# US 11,077,629 B2 · Vacuum pressurized molding

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- Number: US 11,077,629 B2
- Document ID: US11077629B2
- Status: Granted
- Kind: B2
- Application number: 16/026,904
- Filed: 2018-07-03
- Published: 2020-01-09
- Granted: 2021-08-03
- Earliest claimed: 2018-07-03
- Assignees: Rohr, Inc.
- Applicants: Rohr, Inc.
- Inventors: Bryan Thai; Patrick J. Nolan
- Web page: https://patentgrep.com/patent/US11077629B2

## CPC

- B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C 33/68: Release sheets
- B29C 35/0227: {using pressure vessels, e.g. autoclaves, vulcanising pans (B29C35/065 takes precedence)}
- B29C 43/3642: {Bags, bleeder sheets or cauls for isostatic pressing}
- B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C 70/443: {and impregnating by vacuum or injection}
- B29C 70/547: {using channels or porous distribution layers incorporated in or associated with the product}
- B29C 2043/3657: {additional materials, e.g. permeable bleeder or breather sheets, cloths, blankets}
- B29L 2031/7504: {Turbines}
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A system for forming a composite component includes a close mold tool defining a cavity that corresponds to a shape of the composite component and configured to receive a composite material. The system further includes a perforated release film defining a plurality of openings and configured to be positioned on a surface of the composite material within the cavity. The system further includes a breather configured to be positioned on the perforated release film, to allow a vacuum to be applied to the composite material through the breather and the plurality of openings, and to allow pressurized fluid to be applied to the perforated release film through the breather.

## Claims

### Claim 1

A system for forming a composite component, comprising:
a close mold tool defining a cavity that corresponds to a shape of the composite component and configured to receive a composite material, the close mold tool further defining a passageway in fluid communication with the cavity;
a perforated release film defining a plurality of openings and configured to be positioned on a surface of the composite material within the cavity;
a breather configured to be positioned on the perforated release film, to allow a vacuum to be applied to the composite material through the breather and the plurality of openings, and to allow pressurized fluid to be applied to the perforated release film through the breather;
a vacuum source configured to be coupled to the passageway and configured to apply the vacuum to the cavity via the passageway; and
a pressurized fluid source configured to be coupled to the passageway after the vacuum source has been removed from the passageway and configured to apply the pressurized fluid to the cavity via the passageway.

### Claim 2 (depends on 1)

The system of claim 1, wherein the pressurized fluid source is configured to apply pressurized air to the cavity.

### Claim 3 (depends on 1)

The system of claim 1, further comprising a heater configured to apply heat to the close mold tool to heat the composite material in the cavity in order to cause the composite material to at least partially fill the plurality of openings of the perforated release film in response to application of the heat and the vacuum, and in order to cure the composite material in the cavity in response to the application of the heat and the pressurized fluid.

### Claim 4 (depends on 1)

The system of claim 1, further comprising the composite material that includes any thermoset composite material.

### Claim 5 (depends on 4)

The system of claim 4, wherein the thermoset composite material includes a plurality of fibers and a resin.

### Claim 6 (depends on 1)

The system of claim 1, wherein the perforated release film has a film thickness that is between 1 thousandths of an inch (25.4 micrometers, μm) and 3 thousandths of an inch (76.2 μm), and the breather has a breather thickness that is between 1 thousandth of an inch (25.4 μm) and 10 thousandths of an inch (254 μm).

### Claim 7 (depends on 1)

The system of claim 1, wherein the breather includes at least one of woven fiberglass or a porous polytetrafluoroethylene (PTFE) glass product.

### Claim 8 (depends on 1)

The system of claim 1, wherein the perforated release film includes fluorinated ethylene propylene (FEP).

### Claim 9 (depends on 1)

The system of claim 1, wherein the close mold tool includes a metal.

### Claim 10

A system for forming a composite component, comprising:
a close mold tool defining a cavity that corresponds to a shape of the composite component and configured to receive a composite material, the close mold tool further defining a passageway in fluid communication with the cavity;
a perforated release film defining a plurality of openings and configured to be positioned on a surface of the composite material within the cavity;
a breather configured to be positioned on the perforated release film;
a vacuum source configured to be coupled to the passageway and to apply a vacuum to the composite material through the breather and the plurality of openings via the passageway; and
a pressurized fluid source configured to be coupled to the passageway after the vacuum source has been removed from the passageway and to apply a pressurized fluid to the perforated release film through the breather via the passageway.

### Claim 11 (depends on 10)

The system of claim 10 further comprising a heater configured to apply heat to the close mold tool to heat the composite material in the cavity in order to cause the composite material to at least partially fill the plurality of openings of the perforated release film in response to application of the heat and the vacuum, and in order to cure the composite material in the cavity in response to the application of the heat and the pressurized fluid.

### Claim 12 (depends on 10)

The system of claim 10 wherein the pressurized fluid source is configured to apply pressurized air to the cavity.

### Claim 13

A method of forming a composite component, comprising:
placing a composite material in a volume defined by a close mold tool, the close mold tool further defining a passageway in fluid communication with the cavity;
placing a perforated release film defining a plurality of openings on the composite material;
placing a breather on the perforated release film;
applying a vacuum to the volume via the passageway to cause the composite material to at least partially fill the plurality of openings of the perforated release film;
removing the vacuum from the passageway; and
applying a pressurized fluid to the volume via the passageway after removing the vacuum from the passageway to apply pressure to the perforated release film and the composite material.

### Claim 14 (depends on 13)

The method of claim 13 further comprising applying heat to the volume while applying the vacuum to the volume in order to heat the composite material to allow the composite material to fill the at least the portion of the plurality of openings, and applying the heat to the volume while applying the pressurized fluid to the volume in order to cure the composite material.

### Claim 15 (depends on 14)

The method of claim 14 further comprising removing the perforated release film from the composite material after curing of the composite material.

### Claim 16 (depends on 13)

The method of claim 13 wherein applying the pressurized fluid to the volume includes applying the pressurized fluid to the volume in response to the composite material filling the at least the portion of the plurality of openings of the perforated release film to reduce a likelihood of the pressurized fluid flowing through the perforated release film.

### Claim 17 (depends on 13)

The method of claim 13 wherein applying the pressurized fluid to the volume includes applying pressurized air to the volume.