System for molding composite structures

Abstract

A system for manufacturing a molded composite structure is disclosed. In one embodiment, the system includes a first preparing component configured to prepare a material stack, wherein the material stack comprises a core section having first and second opposing sides, and wherein the first preparing component further comprises: a first applying component configured to apply first and second substantially fibrous support layers on the first side and second opposing side of the core section wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; a second applying component configured to apply an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and a third applying component configured to apply a thermoplastic barrier layer on the adhesive layers covering all surfaces of the core; a second preparing component configured to prepare a resin; a third preparing component configured to prepare a mold; a placing component configured to place the material stack in the mold; an evacuating component configured to evacuate air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers; a sealing component configured to seal the evacuated core section, wherein the sealing component further comprises a first curing component configured to cure the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core sections such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; an infusing component configured to infuse the mold and the evacuated material stack with the resin to form the structure; a second curing component configured to cure the structure; and a removing component configured to remove the structure from the mold.

1 - 21 . (canceled) 
   
   
       22 : A system for manufacturing a molded composite structure, comprising:
 a first preparing component configured to prepare a material stack, wherein the material stack comprises a core section having first and second opposing sides, and wherein the first preparing component further comprises:
 a first applying component configured to apply first and second substantially fibrous support layers on the first side and second opposing side of the core section wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; 
 a second applying component configured to apply an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and 
 a third applying component configured to apply a thermoplastic barrier layer on the adhesive layers covering all surfaces of the core; 
   a second preparing component configured to prepare a resin;   a third preparing component configured to prepare a mold;   a placing component configured to place the material stack in the mold;   an evacuating component configured to evacuate air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers;   a sealing component configured to seal the evacuated core section, wherein the sealing component further comprises
 a first curing component configured to cure the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core sections such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; 
   an infusing component configured to infuse the mold and the evacuated material stack with the resin to form the structure;   a second curing component configured to cure the structure; and   a removing component configured to remove the structure from the mold.   
   
   
       23 : The system of  claim 22 , wherein the first preparing component further comprises:
 a fourth applying component configured to apply a laminate layer on at least one of the first side and the second side of the core section.   
   
   
       24 : The system of  claim 22 , wherein the first preparing component further comprises:
 a fourth preparing component configured to prepare at least two material stacks, wherein at least one of the material stacks comprises a core section having first and second opposing sides and at least one of the material stacks does not comprise a core section.   
   
   
       25 - 27 . (canceled) 
   
   
       28 : The system of  claim 22 , wherein the first preparing component further comprises:
 a fourth applying component configured to apply a laminate layer on the thermoplastic barrier layer.   
   
   
       29 : The system of  claim 28 , wherein the fourth applying component further comprises:
 a fifth applying component configured to apply the laminate layer with a specified fiber orientation.   
   
   
       30 : The system of  claim 29 , wherein the third preparing component further comprises:
 a reducing component configured to reduce the modification of the fiber orientation during resin infusion.   
   
   
       31 : The system of  claim 30 , wherein the mold comprises a shape and an internal pressure and wherein the reducing component further comprises:
 an altering component configured to alter the shape and the internal pressure of the mold.   
   
   
       32 . (canceled) 
   
   
       33 : The system of  claim 22 , wherein the third preparing component further comprises:
 a fourth preparing component configured to prepare a first tool to form an exterior shape of the structure; and   a fifth preparing component configured to prepare a second tool to form an interior shape of the structure.   
   
   
       34 : The system of  claim 22 , wherein the second tool includes an elastomeric tool. 
   
   
       35 : The system of  claim 22 , wherein the placing component further comprises:
 a fourth applying component configured to apply a release agent to the mold and to the material stack; and   a placing component configured to place the material stack in the mold.   
   
   
       36 : The system of  claim 22 , wherein the material stack includes cavities, and wherein the infusing component further comprises:
 a closing component configured to close the mold;   a second sealing component configured to seal the mold;   a creating component configured to create a vacuum in the mold; and   an infusing component configured to infuse the mold with the resin until the cavities in the material stack are filled with resin.   
   
   
       37 : The method system of  claim 22 , wherein the second curing component further comprises:
 a fourth applying component configured to apply heat to the mold.   
   
   
       38 : The system of  claim 22 , wherein the second curing component further comprises:
 a fourth applying component configured to apply pressure to the mold.   
   
   
       39 : The system of  claim 22 , wherein the structure has an exterior surface resulting in a smooth laminar flow of air over that surface. 
   
   
       40 : The system of  claim 22 , wherein the structure is a wing panel for an aircraft. 
   
   
       41 : The system of  claim 22 , wherein the structure is a semi-span wing for an aircraft. 
   
   
       42 : The system of  claim 22 , wherein the structure is a full-span wing for an aircraft. 
   
   
       43 . (canceled) 
   
   
       44 : A system for manufacturing a molded composite structure, comprising:
 first preparing means for preparing a material stack, wherein the material stack comprises a core section having first and second opposing sides, and wherein the first preparing means further comprises:
 a first applying means for applying first and second substantially fibrous support layers on the first side and second opposing side of the core section wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; 
 a second applying means for applying an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and 
 a third applying means for applying a thermoplastic barrier layer on the adhesive avers covering all surfaces of the core; 
   second preparing means for preparing a resin;   third preparing means for preparing a mold;   placing means for placing the material stack in the mold;   evacuating means for evacuating air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers;   sealing means for sealing the evacuated core section, wherein the sealing means further comprises
 a first curing means for curing the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core sections such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; 
   infusing means for infusing the mold and the evacuated material stack with the resin to form the structure;   a second curing means for curing the structure; and   removing means for removing the structure from the mold.   
   
