# US 2013/0153144 A1 · Multiple use precision extractable tooling > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0153144 A1 - Document ID: US20130153144A1 - Status: Published application - Kind: A1 - Application number: 13/330,232 - Filed: 2011-12-19 - Published: 2013-06-20 - Earliest claimed: 2011-12-19 - Assignees: Composite Technology Development, Inc. - Inventors: Michael Tupper; Rory Barrett; Larry G. Adams; Robert Taylor; Dana Turse - Web page: https://patentgrep.com/patent/US20130153144A1 ## CPC - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29C 33/405: {Elastomers, e.g. rubber (B29C33/50 takes precedence)} - 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)} - B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure - B32B 37/14: characterised by the properties of the layers - 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) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract Embodiments of the invention are directed toward extractable tooling devices for composite structure manufacturing. An extractable tool, according to some embodiments of the invention, can include a rigid core, one or more foam blocks, an elastic membrane, and a nozzle. The foam blocks can be shaped to provide a mold of the composite structure being manufactured. This mold may require the extractable tool to be trapped by the composite structure after manufacture. Use of the foams can allow the extractable tool to shrink in at least one dimension in order to extract the tool from the trapped configuration. ## Claims ### Claim 1 A tooling device comprising: a rigid core; a foam block disposed next to the core and comprising a shape; and a bladder surrounding the core and the foam block, wherein the bladder forms a barrier between an external environment and the core and the foam block. ### Claim 2 (depends on 1) The tooling device according to claim 1, wherein the foam block comprises a foam assembly including a plurality of foam blocks with a variety of different stiffness coefficients. ### Claim 3 (depends on 2) The tooling device according to claim 2, wherein the plurality of foam blocks are disposed next to or around the core. ### Claim 4 (depends on 1) The tooling device according to claim 1, wherein the foam block comprises a shape memory polymer (SMP), wherein the foam block is deformable at temperatures near or above a glass transition temperature. ### Claim 5 (depends on 1) The tooling device according to claim 1, wherein the shape of the foam block comprises a shape that is the compliment of a trapped shape. ### Claim 6 (depends on 1) The tooling device according to claim 1, wherein the foam block is stiff at temperatures below the glass transition temperature of the foam block. ### Claim 7 (depends on 1) The tooling device according to claim 1, further comprising a nozzle coupled with the bladder. ### Claim 8 (depends on 1) The tooling device according to claim 1, wherein the nozzle and the bladder form a pressure barrier between the external environment and the core and the foam block. ### Claim 9 (depends on 1) The tooling device according to claim 1, wherein positive pressure can be applied internally to the mold to provide consolidation pressure for the composite laminate during cure ### Claim 10 (depends on 1) The tooling device according to claim 1, wherein the core comprises a plurality of vent holes that provide passage for air. ### Claim 11 (depends on 1) The tooling device according to claim 1, wherein the stiffness of the foam block at room temperature comprises a stiffness to allow for use with an automatic tape placement device, vacuum assisted resin transfer molding processes, hand lay up processes, filament winding processes, or an automatic fiber placement device. ### Claim 12 (depends on 1) The tooling device according to claim 1, wherein the bladder comprises a thin membrane. ### Claim 13 (depends on 1) The tooling device according to claim 1, wherein the bladder comprises a silicon membrane. ### Claim 14 A method for forming a composite structure, the method comprising: positioning a tooling device in a workspace, wherein the tooling device comprises a foam material; laying-up composite layers that are supported by the foam material; curing the composite layers; applying positive consolidation pressure in the mold during cure; heating the foam material to a temperature near or above the glass transition temperature of the foam material; compressing the foam material; and extracting the tooling device. ### Claim 15 (depends on 14) The method for forming a composite structure according to claim 14, wherein the foam material comprises a shape memory polymer foam. ### Claim 16 (depends on 14) The method for forming a composite structure according to claim 14, wherein the foam material comprises the compliment of a trapped shape that is a mold of the shape of the composite structure being formed. ### Claim 17 (depends on 14) The method for forming a composite structure according to claim 14, wherein the foam material comprises a shape that is a mold of the shape of the composite structure being formed. ### Claim 18 (depends on 14) The method for forming a composite structure according to claim 14, wherein the foam material is surrounded by a membrane that can be pressurized or evacuated allowing for consolidation of the composite laminate and compression of the foam. ### Claim 19 (depends on 18) The method for forming a composite structure according to claim 18, further comprising pressurizing with air or evacuating air from the tooling device. ### Claim 20 (depends on 18) The method for forming a composite structure according to claim 18, wherein positive pressure is applied that provides consolidation pressure on the composite laminate during cure. ### Claim 21 (depends on 14) The method for forming a composite structure according to claim 14, wherein the tooling device is compressed in a direction that is transverse to the direction the tooling device is extracted. ### Claim 22 A tooling device comprising: a solid core; and a collapsible assembly surrounding portions of the solid core, wherein the collapsible assembly can be used to mold composites structures that have a trapped shape. ### Claim 23 (depends on 22) The tooling device according to claims 22, wherein the collapsible assembly comprises a shape memory polymer foam. ### Claim 24 (depends on 22) The tooling device according to claims 22, wherein the collapsible assembly is deformable at temperatures near or above a glass transition temperature. ### Claim 25 (depends on 22) The tooling device according to claims 22, further comprising a bladder surrounding the solid core and the collapsible assembly, wherein the bladder forms a barrier between an external environment and the solid core and the collapsible assembly. ### Claim 26 (depends on 22) The tooling device according to claims 22, wherein the collapsible assembly comprises a plurality of structures having different stiffness coefficients.