HK1231017B - Thermal processing and curing system and method - Google Patents

Description

Thermal treatment and curing systems and methods

This application is a divisional application of the invention application filed on November 4, 2011, with application number 201180064249.3 and title “Heat treatment and reinforcement system and method”.

Related applications

This patent application claims priority under 35 U.S.C. §119(e) to the following U.S. Provisional Patent Applications, which are hereby incorporated by reference in their entirety for all purposes and are made a part of this patent application:

1. U.S. Provisional Patent Application No. 61/410,753, filed on November 5, 2010, entitled “METHOD OF MAKING COMPOSITE PARTS BY USING MEMBRANE PRESS” (Attorney Docket No. 1189-010PRO), pending.

2. U.S. Provisional Patent Application No. 61/495,661, filed on June 10, 2011, entitled “RAPID CURE SYSTEM FOR THE MANUFACTURE OF COMPOSITE PARTS” (Attorney Docket No. 1189-011 PRO), pending.

3. U.S. Provisional Patent Application No. 61/418,521, entitled “Systems and Methods for Forming Composite Components.”

Technical Field

The present disclosure relates to a system for producing parts, such as composite parts for the automotive, aerospace, sports and other industries, using composite materials. The system is capable of heat treating and consolidating various sizes, shapes and flat parts under pressure (and optionally under vacuum).

Background Art

Composite materials are used to manufacture fiber-reinforced composite (FRC) components, which can be used as key components in modern high-performance aircraft and are also becoming increasingly common in land-based applications such as the automotive industry or the sports industry. Composite materials have many inherent advantages, including light weight, high strength and hardness. For aircraft applications in particular, these composite components, which may be large and complex in shape, are often key components of the aircraft, so the integrity of the material and structure must be strictly ensured. Unfortunately, these materials are often difficult to manufacture and have high manufacturing costs.

A typical composite component comprises two or more layers of woven fabric and/or unidirectional fiber monofilaments (e.g., carbon fiber, glass fiber, etc.) that are infused with a plastic resin (e.g., epoxy resin) in their final heat-treated and consolidated state. Methods for forming such composite components include vacuum bagging, pressurized bagging, autoclave molding, and resin transfer molding (RTM).

New automotive industry regulations (including Corporate Average Fuel Economy (CAFE), Head Impact Characteristics (HIC) and pedestrian protection, etc.) represent a challenge to traditional materials such as steel used in automobiles. Compared to steel, FRC components provide an excellent combination of physical properties including strength, weight and energy absorption. In this way, FRC components are able to meet these new requirements, such as the demand for lightweight and energy absorption. However, in order to be able to cost-effectively replace steel, the amount of time and cost required to manufacture FRC components must be reduced. In addition, manufacturing FRC components with aesthetic surfaces (such as Class A surfaces) is not only time-consuming, but also difficult to manufacture. Class A surfaces are simply surfaces with curvature and tangent alignment to achieve ideal aesthetic reflective qualities. Class A composite surfaces can have additional Class A requirements related to the following: short-range waviness, long-range waviness, gaps and other defects and surface features. People often interpret Class A surfaces as having curvature continuity from one surface to another.

Composite parts are usually made in autoclaves that can utilize vacuum, heating, cooling and pressure. Typical processing chambers include compression molding machines, autoclaves and baking ovens with metal die sets. Parts can be placed in the mold outline by manual or automated means, and optionally bagged for vacuum forming. Usually the prepared mold is transferred from the assembly area to the processing chamber by a truck, conveyor or other manual or automated means. After closing the processing chamber, the laminate is thermoformed to the mold outline by vacuum and/or pressure, and heat treated and reinforced. When the process is completed, the assembly is obtained from the mold. Existing systems and processes for producing high-performance composites are considered to have low production capacity and long production cycles (usually in the range of one to eight hours). Heating is completed by hot air and heated molds, which heats slowly and cools slowly.

Summary of the Invention

Embodiments relating to operating devices and methods are further described in the following brief description of the drawings, detailed description, and claims. Other features will become apparent from the following detailed description given with reference to the accompanying drawings.

One embodiment of the present disclosure provides a method for thermally treating and consolidating untreated components in a thermal treatment and consolidation system. The method involves placing a first tool on a lower chamber assembly, the first tool being aligned with an upper chamber assembly, the first tool contacting and supporting a set of untreated components. The upper chamber assembly is coupled to the lower chamber assembly to form an enclosed plenum, the plenum operable to maintain a pressurized environment associated with the first tool. Services are provided to the first tool via an automated coupling system, wherein the services allow the untreated components in the tool to be thermally treated and consolidated according to a set of process parameters.