   
       45 - 66 . (canceled) 
   
   
       67 : A system for manufacturing a molded composite structure, comprising:
 a first preparing component configured to prepare at least one material stack, wherein the material stack comprises a core section and cavities, and wherein the core section comprises first and second opposing sides and wherein the first preparing component further comprises:
 a first applying component configured to apply first and second substantially fibrous support layers on the first side and second opposing side of the core section wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; 
 a second applying component configured to apply an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and 
 a third applying component configured to apply a thermoplastic barrier layer on the adhesive layers covering all surfaces of the core; 
   a second preparing component configured to prepare a resin;   a third preparing component configured to prepare a first tool to form an exterior shape of the structure;   a fourth preparing component configured to prepare a second tool to form an interior shape of the structure;   an integrating component configured to integrate the second tool with the material stack;   a placing component configured to place the material stack with the second tool inside of the first tool;   an evacuating component configured to evacuate air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers;   a sealing component configured to seal the evacuated core section of the material stack, wherein the sealing component further comprises
 a first curing component configured to cure the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core sections such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; 
   an infusing component configured to infuse the first tool with the resin until the cavities in the evacuated material stack are filled with resin to form the structure;   a second curing component configured to cure the structure;   a first removing component configured to remove the structure from the first tool; and   a second removing component configured to remove the second tool from the structure.   
   
   
       68 : The system of  claim 67 , wherein the first preparing component further comprises:
 a fifth preparing component configured to prepare at least two material stacks, wherein at least one of the material stacks comprises a core section having first and second opposing sides and at least one of the material stacks does not comprise a core section;   
   
   
       69 - 71 . (canceled) 
   
   
       72 : The system of  claim 67 , wherein the first preparing component further comprises:
 a fourth applying component configured to apply a laminate layer on the thermoplastic barrier layer.   
   
   
       73 . (canceled) 
   
   
       74 : The system of  claim 72 , wherein the fourth applying component further comprises:
 a fifth applying component configured to apply the laminate layer with a specified fiber orientation.   
   
   
       75 : The system of  claim 74 , wherein the third preparing component and the fourth preparing component further comprise:
 a reducing component configured to reduce the modification of the fiber orientation during resin infusion.   
   
   
       76 : The system of  claim 75 , wherein the first tool comprises a shape and an internal pressure and wherein the reducing component further comprises:
 an altering component configured to alter the shape and the internal pressure of the first tool.   
   
   
       77 : The system of  claim 67 , wherein the second tool includes an elastomeric tool. 
   
   
       78 : The system of  claim 77 , wherein the infusing component further comprises:
 an altering component configured to alter the internal pressure in the elastomeric tool to alter the rate of infusion.   
   
   
       79 : The system of  claim 67 , wherein the integrating component further comprises:
 a fourth applying component configured to apply a release agent to the second tool; and   a second placing component configured to place the second tool in the material stack.   
   
   
       80 : The system of  claim 67 , wherein the placing component further comprises:
 a fourth applying component configured to apply a release agent to the first tool; and   a placing component configured to place the material stack with the second tool inside the first tool.   
   
   
       81 : The system of  claim 67 , wherein the first curing component and the second curing component are configured to cure at substantially the same temperature. 
   
   
       82 : The system of  claim 67 , wherein the first curing component is configured to cure at a higher temperature than the second curing component. 
   
   
       83 : The system of  claim 67 , wherein the first curing component is configured to cure at a lower temperature than the second curing component. 
   
   
       84 : The system of  claim 67 , wherein the infusing component further comprises:
 a second sealing component configured to seal the first tool; and   a creating component configured to create a vacuum in the first tool.   
   
   
       85 : The system of  claim 67 , wherein the second curing component further comprises:
 a fourth applying component configured to apply heat to the to the structure; and   a fifth applying component configured to apply pressure to the structure.   
   
   
       86 : The system of  claim 67 , wherein the structure is a wing panel for an aircraft. 
   
   
       87 : The system of  claim 67 , wherein the structure is a semi-span wing for an aircraft. 
   
   
       88 : The system of  claim 67 , wherein the structure is a full-span wing for an aircraft. 
   
   
       89 . (canceled) 
   
   
       90 : A system for manufacturing a molded composite structure, comprising:
 first preparing means for preparing at least one material stack, wherein the material stack comprises a core section and cavities, and wherein the core section comprises first and second opposing sides and wherein the first preparing means further comprises:
 a first applying means for applying first and second substantially fibrous support layers on the first side and second opposing side of the core section wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; 
 a second applying means for applying an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and 
 a third applying means for applying a thermoplastic barrier layer on the adhesive layers covering all surfaces of the core; 
   second preparing means for preparing a resin;   third preparing means for preparing a first tool to form an exterior shape of the structure;   fourth preparing means for preparing a second tool to form an interior shape of the structure;   integrating means for integrating the second tool with the material stack;   placing means for placing the material stack with the second tool inside of the first tool;   evacuating means for evacuating air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers;   sealing means for sealing the evacuated core section of the material stack, wherein the sealing means further comprises
 a first curing means for curing the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core sections such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; 
   infusing means for infusing the first tool with the resin until the cavities in the evacuated material stack are filled with resin to form the structure;   second curing means for curing the structure;   first removing means for removing the structure from the first tool; and   second removing means for removing the second tool from the structure.   
   
   
       91 - 100 . (canceled)