US2019351599A1PendingUtilityA1

Method and apparatus for consolidating a bulk molding compound

64
Assignee: BOEING COPriority: May 17, 2018Filed: May 17, 2018Published: Nov 21, 2019
Est. expiryMay 17, 2038(~11.8 yrs left)· nominal 20-yr term from priority
Inventors:Weidong Song
B29C 48/30B29K 2105/14B29C 48/767B29C 48/022B29C 48/693B29C 48/345B29C 48/475B29C 70/12B29C 48/2886B29C 64/20B29C 48/388B29C 48/16B29C 48/70B29C 48/362B29C 47/0004B29C 47/686B29C 47/30B29C 47/767B29C 47/54B29C 48/695B29C 48/06B29C 70/40B29C 48/78B29L 2031/3076B29B 7/86B29B 7/845B29B 7/582
64
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Claims

Abstract

Methods and an apparatus are presented. A bulk molding compound is consolidated by sending the bulk molding compound through a die breaker and an extrusion die of a consolidation system.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A method comprising:
 consolidating a bulk molding compound by sending the bulk molding compound through a die breaker and an extrusion die of a consolidation system.   
     
     
         2 . The method of  claim 1 , wherein consolidating the bulk molding compound comprises:
 sending the bulk molding compound through the die breaker within the consolidation system; and   extruding the bulk molding compound through the extrusion die of the consolidation system after sending the bulk molding compound through the die breaker.   
     
     
         3 . The method of  claim 2 , wherein sending the bulk molding compound through the die breaker axially aligns at least a portion of fibers in the bulk molding compound. 
     
     
         4 . The method of  claim 2  further comprising:
 relaxing the bulk molding compound between sending the bulk molding compound through the die breaker and extruding the bulk molding compound. 
 
     
     
         5 . The method of  claim 2 , wherein sending the bulk molding compound through the die breaker comprises compressing the bulk molding compound within a cylindrical housing of the consolidation system using a piston. 
     
     
         6 . The method of  claim 5  further comprising:
 degassing the bulk molding compound within the cylindrical housing. 
 
     
     
         7 . The method of  claim 5  further comprising:
 heating the cylindrical housing of the consolidation system. 
 
     
     
         8 . The method of  claim 2 , wherein sending the bulk molding compound through the die breaker within the consolidation system comprises sending the bulk molding compound through at least one of a plurality of holes or a plurality of slots. 
     
     
         9 . The method of  claim 8 , wherein sending the bulk molding compound through at least one of a plurality of holes or a plurality of slots consolidates the bulk molding compound. 
     
     
         10 . The method of  claim 1  further comprising:
 heating the bulk molding compound prior to loading the bulk molding compound into the consolidation system. 
 
     
     
         11 . The method of  claim 1 , wherein the bulk molding compound is a loose composite material formed of a resin and fillers. 
     
     
         12 . The method of  claim 1 , wherein consolidating the bulk molding compound forms a consolidated material, the method further comprising:
 forming a composite structure from the consolidated material, wherein the composite structure is a component of an aircraft.   
     
     
         13 . The method of  claim 12 , wherein the composite structure is a composite radius filler. 
     
     
         14 . A method comprising:
 heating a bulk molding compound to form a heated bulk molding compound;   loading the heated bulk molding compound into a consolidation system;   pressing the heated bulk molding compound to form a pressed material; and   extruding the pressed material through an extrusion die of the consolidation system.   
     
     
         15 . The method of  claim 14  further comprising:
 heating a cylindrical housing of the consolidation system. 
 
     
     
         16 . The method of  claim 14  further comprising:
 degassing the heated bulk molding compound after loading the heated bulk molding compound into the consolidation system. 
 
     
     
         17 . The method of  claim 14 , wherein pressing the heated bulk molding compound of the consolidation system to form the pressed material comprises pressing the heated bulk molding compound through a die breaker of the consolidation system, and wherein pressing the heated bulk molding compound through the die breaker of the consolidation system comprises driving a piston towards the extrusion die. 
     
     
         18 . The method of  claim 17 , wherein pressing the heated bulk molding compound through the die breaker of the consolidation system comprises sending the heated bulk molding compound through at least one of a plurality holes or a plurality of slots. 
     
     
         19 . The method of  claim 14 , wherein the bulk molding compound is a loose composite material formed of a resin and fillers. 
     
     
         20 . The method of  claim 14 , wherein extruding the pressed material through the extrusion die of the consolidation system forms a consolidated material, the method further comprising:
 forming a composite structure from the consolidated material, wherein the composite structure is a component of an aircraft.   
     
     
         21 . A method comprising:
 heating a bulk molding compound to form a heated bulk molding compound;   degassing the heated bulk molding compound in a consolidation system;   consolidating the heated bulk molding compound after degassing, in which consolidating comprises pressing the heated bulk molding compound through a die breaker form a pressed material;   relaxing the pressed material; and   extruding the pressed material through an extrusion die of the consolidation system after relaxing the pressed material.   
     
     
         22 . The method of  claim 21 , wherein pressing the heated bulk molding compound through the die breaker axially aligns at least a portion of fibers in the heated bulk molding compound. 
     
     
         23 . The method of  claim 21 , wherein extruding the pressed material axially aligns at least a portion of fibers in the pressed material. 
     
     
         24 . The method of  claim 21 , wherein extruding the pressed material forms a composite radius filler. 
     
     
         25 . A consolidation system configured to consolidate a bulk molding compound, the consolidation system comprising:
 a die breaker; and   an extrusion die.   
     
     
         26 . The consolidation system of  claim 25  further comprising:
 a piston; and 
 a cylindrical housing, wherein the die breaker is contained within the cylindrical housing, and wherein the extrusion die is connected to an end of the cylindrical housing. 
 
     
     
         27 . The consolidation system of  claim 26  further comprising:
 a relaxation chamber formed by the die breaker, the cylindrical housing, and the extrusion die. 
 
     
     
         28 . The consolidation system of  claim 26  further comprising:
 a compression chamber formed by the die breaker, the piston, and the cylindrical housing. 
 
     
     
         29 . The consolidation system of  claim 26  further comprising:
 a vacuum port within the cylindrical housing. 
 
     
     
         30 . The consolidation system of  claim 26  further comprising:
 a heater system associated with the cylindrical housing. 
 
     
     
         31 . The consolidation system of  claim 26 , wherein a diameter of an opening of the extrusion die is at least 25% less than the diameter of the cylindrical housing. 
     
     
         32 . The consolidation system of  claim 25 , wherein the die breaker comprises at least one of a plurality of holes or a plurality of slots. 
     
     
         33 . The consolidation system of  claim 25 , wherein the extrusion die has an opening with a cross-sectional shape that is one of round, square, rectangular, or triangular. 
     
     
         34 . The consolidation system of  claim 25 , wherein the extrusion die has an opening with a cross-sectional shape configured to form a composite radius filler. 
     
     
         35 . The consolidation system of  claim 25 , wherein the consolidation system is part of an end effector.

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