Another embodiment provides a heat treatment and consolidation system. The heat treatment and consolidation system includes an upper chamber assembly, a lower chamber assembly, a first joining and ejection station, a transport assembly, an automatic coupling system, and a controller. The upper chamber assembly is coupled to the lower chamber assembly to form an enclosed plenum, the enclosed plenum operable to maintain a pressurized environment associated with the tool. The first joining and ejection station receives the tool and facilitates joining, bagging, and sealing of unprocessed components at the tool. The transport assembly accurately places the tool on the lower chamber assembly in alignment with the upper chamber assembly. The transport physically moves the tool from the joining and ejection station to the lower chamber assembly in alignment with the upper chamber assembly. The automatic coupling system provides services to the tool and the enclosed plenum. A controller coupled to the upper chamber assembly, the lower chamber assembly joining and ejection station, the transport assembly, and the automatic coupling system directs the supply of services to the enclosed plenum and tool according to a set of processing parameters. The set of processing parameters allows a single set of unprocessed components to be in contact with and supported by the tool for thermal processing and consolidation.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure may be understood by reference to the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like features, and in which:

FIG1 is a side view of a thermal treatment and reinforcement system according to an embodiment;

FIG2 is a cross-sectional view of an automatic coupling system according to an embodiment;

3 is a partial cross-sectional view of a mold tool with preformed material disposed on the mold tool according to an embodiment;

4 is a partial perspective view of a mold tool with a vacuum bag disposed on the mold tool according to an embodiment;

5 is a partial perspective view of a press and mold tool with a vacuum bag disposed on the mold tool and over a preformed material, according to an embodiment;

6 is a schematic diagram of a tool connection system plate of an automated coupling system for coupling a mold tool to a thermal processing and consolidation system according to an embodiment;

7 is a partial perspective scaled engineering illustration of a feed mechanism that moves mold tools into a press to begin during a profiling cycle and removes one or more mold tools from the press after the profiling cycle is complete, according to an embodiment;

FIG8 is a block diagram of a thermal treatment and reinforcement system according to an embodiment; and

9 is a logic flow diagram associated with a method of thermally treating and consolidating an untreated component in a thermal treatment and consolidation system, according to an embodiment.

DETAILED DESCRIPTION

Some embodiments of the present invention are described below with reference to the accompanying drawings, in which like numerals are used to designate like and corresponding components throughout the various drawings.

Embodiments provide systems for forming composite components by heat treatment and reinforcement, such as carbon fiber reinforced plastics, glass fiber reinforced plastics, or fiber reinforced composite (FRC) components. FRC components can be used in many industries, such as the automotive, marine, military defense, aviation, and medical device industries. Embodiments are particularly suitable for forming Class A FRC body panels across the entire vehicle platform. Examples of body panels and related components include, but are not limited to, shields, fenders, roofs, rockers, spoilers, roof beams, vertical planes, fenders, mirror covers, wind deflectors, etc. Further examples of FRC components include, but are not limited to, tonneau covers, battery applications, joysticks, bumpers, subframes, and other structural components. Embodiments are not limited to forming any specific type of composite product, and such composite components can have various sizes, shapes, and uses. It should also be understood that embodiments are not limited to any specific industry.

One embodiment of the present disclosure provides a method for thermally treating and reinforcing untreated components using a thermal treatment and reinforcement system. The method involves placing a first tool on a lower chamber assembly, the first tool being positioned to align with the upper chamber assembly, the first tool contacting and supporting a group of untreated components. The upper chamber assembly is coupled to the lower chamber assembly to form a closed air-filled space, which can be used to maintain a pressurized environment relative to the first tool. The lower chamber assembly can be a platen (i.e., a flat surface) or a surface having a certain volume. Service is provided to the first tool via a service interface, which can be a permanent or temporary automatic coupling system. The service allows the untreated components within the tool to be thermally treated and reinforced according to a set of processing parameters (i.e., a temperature and pressure distribution diagram).

Another embodiment provides a thermal treatment and consolidation system. The thermal treatment and consolidation system includes an upper chamber assembly, a lower chamber assembly, a first layup and ejection station, a transport assembly, an automated coupling system, and a controller. The upper chamber assembly is coupled to the lower chamber assembly to form an enclosed plenum chamber that can be used to maintain a pressurized environment associated with a tool. The first layup and ejection station receives the tool and facilitates the joining, packaging, and sealing of unprocessed components at the tool. The transport assembly accurately places the tool on the lower chamber assembly in alignment with the upper chamber assembly. The transport physically moves the tool from the layup and ejection station to the lower chamber assembly in alignment with the upper chamber assembly. The automated coupling system provides services to the tool and the enclosed plenum chamber. A controller coupled to the upper chamber assembly, the lower chamber assembly, the layup and ejection station, the transport assembly, and the automated coupling system directs services to be supplied to the enclosed plenum chamber and the tool according to a set of processing parameters. The set of processing parameters causes a separate set of unprocessed components to be in contact with and supported by the tool to be heat treated and consolidated.

FIG1 is a side view of a heat treatment and reinforcement system according to an embodiment. The heat treatment and reinforcement system 100 includes a lower chamber assembly 102, an upper chamber assembly 104, a conveyor assembly 106 and a hydraulic press 108, an upper chamber assembly guide 110, a tool guide 112, an integrated roller system 114 mounted on the tool, a push-pull assembly 116, multiple tool placement sensors 118, an air duct 120, a hot oil pipe 122, and an automatic coupling system 124. In operation, the tool 126 at the joining and ejection station 128 can be loaded with a group of untreated composite components or a group of components to be heat treated and reinforced and/or prepared in the provided heat treatment and reinforcement system. After the components have been joined within or on the tool 126, the components can be bagged. Alternatively, when a bag system is not used in the heat treatment and reinforcement system, a film-type press can be used for sealing. Another embodiment can use a permanently attached bag and sealing system integrated into the upper chamber assembly. A push-pull assembly 116 coupled to the tool and, via the conveyor assembly 106, repositions the tool 126 from the engagement and ejection station to a point on the lower chamber assembly 102 aligned with the upper chamber assembly 104. A hydraulic press 108 can be used to couple and maintain pressure between the upper chamber assembly 104 and the lower chamber assembly 102. The lower chamber assembly and the upper chamber assembly combine to create a gas-filled space. Various sensors 118 along the tool guide 112 report the position of the tool 126 to a controller (not shown), which directs the operation of the heat treatment and consolidation system.

