Patent Description:
To ensure composite parts meet design, strength, and durability requirements, composite materials must be manufactured such that the cure profile of the part is maintained within process specification requirements.

<CIT>, according to its abstract, states "a composite structure is fabricated by staging at least a portion of an uncured, first composite component. The first composite component is assembled with a second composite component, and the staged portion of the first composite component is cocured with the second composite component".

<CIT>, according to its abstract states "a method and system for fabricating a composite structure is disclosed. A composite preform has an upper surface and an opposing lower surface. The upper and lower surfaces each define a preform major surface. A heat sink is located in proximity to one of the preform major surfaces so as to extend across only a portion of the composite preform. A resin is cured in the composite preform to form the composite structure. The resin cures exothermically. During curing of the resin, heat is conducted away from the portion of the composite preform into the heat sink" (reference numerals omitted for clarity).

Thus, there is a need in the art to address one or more deficiencies in the composite manufacturing process.

A tool for forming a composite part is disclosed. The tool comprises a support surface, optionally a top surface, that supports the composite part during forming, the support surface comprising a first lateral portion and a second lateral portion arranged on either side of a central part contacting surface; a first integrated heat sink arranged on an opposite surface of the support surface, wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool; a first vacuum port arranged at a first location on the first lateral portion; and a second vacuum port arranged at a second location on the first lateral portion, wherein the first vacuum port and the second vacuum port provide access to a vacuum pump to provide at least a partial vacuum to the support surface during composite part formation. The thermal topology optimization process comprises an integrated heat sink design process, a thermal optimization process, and an analysis process. To create the integrated heat sink, a geometrical envelope, one or more structural parameters, and one or more thermal inputs are provided as inputs to the thermal topology optimization process.

Various additional features can be included in the tool including one or more of the following features. The tool can further comprise a second integrated heat sink arranged on the first lateral portion, the second lateral portion, or the opposite surface. The tool, the first integrated heat sink, or both the tool and the first integrated heat sink comprise one or more fluidic pathways for additional air-cooling heat dissipation. The tool can further comprise an enclosure that is arranged over the top surface to provide the partial vacuum during the composite part formation. The tool, the first integrated heat sink, and the second integrated heat sink are formed by an additive manufacturing process.

A method of forming a composite part using a tool with an integrated heat sink is disclosed. The method comprises placing the composite part on the support surface of the tool during manufacture; providing at least a partial vacuum to the composite part; and dissipating heat away from the composite part by the integrated heat sink toward a surface opposite the support surface. The shape of the integrated heat sink is based on the thermal topology optimization process of the tool to cure the composite part. The thermal topology optimisation process may comprise inputs comprising a geometical envelope, one or more structural paramters, and one or more thermal inputs.

A method for manufacturing of a tool for forming a composite part with an integrated heat sink is disclosed. The method comprises obtaining a digital representation of the tool to be manufactured; performing, using one or more hardware processors, a first thermal topology optimization process of the digital representation using one or more thermal computer models; determining, using the one or more hardware processors, a first thermal hot spot of the tool after manufacture using the first thermal topology optimization process; creating, a first digital representation of a first integrated heat sink that is configured to mitigate the first thermal hot spot based on the first thermal topology optimization process; and generating the tool and the first integrated heat sink using a manufacturing tool, wherein a shape of the first integrated heat sink is based on the first thermal topology optimization process of the tool, wherein a shape of the first integrated heat sink is based on the first thermal topology optimization process of the tool. The thermal topology optimization process can comprise an integrated heat sink design process, a thermal optimization process, and an analysis process. To create the heat sink, a geometrical envelope, one or more structural parameters, and one or more thermal inputs are provided as inputs to the thermal topology optimization process. The functional generative process uses these inputs to automate an iterative thermal topology optimization process and output geometry from data inputs.

Various additional features can be included in the tool including one or more of the following features. The digital representation of the tool is a computer-aided design drawing. The first thermal topology optimization process is based on one or more parameters for heat transfer efficiency and maximizing surface area of the tool where the integrated heat sink is applied. The tool and the first integrated heat sink are generated at the same time. The tool and the first integrated heat sink are generated at different times. The tool, the first integrated heat sink, or both the tool and the first integrated heat sink comprise one or more air cooling fluidic pathways for additional heat dissipation. The method further comprises performing, using the one or more hardware processors, a second thermal topology optimization process of the tool during or after manufacture; determining, using the one or more hardware processors, a second thermal hot spot of the tool during or after manufacture; creating, a second digital representation of a second integrated heat sink that is configured to mitigate the second thermal hot spot based on the second thermal topology optimization process; and generating the second integrated heat sink. The second thermal topology optimization process is similar to the first thermal topology optimization process discussed above and further below.

