# US 10,479,032 B2 · Method of fabricating a vacuum barrier system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,479,032 B2 - Document ID: US10479032B2 - Status: Granted - Kind: B2 - Application number: 15/193,974 - Filed: 2016-06-27 - Published: 2016-10-13 - Granted: 2019-11-19 - Earliest claimed: 2012-10-31 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Brett I. Lyons; Robert G. Albers - Web page: https://patentgrep.com/patent/US10479032B2 ## CPC - B29C 70/446: {Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames} - B29C 33/448: {destructible (B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457)} - B29C 33/505: {cores or mandrels, e.g. inflatable (B29C33/0016 takes precedence; for winding and joining B29C53/824; for supporting articles during joining B29C66/634; flexible cores for vulcanizing tyres B29D30/0654)} - B29C 33/52: soluble or fusible {(in particular used in injection moulding B29C45/4457)} - B29C 70/342: {using isostatic pressure} - B29C 70/443: {and impregnating by vacuum or injection} - B29K 2105/06: containing reinforcements, fillers or inserts - B29K 2995/0059: Degradable - B29L 2031/757: {Moulds, cores, dies} - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A method of fabricating a vacuum barrier system includes fabricating a soluble forming mandrel, laying up composite material over the soluble forming mandrel, and applying a forming mandrel vacuum bag over the composite material and curing the composite tooling material to form a cured composite bag carrier. The method also includes de-bagging and trimming the cured composite bag carrier. ## Claims ### Claim 1 A method of fabricating a vacuum barrier system, comprising the steps of: fabricating a soluble forming mandrel; laying up composite material over the soluble forming mandrel; applying a forming mandrel vacuum bag over the composite material and curing the composite material; removing the forming mandrel vacuum bag to reveal a cured non-soluble composite bag carrier; assembling a soluble detail onto an end of the cured non-soluble composite bag carrier to form a bag carrier assembly; and applying rubber material over the bag carrier assembly and curing to form a cured bladder. ### Claim 2 (depends on 1) The method of claim 1, further comprising the step of: washing out the soluble forming mandrel. ### Claim 3 (depends on 2) The method of claim 2, further comprising the step of: applying a thin film vacuum bag over the cured bladder to provide a redundant gas barrier for sealing the bag carrier assembly. ### Claim 4 (depends on 3) The method of claim 3, further comprising the step of: adding a vacuum fitting to the cured bladder; and drawing, via the vacuum fitting, a vacuum on the cured bladder to draw the cured bladder against bag carrier tool surfaces and soluble detail surfaces to assist in installing the bag carrier assembly into a composite part. ### Claim 5 (depends on 1) The method of claim 1, wherein the step of fabricating the soluble forming mandrel comprises at least one of: curing a foam mixture within a mold of the forming mandrel; and three-dimensional printing the forming mandrel. ### Claim 6 (depends on 1) The method of claim 1, further comprising the step of: forming the bag carrier with a hollow bag carrier interior. ### Claim 7 (depends on 1) The method of claim 1, further comprising the step of: forming the soluble detail in a shape that is complementary to non-draftable geometry of a composite part. ### Claim 8 (depends on 1) The method of claim 1, further comprising the step of: forming the bag carrier and the soluble detail with a keyed geometry. ### Claim 9 (depends on 1) The method of claim 1, wherein: the non-soluble composite bag carrier is formed of carbon fiber-reinforced polymeric material or fiberglass fiber-reinforced polymeric material. ### Claim 10 (depends on 1) The method of claim 1, wherein laying up composite material over the soluble forming mandrel comprises: applying prepreg over the soluble forming mandrel. ### Claim 11 (depends on 1) The method of claim 1, wherein: the non-soluble composite bag carrier includes one or more openings on one or both bag carrier ends. ### Claim 12 (depends on 1) The method of claim 1, wherein: the non-soluble composite bag carrier has a hollow bag carrier channel extending at least partially through the non-soluble composite bag carrier along a bag carrier length. ### Claim 13 (depends on 1) The method of claim 1, wherein: the soluble detail is solid. ### Claim 14 (depends on 1) The method of claim 1, wherein: the soluble detail is soluble in a polar solvent. ### Claim 15 (depends on 8) The method of claim 8, wherein: the non-soluble composite bag carrier has a bag carrier keyed end; and the keyed geometry of the soluble detail is configured complementary to the bag carrier keyed end. ### Claim 16 (depends on 8) The method of claim 8, wherein: the keyed geometry of the soluble detail is configured to prevent movement of the soluble detail relative to the bag carrier. ### Claim 17 (depends on 1) The method of claim 1, wherein: the bladder is formed of natural polymeric material and/or synthetic polymeric material. ### Claim 18 (depends on 17) The method of claim 17, wherein: the polymeric material is one of nylon material, polyamide material, or rubber material. ### Claim 19 (depends on 18) The method of claim 18, wherein: the rubber material is one of silicone rubber, latex rubber, or fluoropolymeric rubber. ### Claim 20 (depends on 1) The method of claim 1, wherein: the bladder is formed to a thickness of 0.005 to 0.25 inch.