Once aligned, the upper chamber assembly is lowered by hydraulic press 108 to form a pressure seal with lower chamber assembly 102. Tool 126 is aligned and mated to auto-coupling system 124. Auto-coupling system 124 can provide various services to the tool and the enclosed plenum space formed by upper and lower chamber assemblies 104, 102. These services can include high-pressure fluids or gases for pressurizing the plenum space environment relative to tool 126. A vacuum can be used to extract air or other gases from the set of components to be heat-treated and consolidated in tool 126. In one embodiment, hot oil can be used to heat the components to be heat-treated and consolidated by conduction and/or convection. Other embodiments may place radiators, infrared panels, resistive heating plates, or other heating systems to provide heat to heat-treat and consolidate the components within tool 126. Because the tool can encompass 80% or more of the plenum space, a heat exchange system (with or without shims and dividers) provides a more efficient method for controlling the thermal profile of the components during processing than previously available methods using conventional autoclaves. For example, in an autoclave, the tools occupy less than 20% of the chamber volume. This means that rapid temperature changes in the autoclave are thermodynamically inefficient, resulting in uneven heating of the tools and materials due to the low thermal conductivity of most autoclaves and the high thermal mass of most tools. This makes uniform heating and control of the autoclave, tools, and materials difficult to achieve. Due to the limited thermal conductivity of most autoclaves, runaway exothermic reactions in certain materials are another drawback of most autoclave systems. These systems can heat the autoclave atmosphere at a relatively rapid rate, but do not have sufficient thermal energy conductivity to extract sufficient exothermic heat from the material. The heat transfer and consolidation system described herein has sufficient thermal conductivity to control most exothermic reactions, which are typically the result of rapid heating rates of reactive materials. The components at tool 126 are heat treated and consolidated according to a pressure and temperature profile maintained as a set of process parameters and executed by a controller. After heat treatment and consolidation, the plenum is depressurized before opening. Furthermore, the auto-coupling system can be retracted from the tool before opening. The automatic coupling system is a self-sealing system so that hot oil, hydraulic fluid, or other fluid contained in the tool does not leak from the upper chamber assembly side of the automatic chamber coupling system or the tool side of the plenum space on the lower chamber assembly. The upper chamber assembly is raised to a certain height to accommodate the insertion and retraction of the tool 126.

FIG2 is a more detailed cross-sectional view of the automatic coupling system 124 according to an embodiment. FIG2 illustrates the upper chamber assembly 104 and the automatic coupling system extending therethrough. The coupling system includes external connections 202 for various services and internal self-sealing connections 206 that provide self-sealing and automatic coupling between the tool 126 and the automatic coupling system 124. As described above, the services provided to the external connections 202 may include thermal fluids for heating and/or cooling the tool and component according to a set of process parameters, vacuums for extracting gas from an unprocessed component, gas or fluids for pressurizing the plenum space according to a set of process parameters, communication pathways for exchanging information and/or control signals between the tool or plenum space and a thermal treatment and reinforcement system, injection materials for injection into the unprocessed component, and hydraulic systems for actuating mechanical systems within the automatic coupling system that allow the tool to be secured to the automatic coupling system. The extraction gas serves not only to remove the gas, but also to reduce the voids that would result if the gas were not removed. The extraction gas applied with a vacuum strengthens the laminate by creating a pressure differential, causing the film/vacuum bag to compress the laminate at atmospheric pressure or a pressure differential if a partial vacuum is used. The pressure differential created by the application of the vacuum under the film/vacuum bag causes a positive atmospheric pressure (greater than one atmosphere and up to 500 psi or more) to be applied to the material placed between the tool and the film/vacuum bag.

A hydraulic system can be used to operate the locking mechanism that secures the tool to the automatic coupling system 124. The coupling system locking system can be either hydraulic or electromechanical. A hydraulic push/pull system 208 allows the tool to engage/disengage with the chamber assembly. In other embodiments, the push/pull system 208 can also serve as the engaging/disengaging mechanism for the locking mechanism. A communication path can provide an electrical or optical path for sensor information collected in the plenum or from the tool to be provided to the controller by the automatic coupling system. This can allow the controller to monitor and control various stages of the process performed during treatment, manipulate the flow of hot oil, or manipulate heat transfer between the tool and an external source. Additionally, an identifier encoded on the tool can be provided to the controller via the communication path to ensure selection of the appropriate set of process parameters based on the component and tool ID. Alternatively, the identifier encoded in the tool facilitates seamless connection between the tool and its associated stored process parameters, so that when multiple unique tools are used in a system, the stored process parameters are automatically selected based on the tool in the position to be treated.

In at least some embodiments, suitable preform tools are used to support, bond, pack, and seal the unprocessed components. These tools can use fluids to heat or cool the tools, and the preform tools are used to form the composite components.

