Method of transferring large uncured composite laminates

A method of forming individual vacuum zones on a lay-up surface of a mandrel tool, comprising the steps of:

• defining a first vacuum zone on the lay-up surface;
• defining a second vacuum zone on the lay-up surface;
• placing a first breather over the lay-up surface within said first vacuum zone;
• placing a second breather over the lay-up surface within said second vacuum zone;
• placing a first membrane over said first breather, said first membrane covering said first vacuum zone;
• placing a second membrane over said second breather, said second membrane covering said second vacuum zone;
• forming a first vacuum seal between said first membrane and the lay-up surface;
• forming a second vacuum seal between said second membrane and the lay-up surface;
• covering said first vacuum seal with a first laminate release surface;
• and
• covering said second vacuum seal with a second laminate release surface.

A method of transferring an uncured composite laminate skin from a lay-up surface of a male mandrel tool to a female cure tool, comprising the steps of:

• defining a first vacuum zone on the lay-up surface by applying a first double-stick tape to the lay-up surface;
• defining a second vacuum zone on the lay-up surface by applying a second double-stick tape to the lay-up surface, wherein said first vacuum zone and said second vacuum zone are adjacent;
• placing a first breather over the lay-up surface within said first vacuum zone;
• placing a second breather over the lay-up surface within said second vacuum zone;
• placing a first membrane over said first breather, said first membrane covering said first vacuum zone, and adhering said first membrane to said first double-stick tape;
• placing a second membrane over said second breather, said second membrane covering said second vacuum zone, and adhering said second membrane to said second double-stick tape;
• forming a first redundant vacuum seal between said first membrane and the lay-up surface by covering a first edge of said first membrane with a first seal tape, said first seal tape adhering to said first membrane and to the lay-up surface;
• forming a second redundant vacuum seal between said second membrane and the lay-up surface by covering a second edge of said second membrane with a second seal tape, said second seal tape adhering to said second membrane and to the lay-up surface, wherein said second redundant vacuum seal is adjacent to said first redundant vacuum seal;
• covering said first redundant vacuum seal with a first laminate release surface;
• covering said second redundant vacuum seal with a second laminate release surface;
• laying up a composite laminate skin on said lay-up surface over said first vacuum zone and over said second vacuum zone, wherein:
• said composite laminate skin smoothly covers said first redundant vacuum seal and said second redundant vacuum seal adjacent to said first redundant vacuum seal;
• and
• said composite laminate skin smoothly covers said first membrane and said first laminate release surface, said second membrane and said second laminate release surface.

A method of transferring an uncured composite laminate skin from a lay-up surface of a mandrel tool to a cure tool, comprising:

• a step for forming a first low profile seal of a first membrane to a surface of a mandrel tool at a first vacuum zone;
• a step for forming a second low profile seal of a second membrane to a surface of a mandrel tool at a second vacuum zone;
• a step for smoothly laying up a composite laminate skin over said first vacuum zone and said second vacuum zone;
• a step for separating said composite laminate skin into a first portion over said first vacuum zone and a second portion over said second vacuum zone;
• and
• a step for releasing said first portion individually of said second portion into a first cure tool.

A system for manufacturing large aircraft parts, comprising:

• a multiple head automated tape laying machine;
• a male mandrel lay-up tool having a lay-up surface with a plurality of vacuum zones defined on said lay-up surface including:
• a first vacuum zone of said plurality of vacuum zones, said first vacuum zone having a first low profile vacuum seal at a first boundary of said first vacuum zone;
• a second vacuum zone of said plurality of vacuum zones;
• said second vacuum zone having a second low profile vacuum seal at a second boundary of said second vacuum zone;
• and
• a rebate that separates said first vacuum zone from said second vacuum zone;
• and
• a plurality of female cure tools.