A system is disclosed. The system comprises a computer comprising a hardware processor and a storage media that stores instruction that when executed by the hardware processor perform a method for additive manufacturing of a tool for forming a composite part with an integrated heat sink, the method comprising: obtaining a digital representation of a tool to be manufactured; performing, using one or more hardware processors, a first thermal topology optimization process of the digital representation using one or more thermal computer models; determining, using the one or more hardware processors, a first thermal hot spot of the tool after manufacture using the first thermal topology optimization process; creating, a first digital representation of a first integrated heat sink that is configured to mitigate the first thermal hot spot based on the first thermal topology optimization process; and generating the tool and the first integrated heat sink using a manufacturing tool, wherein a shape of the first integrated heat sink is based on the first thermal topology optimization process of the tool. In some examples, the tool with a topologically optimized geometry can be manufactured using an additive manufacturing tool.

Various additional features can be included in the tool including one or more of the following features. The first digital representation of the tool is a computer-aided design drawing. The first thermal topology optimization process/thermal analysis is based on one or more parameters for heat transfer efficiency and maximizing surface area of the tool where the integrated heat sink is applied. The tool and the first integrated heat sink are generated at the same time. The tool and the first integrated heat sink are generated at different times. The tool, the first integrated heat sink, or both the tool and the first integrated heat sink comprise one or more fluidic pathways for additional heat dissipation. The hardware processor is further configured to perform the method comprising: performing, using the one or more hardware processors, a second thermal topology optimization process of the tool during or after manufacture; determining, using the one or more hardware processors, a second thermal hot spot of the tool during or after manufacture; creating, a second digital representation of a second integrated heat sink that is configured to mitigate the second thermal hot spot based on the second thermal topology optimization process; and generating the second integrated heat sink using an additive manufacturing tool. The system can further comprise the additive manufacture tool that is electrically connected to the computer. The first thermal topology optimization process may comprise inputs comprising a geometrical envelope, one or more structural parameters and one or more thermal inputs.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present teachings, as claimed.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrates features of the present teachings and together with the description, serve to explain the principles of the present teachings.

It should be noted that some details of the figures have been simplified and are drawn to facilitate understanding rather than to maintain strict structural accuracy, detail, and scale.

Reference will now be made in detail to the present teachings, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific examples of practicing the present teachings. The following description is, therefore, merely exemplary.

During the part and tool qualification process, thermal profile(s) are performed to understand the temperature across the part/tool and to identify leading and lagging thermocouple locations. Non-uniform thermal profiles can impact cure kinetics and result in cooler areas of the part having lower degree of cure or glass transition temperature. If a thermal profile were normalized and predictable across the face of a tool, a higher quality cure is possible. Tooling that is used to make composite parts can comprise large, complex geometry and will typically utilize heavy, low CTE materials. Tools may have additional requirements that affect design of tool (i.e., "must be mounted on rotating fiber placement machine"). A composite can include, but is not limited to, glass fiber reinforced plastics (GFRP), carbon fiber reinforced plastics (CFRP), aramid fiber reinforced plastic (AFRP), such as Kevlar® para-aramid fiber, ceramic matrix composites (CMC), metal matrix composites (MMC), etc..

The present disclosure is directed to tooling including integrated heat sinks, and in particular integrated heat sinks and method of making the same. The integrated heat sinks are part of a tool, which can be composed of a metallic material. The tool which features one or more integrated heat sinks is used to cure composite parts which have been laid up on the tool. The integrated heat sink can be integrally formed with a tool being manufactured, for example using an additively manufacturing (AM) process, and at a location of a thermal hotspot. AM enables less material consumption on a supporting structure, such as a bond jig. In some cases, a tool is manufactured by means of a large scale additive manufacturing process where the geometric dimensions of an additive manufacturing printer's head is not a factor. The thermal hotspot can be determined before the part is manufactured by performing a thermal analysis of the part. The integrated heat sink can be used to mitigate concerns of tool temperature peaks during cure cycle. The integrated heat sink can be printed in place, or printed and attached to a part, such as an existing machined tool. This provides the ability of a retrofit thermally-based option for all composite tools. For example, a new tool that is just manufactured may offer an effective solution. However, a composite tool may exist and may cost many millions of dollars. In this case, this present tool design and fabrication process may be used to create integrated heat sinks that can be retrofitted to existing tools to improve effectiveness.

The thermal analysis provides a predictive model of tool thermal profiles. The thermal analysis can include a part-tool thermal profile process to characterize the thermal profile of a tool's functional surface and how it will affect a part during a cure cycle. A part-tool thermal profile can be performed with physical hardware and instrumentation, or it can be performed virtually with models in a software such as COMPRO or RAVEN. This part-tool thermal profile takes into account the shape, mass, material of a part and the tool as well as the equipment used to cure the part, such as an oven, an autoclave, or a press, and the conditions of that equipment, such as pressure, air circulation, volume of chamber, temperature, heat up rate, etc. Thermocouples can be affixed between the part and the tool all across the surface area of the part and data points are generated across the entirety of the cure process to characterize the thermal profile of the part and tool during this process. These data points are then input into a digital analysis process which simulates the integrated heat sink on the tool to augment thermal flow during cure and thus change the thermal profile. According to examples, a shape, a placement, and a complexity of the integrated heat sink geometry is tailorable and is configured to be placed to mitigate hot spots on a part-tool thermal profile. Additionally, examples of the present disclosure provide for modification of existing tools (or modifying a tool is if the initial optimization is off). If an existing tool has hotspots, examples of the present disclosure provide for a custom AM integrated heat sink to be designed and added to a backside of an existing tool.