Figure 3 is a schematic diagram of a mold tool with a preform material arranged on a mold tool according to an embodiment. The mold tool 300 can interface with a press 302. The press 302 can also be referred to as a pressure press, or a bladder press, or a diaphragm/membrane press. The mold tool 300 is used to hold an unprocessed component 304 thereon. Optionally, the unprocessed component 304 is formed with a preform tool and typically includes a fiber mat and a resin. This can include carbon fiber, glass fiber, pre-impregnated fiber and plastic fiber mat; and a resin film layer or an injected resin. The component can also be formed directly into the tool manually or automatically. The mold tool 300 can be heated and/or cooled to interact with the resin of the unprocessed component 304.

FIG4 is a partial perspective view of a mold tool. FIG5 is a partial perspective view of a mold tool with a vacuum bag disposed on the mold tool and above the preformed material. Referring to FIG4 and FIG5 , a vacuum bag 306 is shown disposed on the mold tool 300. The vacuum bag 306 is used to form the FRC assembly from the untreated assembly 304. The vacuum bag 306 can have various configurations. The vacuum bag 306 is resealable with an integrated release mechanism for ease of use. The bag can include a stack of materials, including sealing tape, a glass layer/release film (sometimes perforated), a leather layer, a barrier film with a flexible film (typically silicone) placed thereon, or a single-use vacuum bag film. In one embodiment, the bagging system is a reusable bag comprising a preformed silicone film with a permanent release film and an integrated leather/sealing periphery, the permanent release film being applied to the material side of the bag. The vacuum bag 306 can be evacuated and used to drive resin into the fiber mat of the untreated assembly 304. In other embodiments, resin can be injected into the unprocessed components joined in the tool as one of the services provided by the automated coupling system. In certain embodiments, a vacuum bag 306 is provided for the removal of components such as leather layers, release films, and/or tapes. Other embodiments may integrate the vacuum bag into the interior surface of the upper chamber assembly or use a film integrated with the upper chamber assembly to form the FRC assembly.

FIG6 is a schematic diagram of a tool connection system board for an automatic coupling system that couples a mold tool to a heat treatment and reinforcement system. The tool connection system 600 includes internal and external connections 602, external and internal connections 604, static lines 606, external and internal connections 608, and communication path connections 610. The internal and external connections 602 are used to feed and return hot fluids, the external and internal connections 604 are used for vacuum lines, the static lines 606 are used for pressure monitoring of the mold tool, the external and internal connections 608 are used for pressurization of the closed gas-filled space, and the communication path connections 610 are used for information exchange, such as, but not limited to, resistive thermal devices (RTDs) for temperature monitoring and providing feedback of the mold tool. It can also be implemented by thermocouples, optical pyrometers, and other similar systems. Embodiments can monitor the actual temperature or the rate of change of temperature. The tool connection system includes multiple connections and sensors for connecting each component to the mold tool 300, such as fluid feed and fluid return. Typically, the components provide services and communication with the mold tool 300. These elements are generally in communication with the mold tool 300 , such as in fluid communication with the mold tool 300 .

In some embodiments, the tool connection system includes resistive thermal device (RTD) male and female connectors for temperature monitoring and feeding the mold tool 300. In addition to or in place of RTDs, other forms of temperature and pressure measurement of the mold tool 300 can also be used. These forms include thermocouples, optical pyrometers, and other similar systems. Embodiments can monitor the actual temperature or the rate of change of temperature.

The internal connections of the auto-coupling system include connections for hot fluid feed and return, connections for vacuum and static lines for pressure monitoring of the press, and communication path connections (optical or electrical) to relay temperature and pressure monitoring data and identification data to the controller. The internal connections 600 of the auto-coupling system also include a hot fluid exhaust valve 602 for feeding hot fluid to the tool, a hot fluid intake valve 604 for returning hot fluid, a first alignment pin 612, a vacuum connector 605 and a static connector 606 for pressure monitoring of the plenum space, a locking ring operated by a hydraulic actuator supplied by connector 607, and a second alignment pin or sleeve 614.

By pressurizing the plenum space, pressure is applied to the mold tool 300 and the unprocessed component during the profiling cycle to form the FRC component from the unprocessed component 304. The plenum space and mold tool 300 have a pressure, temperature, and/or vacuum profile imparted by the internal connections 600 of the automated coupling system. The heat treatment and consolidation system includes a lower frame for supporting the mold tool 300.

A programmable logic controller (PLC) monitors and controls the operation of the heat treatment and reinforcement system, including the positioning of the tools and the temperature and pressure applied. The PLC can be implemented using shared processing equipment and/or separate processing equipment. The processing equipment can include a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a state machine, a logic circuit, an analog circuit, a digital circuit, and/or a device that manipulates (analog and/or digital) signals based on operating instructions. The memory can be a single memory device or multiple memory devices. Such a memory device can be a read-only memory, a random access memory, a volatile memory, a non-volatile memory, a static memory, a dynamic memory, a flash memory, and/or any device for storing digital information. It should be noted that when the baseband processing module implements one or more of its functions via a state machine, analog circuits, digital circuits, and/or logic circuits, the memory storing the corresponding operating instructions is embedded with circuitry, including a state machine, analog circuits, digital circuits, and/or logic circuits.

