# US 11,999,115 B2 · Apparatus and method for processing a composite structure

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- Number: US 11,999,115 B2
- Document ID: US11999115B2
- Status: Granted
- Kind: B2
- Application number: 17/701,849
- Filed: 2022-03-23
- Published: 2022-10-20
- Granted: 2024-06-04
- Earliest claimed: 2021-04-14
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: James R. Kendall; Byron James Autry; Santiago M. Mejia; Brian T. Peters; Brian S. Carpenter
- Web page: https://patentgrep.com/patent/US11999115B2

## CPC

- B29C 70/342: {using isostatic pressure}
- B29C 70/544: {Details of vacuum bags, e.g. materials or shape}
- B29C 43/36: Moulds for making articles of definite length, i.e. discrete articles
- B29C 43/56: Compression moulding under special conditions, e.g. vacuum
- B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C 70/54: Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing}
- B29C 70/549: {Details of caul plates, e.g. materials or shape}
- B29C 70/443: {and impregnating by vacuum or injection}
- B29C 70/446: {Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames}
- B29C 2043/3649: {Inflatable bladders using gas or fluid and related details}
- B29C 2043/561: {under vacuum conditions}
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- 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

An apparatus for processing a composite structure includes a mandrel that includes a tooling surface and vacuum bagging that includes an elastomeric membrane and a bagging surface. The apparatus also includes a surface interface formed between the mandrel and the elastomeric membrane. The surface interface includes a suction channel formed in at least one of the tooling surface of the mandrel and the bagging surface of the elastomeric membrane. The elastomeric membrane is configured to be sealed to the mandrel along the suction channel in response to a vacuum applied to the suction channel.

## Claims

### Claim 1

A method of processing a composite structure, the method comprising:
supporting a composite layup on a tooling surface of a mandrel;
positioning a caul of a vacuum-bag assembly over the composite layup;
draping an edge portion of vacuum bagging of the vacuum-bag assembly, extending from a perimeter edge of the caul, over a portion of the tooling surface;
receiving a pair of seals, coupled to the edge portion of the vacuum bagging, in a pair of seal grooves, formed in the tooling surface alongside a vacuum channel, formed in at least one of the tooling surface of the mandrel and a bagging surface of the vacuum bagging;
applying a vacuum to the vacuum channel;
sealing the pair of seals within the pair of seal grooves in response to applying the vacuum;
forming a vacuum seal between the tooling surface of the mandrel and the bagging surface of the vacuum bagging and along the vacuum channel; and
forming a sealed vacuum chamber that encloses the composite layup with the mandrel, the vacuum-bag assembly, and the vacuum seal.

### Claim 2 (depends on 1)

The method of claim 1, further comprising reducing a pressure within the sealed vacuum chamber.

### Claim 3 (depends on 2)

The method of claim 2, further comprising, with the vacuum seal formed and the pressure within the sealed vacuum chamber reduced, applying at least one of an elevated temperature and an elevated pressure to the composite layup.

### Claim 4 (depends on 1)

The method of claim 1, further comprising applying a clamping force to the vacuum bagging to hold an edge portion of the vacuum-bag assembly against the tooling surface of the mandrel.

### Claim 5

An apparatus for processing a composite structure, the apparatus comprising:
a mandrel comprising a tooling surface, configured to support a composite layup, and a pair of seal grooves, formed in the tooling surface;
a vacuum-bag assembly configured to be placed over the mandrel and comprising:
a caul, comprising a perimeter edge;
vacuum bagging, extending from the perimeter edge of the caul and comprising a bagging surface; and
a pair of seals coupled to an edge portion of the vacuum-bag assembly, formed by the vacuum bagging extending from at least a portion of the perimeter edge of the caul; and
a vacuum channel formed in at least one of the tooling surface of the mandrel and the bagging surface of the vacuum bagging,
wherein:
a vacuum seal is formed between the vacuum bagging and the mandrel along the vacuum channel when the vacuum bagging is placed over the mandrel and a vacuum is applied to the vacuum channel;
the mandrel, the vacuum-bag assembly, and the vacuum seal form a sealed vacuum chamber that encloses a composite layup;
the pair of seal grooves is located alongside the vacuum channel such that the vacuum channel is located between the pair of seal grooves;
the pair of seals is configured to be received within the pair of seal grooves when the edge portion of the vacuum-bag assembly is draped over the tooling surface of the mandrel; and
the pair of seals is sealed with the pair of seal grooves in response to the vacuum applied to the vacuum channel.

### Claim 6 (depends on 5)

The apparatus of claim 5, wherein the vacuum channel comprises:
a plurality of primary grooves; and
a plurality of jumper grooves extending between the plurality of primary grooves such that the plurality of primary grooves is in fluid communication with each other via the plurality of jumper grooves.

### Claim 7 (depends on 1)

The apparatus of claim 1, wherein:
a perimeter vacuum chamber is formed by the tooling surface, the bagging surface, and the vacuum channel;
the vacuum is applied to the perimeter vacuum chamber via the vacuum channel to form the vacuum seal;
the perimeter vacuum chamber forms a portion of a perimeter boundary of the sealed vacuum chamber; and
the sealed vacuum chamber is fluidly isolated from the perimeter vacuum chamber.

### Claim 8 (depends on 5)

The apparatus of claim 5, wherein:
the tooling surface is configured to support a composite layup; and
the caul comprises a caul surface that is configured to contact a surface of the composite layup, opposite the tooling surface.

### Claim 9 (depends on 1)

The apparatus of claim 1, wherein the vacuum bagging forming at least the edge portion of the vacuum-bag assembly comprises an elastomeric membrane.

