the tool.

4. The method of claim 1 wherein:
adjusting the heat comprises altering a temperature of an autoclave surrounding the tool.

5. A method comprising:
integrating traces and an integral amplifier into a forming tool during fabrication of the forming tool, including printing a solid-state capacitor into the forming tool;
initiating curing of a composite part in a vacuum bag sealed to the forming tool holding the composite part in a defined shape;
detecting temperatures of the composite part at different locations during curing based on input from thermocouples at the forming tool, wherein the forming tool operates the amplifier to amplify signal output from the thermocouples; and
adjusting amounts of heat applied to the different locations of the composite part in response to the detected temperatures by energizing heating elements for the different locations.

6. The method of claim 5 wherein:
integrating comprises performing additive manufacturing.

7. The method of claim 5 wherein:
the heating elements comprise susceptors, and
adjusting the amounts of heat comprises altering amounts of electromagnetic energy applied to the susceptors.

8. The method of claim 5 wherein:
each of the heating elements is at one of the different locations on the composite part, and the method further comprises:
identifying a location on the composite part corresponding to the detected temperature;
selecting one of the heating elements within the tool at the identified location; and
adjusting an amount of heat generated by the selected heating element.

9. An apparatus comprising:
a forming tool configured to hold a composite part in a defined shape while the composite part is curing in a vacuum bag sealed to the forming tool;
a thermocouple integrated within the forming tool configured to sense temperature at a surface of the tool;
traces integrated within the forming tool that carry temperature signals generated by the thermocouple while the composite part is curing;
an amplifier integrated within the forming tool, wherein the amplifier includes a solid- state capacitor; and
a controller including a processor configured to detect a temperature of the composite part during curing via the thermocouple wherein the amplifier amplifies the temperature signals output from the thermocouple, and to adjust heat applied to the composite part in response to the temperature of the composite part.

10. The apparatus of claim 9 wherein:
the thermocouple is surrounded by an electrically resistive ceramic that is integrated within the forming tool.

11. The apparatus of claim 9 wherein:
the thermocouple comprises a three dimensional (3D) printed structure within the tool.

12. The apparatus of claim 9 wherein:
the thermocouple includes a portion at the surface of the forming tool where the composite part will be placed during curing.

13. The apparatus of claim 9 wherein:
the thermocouple extends beneath the surface of the tool.

14. The apparatus of claim 9 further comprising:
at least one heating element integrated within the forming tool configured to generate heat that conducts to the surface of the forming tool.

15. The apparatus of claim 14 wherein:
the at least one heating element comprises a resistor that heats the forming tool in response to receiving electrical current.

16. The apparatus of claim 14 wherein:
the at least one heating element comprises a susceptor that heats the forming tool in response to receiving electromagnetic energy.

17. The apparatus of claim 14 wherein:
the at least one heating element extends beneath the surface of the forming tool.

18. The apparatus of claim 14 wherein:
the heating element comprises multiple at least one heating elements integrated within the forming tool.

19. The apparatus of claim 18 further comprising:
at least one of the multiple heating elements is at a location which is occupied by the composite part during curing.

20. The apparatus of claim 18 wherein:
each of the multiple heating elements is at a distinct location which is occupied by the composite part during curing.

Assignees

• Boeing Co

Inventors

• Humfeld Keith Daniel
• Rugtvedt Arthur August
• Duce Jeffrey Lynn

Classifications

• B29C70/549

  Details of caul plates, e.g. materials or shape · CPC title

• B29C33/02 Primary

  with incorporated heating or cooling means · CPC title

• B29C35/0294

  using tempering units for temperature control of moulds or cores · CPC title

• B29C70/44 Primary

  using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding · CPC title

• B29L2031/757

  Moulds, cores, dies · CPC title