Typically, after the upper chamber assembly is coupled to the lower chamber assembly, a common connection design is utilized to automatically realize the connection between the mold tool 300 and the heat treatment and reinforcement system. Specifically, once the mold tool enters the gas-filled space, the internal connection 600 of the tool and the automatic coupling system is coupled and combined. Once coupled, the mold tool 300 and the heat treatment and reinforcement system are in fluid (and usually communicate electrically) with each other. The coupling of the elements is typically as follows (once the mold tool 300 and the automatic coupling system are combined): vacuum connector coupling, static connector coupling, positive locking pin and negative locking ring coupling, alignment sleeve and alignment pin coupling, RTD positive connector and RTD negative connector coupling, hot fluid inlet valve coupling, and hot fluid outlet valve coupling. The fluid containing the connection is self-sealed to prevent the fluid from leaking into the gas-filled space during this process. Such a configuration provides manufacturing diversity, for example, allowing the use of multiple tool variants (such as mold tool 300 variants) without the occurrence of attached changes over time. For example, the various configurations of the mold tool 300 can be utilized and simply "inserted into" the heat treatment and reinforcement system via the connection system. It should be understood that the mold tool 300 can be of various sizes, shapes, and configurations.

The heat treatment and reinforcement system can create a closed pressurized environment that can be pressurized to various pressures for various amounts of time depending on the needs of the untreated component. For example, the heat treatment and reinforcement system can create a closed, air-filled space that can be pressurized to approximately 150 psi in approximately 2 minutes. The air-filled space can also be pressurized to above or below approximately 150 psi for various amounts of time greater than or less than 2 minutes. The treatment pressure can be in the range of 80 to 150 psi, but can also be more or less depending on the material and desired component properties. The treatment pressure in at least some embodiments can be significantly greater than 150 psi; for example, one embodiment can use a pressure of approximately 300 psi. Similarly, the treatment pressure in at least some embodiments can be significantly less than 80 psi. The pressure or pressure range is selected based on the properties of the untreated component and the resin, material, or adhesive used in the treatment.

In at least some embodiments, a hydraulic actuator system in the upper chamber assembly of FIG1 provides selected pressure to some or all of the mold tools 300, thereby profiling the unprocessed component 304. A human machine interface (HMI), such as a graphical user interface (GUI), can be used to monitor and control processing parameters associated with the process. Processing parameters include temperature, pressure, and/or vacuum of the plenum and tool during the processing cycle.

7 is a partial perspective scale engineering drawing of a feeding mechanism that moves mold tools into the press to begin during the press cycle and removes one or more mold tools from the press after the press cycle is completed, according to an embodiment. The feeding mechanism 700 feeds the mold tools 300 into the heat treatment and reinforcement system during the press cycle and removes the mold tools 300 from the heat treatment and reinforcement system after the press cycle. The feeding mechanism 700 can be coupled to a tray to hold, send, and receive the mold tools 300. In at least one embodiment, the feeding mechanism is an energized push/pull bar coupled to the tool or tray. In at least some embodiments, the tray can interface with the upper chamber assembly and the lower chamber assembly to form a pressure boundary. The tray can also have internal piping and connections that allow service to be provided to the tool by a mobile workbench or tray. The tray can also be part of the lower chamber assembly.

8 provides a block diagram of a heat treatment and reinforcement system 800 according to an embodiment. Heat treatment and reinforcement system 800 includes a processing chamber 802, at least one joining and ejection station 804, an optional additional joining and ejection station 806, a transport assembly 808, a coupling system 810, a controller 812, and a service module 814. The processing chamber 802 can form a pressurized, closed, gas-filled space from an upper chamber assembly in conjunction with a lower chamber assembly, wherein the upper chamber assembly is coupled and decoupled with the lower chamber assembly via a hydraulic profiling system 816. The joining and ejection station 804 receives a tool 818, which can be used as a support for the unprocessed component to be processed (i.e., to be heat treated and reinforced in the processing chamber). Joining can involve joining, bagging, and sealing the unprocessed component to the tool 818 before being transferred to the processing chamber 802 from the joining and ejection station 804 via the transport assembly 808.

Controller 812 is coupled to sensor network 820, hydraulic press 816, process chamber 820, bonding and ejection station 804, optional bonding and ejection station 806, transport assembly 808, coupling module 810, and service module 814. The transport assembly directs the movement of tools from bonding and ejection station 804 to process chamber 802. The tools are positioned so that they can be coupled to coupling module 810 in an automated manner. Controller 812 can then direct the closing of the process chamber and can provide services such as heating, cooling, pressurization, vacuum, and exchange of information/data via the service module.

The controller 812 directs the service module to execute a set of process parameters to cure the bond of the components in the tool 818 according to a predetermined pressure, temperature, and/or vacuum profile.

In at least some embodiments, additional engagement and ejection stations are provided that can receive additional tools 822. This allows an additional set of unprocessed components to be engaged, bagged, and sealed in tool 822 while the first set of unprocessed components is being processed on tool 818. This allows for significant throughput improvements by minimizing process chamber downtime to only the time required to transfer tools into and out of the process chamber.