### Claim 10 (depends on 1)

The apparatus of claim 1, wherein:
the vacuum-bag assembly further comprises a stiffener coupled to the edge portion; and
the stiffener is located across the vacuum channel and the pair of seals sealed with the pair of seal grooves when the edge portion of the vacuum-bag assembly is draped over the tooling surface of the mandrel.

### Claim 11 (depends on 1)

The apparatus of claim 1, further comprising a fastening device configured to apply a clamping force to the edge portion of the vacuum-bag assembly to hold the vacuum-bag assembly against the tooling surface of the mandrel.

### Claim 12 (depends on 11)

The apparatus of claim 11, wherein the fastening device is configured to engage the edge portion of the vacuum-bag assembly over at least one of the pair of seals.

### Claim 13 (depends on 1)

The apparatus of claim 1, wherein:
the vacuum channel comprises:
a mandrel vacuum channel formed in the tooling surface; and
a second mandrel vacuum channel formed in the tooling surface and spaced away from the mandrel vacuum channel;
the mandrel vacuum channel and the second mandrel vacuum channel are located between the pair of seal grooves formed in the tooling surface;
the mandrel further comprises an inflatable seal located between the mandrel vacuum channel and the second mandrel vacuum channel; and
the inflatable seal is configured to be pressurized to apply a force against the edge portion of the vacuum-bag assembly when the vacuum is being applied to the mandrel vacuum channel and the second mandrel vacuum channel.

### Claim 14 (depends on 5)

The apparatus of claim 5, wherein:
the vacuum-bag assembly further comprises:
a second caul coupled to the vacuum bagging and comprising a coupling surface;
an extension portion that is formed from the vacuum bagging extending from a portion of the perimeter edge of the caul; and
a second vacuum channel formed in at least one of the coupling surface of the second caul and the bagging surface of the extension portion of the vacuum-bag assembly; and
the extension portion of the of the vacuum-bag assembly is configured to be draped over a portion of the second caul and to be sealed to the second caul along the second vacuum channel in response to a vacuum applied to the second vacuum channel.

### Claim 15 (depends on 5)

The apparatus of claim 5, wherein:
the mandrel further comprises a mandrel bladder and a bladder vent aperture formed in the mandrel bladder;
the vacuum-bag assembly further comprises a vent fitting that extends through the vacuum bagging; and
the vent fitting is configured to be coupled to the bladder vent aperture such that the mandrel bladder is in fluid communication with atmosphere that is external to the vacuum-bag assembly.

### Claim 16 (depends on 5)

The apparatus of claim 5, wherein the mandrel further comprises:
a mandrel bladder;
a bladder vent aperture formed in the mandrel bladder;
a mandrel vent aperture in fluid communication with the bladder vent aperture; and
a vent fitting that is configured to extend through the mandrel vent aperture and to be coupled to the bladder vent aperture such that the mandrel bladder is in fluid communication with atmosphere that is external to the mandrel.

### Claim 17

A mandrel for processing a composite structure, the mandrel comprising:
a tooling surface on which a composite layup is configured to be supported;
a mandrel vacuum channel formed in the tooling surface;
a pair of seal grooves formed in the tooling surface and located alongside the mandrel vacuum channel such that the mandrel vacuum channel is located between the pair of seal grooves,
wherein:
a vacuum seal is formed between the tooling surface and an edge portion of a vacuum-bag assembly, placed over the composite layup and the mandrel, in response to a vacuum applied to the mandrel vacuum channel;
the pair of seal grooves received a pair of seals, coupled to the edge portion of the vacuum-bag assembly, when the edge portion of the vacuum-bag assembly is draped over the tooling surface of the mandrel;
the pair of seal grooves is sealed with the pair of seals in response to the vacuum applied to the vacuum channel; and
a sealed vacuum chamber that encloses the composite layup is formed by the mandrel, the vacuum-bag assembly, and the vacuum seal.

### Claim 18

An apparatus for processing a composite structure, the apparatus comprising:
a mandrel comprising a tooling surface, configured to support a composite layup;
a vacuum-bag assembly configured to be placed over the mandrel and comprising:
a caul, comprising a perimeter edge; and
vacuum bagging, extending from the perimeter edge of the caul and comprising a bagging surface;
a vacuum channel formed in at least one of the tooling surface of the mandrel and the bagging surface of the vacuum bagging;
a second caul coupled to the vacuum bagging and comprising a coupling surface;
an extension portion that is formed from the vacuum bagging extending from a portion of the perimeter edge of the caul; and
a second vacuum channel formed in at least one of the coupling surface of the second caul and the bagging surface of the extension portion of the vacuum-bag assembly;
wherein:
a vacuum seal is formed between the vacuum bagging and the mandrel along the vacuum channel when the vacuum bagging is placed over the mandrel and a vacuum is applied to the vacuum channel;
the mandrel, the vacuum-bag assembly, and the vacuum seal form a sealed vacuum chamber that encloses a composite layup; and
the extension portion of the of the vacuum-bag assembly is configured to be draped over a portion of the second caul and to be sealed to the second caul along the second vacuum channel in response to a vacuum applied to the second vacuum channel.

### Claim 19 (depends on 18)

The apparatus of claim 18, wherein:
the tooling surface is configured to support a composite layup; and
the caul comprises a caul surface that is configured to contact a surface of the composite layup, opposite the tooling surface.

### Claim 20 (depends on 18)

The apparatus of claim 18, wherein the vacuum bagging forming at least the edge portion of the vacuum-bag assembly comprises an elastomeric membrane.