The coupling system 810 can penetrate the processing chamber wall, the lower chamber assembly or the tray support tool and provide services to the interior of the processing chamber and the tools as required by the set of processing parameters. All of these coupling systems can be self-sealing systems so that the processing fluid does not leak in the processing chamber or on the tools. These services can also include thermal fluids, vacuums, gases, and communication pathways. The thermal fluids are used to exchange heat with the tools or other heat exchange structures located in the processing chamber. The vacuums are used to extract gases from the unprocessed components. The gases are used to pressurize the closed plenum space of the processing chamber 802, and the communication pathways allow sensors and tools in the processing chamber to transmit processing data back to the controller 812. Further identification information associated with the tool 818 or tool 822 can be used by the controller 812 to determine a set of processing parameters to be executed to cure the unprocessed components. Injection materials such as resins can be injected into the unprocessed components that are joined and bagged in the tools while the tools are already in the processing chamber. The hydraulic system can also be used to fix the tools to the coupling system under the guidance of the controller 812. In order to speed up the process, tools 818 and 822 may include a carriage for receiving a slide block. The slide block may hold a group of unprocessed components. When the slide block is received at the engagement and ejection station, the slide block may be placed as a unit on the carriage to facilitate engagement of the components in the tool. A large number of slide block tools may be used in such situations that the work associated with engagement in the slide block tool is substantially longer than the heat treatment/reinforcement cycle in such an environment. The slide block tool approach allows for cost reduction compared to creating a large number of complete tools. The slide block may include a housing that may be "engaged" and vacuum bagged before being placed into a heated carriage tool that transfers in and out of the chamber/plenum space.

These components can be made from composite materials using reinforced fibers such as, but not limited to, glass, carbon, ceramic, metal, or polymer fibers; composite matrix materials such as, but not limited to, thermosetting polymers, thermosetting polymer matrix composites, thermoplastic polymer matrix composites, thermoplastic polymer resins, thermosetting polymer resins; fiber/metal interwoven laminates, fiber/low density core interwoven composites, low density core composite laminates, metal matrix composites, low melting point metals, low melting point metal matrix composites; and metals with adhesives or polymer adhesives.

The plenum of process chamber 802 may have a variable volume, effected by the installation or removal of spacers or dividers, to allow the volume of the plenum to be substantially matched to the size of the tool being processed. Other types of heating and cooling may include the use of infrared radiation and/or microwave radiation.

Fig. 9 is a logic flow chart (e.g., performed by controller 812) associated with a method for heat treatment and reinforcement of untreated components in a heat treatment and reinforcement system according to an embodiment. Operation 900 begins in frame 902, where a first tool is placed on the lower chamber assembly. The first tool is placed to align with the upper chamber assembly, where the first tool supports a first group of untreated components. These components can be materials of metal, composite material, fiberglass, thermosetting material, thermoplastic or other types. In frame 904, the upper chamber assembly and the lower chamber assembly are combined or coupled to form a gas-filled space. The gas-filled space can provide a pressurized environment relevant to the tool and the untreated component so that they are in contact with the pressurized environment and are supported therein. The pressurized environment can be controlled to have a specific pressure distribution diagram so that the untreated component is supported in the upper chamber assembly. In frame 906, service is provided to the tool in the gas-filled space via a coupling system. Services may include providing injection material, gas or fluid for pressurizing the plenum space, hot oil or fluid for exchanging heat with heat exchange structures or tools in the plenum space, communication pathways for exchanging information, data and/or electrical signals, and vacuum, wherein the electrical signals include power signals to tools and other features in the plenum space, and the vacuum can be applied to the untreated component according to the set of treatment parameters.

In frame 908, the untreated component is processed and heat treated and reinforced in the plenum as guided by a set of processing parameters. A further step associated with the processing of the untreated component can be to couple/disengage the tool as a plenum via a coupling system. As described above, the service can be permanently attached to the tool and/or the plenum, or they can be coupled or decoupled as currently described. The upper chamber assembly can be opened to minimize the separation between the upper chamber assembly and the lower chamber assembly, so that the opening is only sufficient to transfer the tool to and from the aligned position in the plenum. This positioning is facilitated by a transport assembly coupled to a joining and ejection station, wherein the tool can be prepared for processing, and the processing assembly can be removed after processing. In at least some embodiments, the transport assembly can simultaneously retrieve a tool from the plenum and simultaneously place additional tools on the lower chamber assembly aligned with the upper chamber assembly for further processing. This minimizes the time required to open the plenum.

In summary, an embodiment provides a heat treatment and reinforcement system. The heat treatment and reinforcement system includes an upper chamber assembly, a lower chamber assembly, a first joining and ejecting station, a transport assembly, an automatic coupling system, and a controller. The upper chamber assembly is coupled to the lower chamber assembly to form a closed plenum, which can be used to maintain a pressurized environment associated with the tool. The first joining and ejecting station receives the tool and facilitates joining, packaging, and sealing of untreated components at the tool. The transport assembly accurately places the tool on the lower chamber assembly in alignment with the upper chamber assembly. The transport physically moves the tool from the joining and ejecting station in alignment with the upper chamber assembly to the lower chamber assembly. The automatic coupling system provides services to the tool and the closed plenum. A controller coupled to the upper chamber assembly, the lower chamber assembly, the joining and ejecting station, the transport assembly, and the automatic coupling system directs the services to be supplied to the closed plenum and the tool.

As will be understood by one of ordinary skill in the art, the terms "substantially" or "approximately" as used herein provide an industry-accepted tolerance to their corresponding terms. Such industry-accepted tolerances range from less than one percent to twenty percent and correspond to, but are not limited to, component values, integrated circuit process variables, temperature variables, rise and fall times, and/or thermal noise. As will be understood by one of ordinary skill in the art, the term "operably coupled" as used herein includes direct coupling and indirect coupling via another component, element, circuit, or module, wherein for indirect coupling, the intervening component, element, circuit, or module does not modify the information of the signal, but rather modifies its current level, voltage level, and/or power level. As will be understood by one of ordinary skill in the art, inferred coupling (i.e., wherein one element is connected to another element by inference) includes direct and indirect coupling between two elements in the same manner as "operably coupled."

The above description of some embodiments of the present invention has been presented for the purpose of description and illustration. It is not intended to be exhaustive or to limit the invention to the specific form disclosed, and various modifications and variations are possible in view of the above teachings and can be obtained from the practice of the present invention. The specifically described embodiments explain the main idea and practical application so that those skilled in the art can utilize the various embodiments and conceive various modifications suitable for specific uses. It is expected that the scope of the present invention is defined by the claims attached hereto and their equivalents. In addition, it should be understood that the various modifications, substitutions and variations that can be made here do not deviate from the spirit and scope of the present invention as described by the appended claims.

Claims (40)

1. A method for heat-treating and curing an untreated component in a heat treatment and curing system, the heat treatment and curing system comprising an upper assembly and a lower assembly coupled to each other, and a first tool, at least one of the upper assembly and the lower assembly being a chamber assembly, the method comprising: The first set of unprocessed components in the first tool are joined, bagged, and sealed. The first tool is placed on the lower assembly, wherein at least after the first tool is placed on the lower assembly, the first tool contacts and supports the first set of unprocessed components; At least one of moving the upper assembly relative to the lower assembly or moving the lower assembly relative to the upper assembly, and coupling the upper assembly and the lower assembly to form an inflatable space, thereby completely enclosing the first tool in the inflatable space, the inflatable space being operable to maintain a pressurized and/or temperature-controlled environment for the first tool; The service is provided to the first tool and the inflatable space via a service interface; and Heat treatment and curing of the first set of untreated components in the first tool, wherein the service is supplied to the first tool as guided by a set of processing parameters. 2. The method of claim 1, wherein the first tool substantially fills the inflatable space. 3. The method of claim 1, wherein the first tool fills 80% of the inflatable space. 4. The method of claim 1, further comprising: The service is detached from the first tool and the inflatable space via a service interface, the service interface including an automatic coupling system; Decouple the upper assembly from the lower assembly to form a gap between the upper assembly and the lower assembly; and The first tool is retrieved via the interval, the height of which is substantially the same as but greater than the height of the first tool. 5. The method of claim 4, further comprising: At least one additional tool is placed on the lower assembly aligned with the upper assembly, while the first tool is effectively retrieved from the inflatable space, the at least one additional tool contacting and supporting at least one additional set of unprocessed components. 6. The method of claim 1, wherein the service comprises at least one of the following: A hot fluid for heating and/or cooling the components according to the set of processing parameters; Vacuum, used to extract gas from the first set of untreated components in the first tool; Gas, used to pressurize the inflatable space according to the set of processing parameters; A communication channel for exchanging information and/or control signals between the first tool and the heat treatment and curing system; or Injection material is used to inject into the untreated component. 7. The method of claim 6, wherein the information includes a tool identifier, wherein the set of processing parameters is selected based on the tool identifier. 8. The method of claim 6, wherein the information includes processing data, wherein the processing data is used by the set of processing parameters. 9. The method of claim 1, further comprising: Data is collected and processed using at least one sensor associated with the first tool, material, and/or inflatable space. 10. The method of claim 9, wherein the processed data includes temperature, pressure, and/or material state data. 11. The method of claim 4, wherein the automatic coupling system is a self-sealing system. 12. The method of claim 11, wherein the actions of joining, bagging and sealing the first set of untreated components in the first tool are performed at the first joining and demolding station of the heat treatment and curing system. 13. The method of claim 1, wherein: At the first joining and demolding station of the heat treatment and curing system, the actions of joining, bagging and sealing the first set of untreated components in the first tool are performed. The method further includes: performing at least one additional set of additional untreated components for at least one additional tool at at least one additional joining and demolding station of the heat treatment and curing system; the joining, bagging and sealing of the at least one set of additional untreated components occurring while the first tool is in an inflatable space. 14. The method of claim 1, wherein the set of processing parameters includes temperature, pressure, and/or vacuum profiles applied to untreated components. 15. The method of claim 1, wherein the unprocessed component comprises at least one type of unprocessed component selected from the group consisting of: Composite materials, including: glass, carbon, ceramics, metals and/or polymer fibers; and composite matrix materials, including: thermosetting polymers and thermoplastic polymers; Fiber/metal interwoven laminated products; Fiber/low-density core interwoven composite material; Low-density core composite laminate products; Metal matrix composites; Low melting point metals; Low-melting-point metal matrix composites; and Metal bonded to a polymer adhesive. 16. The method of claim 1, further comprising: The volume of the inflation space is reduced so that the volume of the inflation space substantially matches the size of the first tool. 17. The method of claim 1, wherein the heating/cooling distribution of the set of processing parameters is supplied by at least one heat transfer method selected from the group consisting of: Conduction and/or convection from circulating fluid; Conduction and/or convection from the electric heater; Conduction and/or convection from the heat sink; Infrared heating; and Microwave heating. 18. The method of claim 1, further comprising: providing a pressurized environment completely surrounding the untreated component via the system. 19. The method of claim 15, wherein the thermosetting polymer comprises a thermosetting polymer resin. 20. The method of claim 15, wherein the thermoplastic polymer comprises a thermoplastic polymer resin. 21. The method of claim 1, wherein the untreated component comprises a thermosetting polymer matrix composite. 22. The method of claim 1, wherein the untreated component comprises a thermoplastic polymer matrix composite. 23. A heat treatment and curing system, comprising: Upper assembly; The lower assembly, wherein at least one of the upper assembly or the lower assembly is movable relative to the other, wherein at least one of the upper assembly or the lower assembly is a chamber assembly, and wherein the upper assembly and the lower assembly are operatively coupled to each other to form a closed inflatable space, the inflatable space being operatively maintained in a pressurized and/or temperature-controlled environment. A tool for receiving a set of unprocessed components, the tool being movable from a second position aligned with the upper assembly to a first position on the lower assembly so as to be completely enclosed in the inflatable space, wherein the tool cannot be enclosed in the inflatable space at the second position; A flexible member is capable of being placed above the set of unprocessed components in the tool, wherein the flexible member is not attached to the upper and lower assemblies when the tool is in the second position; A coupling system capable of providing services to the tool and the inflatable space; and A controller coupled to the upper or lower assembly and the coupling system, the controller being operable to direct the service to the tool according to a set of processing parameters for heat treatment and curing of the set of untreated components in the tool while the tool is enclosed in the inflatable space. 24. The heat treatment and curing system of claim 23, further comprising: At least one additional tool for receiving at least one additional set of unprocessed components; and Transmission assembly; The controller operably guides the transport assembly to retrieve the tool from the first position, while placing the at least one additional tool into the first position after heat treatment of the set of untreated components in the tool. 25. The heat treatment and curing system of claim 23, wherein the coupling system includes a permanent connection that penetrates the upper assembly or the lower assembly to supply the service to the tool within the enclosed inflatable space. 26. The heat treatment and curing system of claim 23, further comprising a tray, the tray being operable to: Keep the tool; The service is delivered to the tool; and The inflatable space is formed in combination with the upper and lower assemblies. 27. The heat treatment and curing system of claim 26, further comprising at least one additional tool for receiving at least one additional set of untreated components; The tray described thereon is operable to: Keep at least one additional tool, The tool is repositioned so that it is aligned with the upper and lower assemblies; and The upper assembly and the lower assembly together form an inflatable space associated with the at least one additional tool. 28. The heat treatment and curing system of claim 25, wherein the coupling system further comprises an automatic coupling arrangement configured to automatically couple the tool in the enclosed inflatable space to the permanent connection to supply the service to the tool in the enclosed inflatable space. 29. The heat treatment and curing system of claim 28, wherein the automatic coupling between the tool and the permanent connection in the enclosed inflatable space is self-sealing. 30. The heat treatment and curing system of claim 28, wherein the service of supplying the tool directly to the enclosed inflatable space via the coupling system comprises at least one of the following: A hot fluid for heating and/or cooling the untreated components according to the set of processing parameters; Vacuum, used to extract gas from the untreated components of the tool within the enclosed, inflated space; A communication channel for exchanging information and/or control signals between the tool and the controller within the enclosed inflatable space; or Injection material is used to inject into the untreated component. 31. The heat treatment and curing system of claim 23, further comprising: A vacuum device that can be coupled to the tool to extract gas from the untreated component located between the flexible member and the tool, and to compress the flexible member and apply pressure to the untreated component located between the flexible member and the tool. 32. The heat treatment and curing system of claim 23, wherein the tools comprise: bracket, and A sliding block for receiving the set of unprocessed components, the sliding block being able to be placed in the bracket and removed from the bracket. 33. The heat treatment and curing system of claim 28, wherein the automatic coupling arrangement includes a mechanism configured to: When the tool is within the enclosed inflatable space, the tool and the permanent connection within the enclosed inflatable space are automatically coupled to achieve automatic coupling between the tool and the permanent connection, thereby connecting the service to the tool. When the tool is to be retrieved from the enclosed inflatable space back to the second or third position, the tool is automatically released from the permanent connection in the enclosed inflatable space to release the automatic coupling between the tool and the permanent connection, thereby disconnecting the service from the tool. In the second or third position, the tool cannot be enclosed in the inflatable space, so that when the tool is in the second or third position, the tool has no interconnecting piping and wiring. 34. The heat treatment and curing system of claim 23, wherein the flexible member comprises a membrane or vacuum bag and is not permanently attached to the upper and lower assemblies. 35. The heat treatment and curing system of claim 23, wherein the system is configured to provide a pressurized environment completely surrounding the untreated component. 36. A heat-treated and cured material produced by the method of claim 1, wherein the untreated component comprises at least one type of untreated component selected from the group consisting of: Composite materials, including: glass, carbon, ceramics, metals and/or polymer fibers; and composite matrix materials, including: thermosetting polymers and thermoplastic polymers; Fiber/metal interwoven laminated products; Fiber/low-density core interwoven composite material; Low-density core composite laminate products; Metal matrix composites; Low melting point metals; Low-melting-point metal matrix composites; and Metal bonded to a polymer adhesive. 37. The material of claim 36, wherein the thermosetting polymer comprises a thermosetting polymer resin. 38. The material of claim 36, wherein the thermoplastic polymer comprises a thermoplastic polymer resin. 39. The material of claim 36, wherein the untreated component comprises a thermosetting polymer matrix composite. 40. The material of claim 36, wherein the untreated component comprises a thermoplastic polymer matrix composite.