Moreover, if one's initial modified model was off or if the part-tool thermal profile were to change due to a manufacturing decision, such as tool placement or orientation in autoclave/oven, examples of the present disclosure can allow for a modular integrated heat sink to be taken out and replaced with one with a different geometry or can allow for a tooling component swap to mitigate hot spots associated with a new thermal profile. This modularity feature allows additional integrated heat sink geometry to be added with only a tool modular modification rather than the design and manufacture of a completely new tool.

In further examples, the integrated heat sink or part, can be manufactured with integral vacuum ports, which can allow a user to eliminate cutting vacuum holes into a bag that is used during manufacture to mitigate risk of leakage. Vacuum ports can be positioned in a manner which will not deleteriously affect surface quality of the integrated heat sink or the part being manufactured. For example, when a composite part is cured in an oven or autoclave a bagging material covers the part and is sealed to the tool such that air cannot escape or enter under the bag. Vacuum ports are then added to a tool by piercing and penetrating the bag. The ports seal to the bag and allow the user to draw vacuum on the bag and draw out all air and volatiles under the bag. This is a step to composite cure as it ensure proper compaction and consolidation of the material. However, each time that a bag is creased, pierced, punctured, etc. there is a possibility for that bag to leak air during cure. If this occurs, the part is usually scrapped. By integrating vacuum ports into the tool, an integrated air channel(s) within the tool allows air and volatiles to be drawn out from under the bag via vacuum without the additional risk of piercing the bagging material and creating opportunity for leakage.

In some examples, the integrated heat sink geometry in plumbed cavity can incorporate turbulator features to break up fluid boundary layer, which aids in thermal conductivity at wall/tool surface. A turbulator can be printed in place to mitigate fluid boundary effects seen in laminar or near laminar flow. This feature can provide a controlled but expedient cooling feature after laminate consolidation to increase manufacturing rate.

In some examples of the present disclosure, a thermal optimization process can also be used to optimize thermal profile on a bag-side of the part being manufactured. As cauls and pressure intensifiers are being used during AM, they could negatively affect cure kinetics depending on cure recipe and geometry of caul. A customized caul can be inserted in the tool to achieves a more predictable resin performance during cure. A similar thermal optimization concept to cauls and pressure intensifiers can be used to modify thermal profile upper and lower platen of a heat press. For example, a bag is a flexible material which confirms to the shape of the laid up composite material. On the bag side of a cured composite (in an autoclave or oven), a caul is used to create a smooth and more uniform surface that has tight profile tolerance requirements. A caul is typically a plate which mimics the bag side shape of the part. In places where there is a much more severe concavity (such as a c-channel, L or T profile with an up-standing leg, etc), a plate cannot be used to achieve the effects of a caul plate. In that case, a pressure intensifier which mimic the volume inside the concavity is used to provide to appropriate rigid surface to intensify pressure where a bag cannot.

<FIG> shows a top view <NUM> of a tool showing a thermal profile according to examples of the present disclosure. <FIG> shows a side view <NUM> cross section taken along the line A-A of <FIG>. As shown in <FIG>, top surface <NUM> of tool <NUM> composed of one or more materials, has a thermal hot spot <NUM> radiating from a center location on top surface <NUM>. Tool <NUM> is used to form composite part <NUM>. Tool <NUM> can be manufactured to be shaped in a variety of manners depending on the type of composite part <NUM> that is to be formed, including but is not limited to, one or more straight portions and/or one or more curved portions. Tool <NUM> is connected to computer <NUM>, which is configured with a thermal analysis software that can determine potential thermal hot spots based on one or more factors, including to, but are not limited, to computer-aided design drawings of the part being manufactured. The thermal analysis software can be configured to perform one or more thermal topology optimization processes of tool <NUM>. In some non-limiting examples, a computer <NUM> can use a thermal optimization modeling and simulation tool such as COMPRO or other optimization tool suite, where thermal inputs can be generated as a composite bond jig that is designed in 3DX, Inspire, or other topological digital modeling CAD tools. As discussed above, the thermal inputs represent factors that affect the heat transfer during the curing process. For example, the thermal input factors can include, but are not limited to, air flow in an autoclave or a press, a mass of a part tool in an oven or an autoclave, whether or not other parts are in the autoclave or the oven for the purposes of a batch cure, part material, tool material, etc..

The thermal topology optimization process comprises an integrated heat sink design process, a thermal optimization process, and an analysis process. To create the integrated heat sink, a geometrical envelope, one or more structural parameters, and one or more thermal inputs are provided as inputs to the thermal topology optimization process. The geometrical envelope is a block of 3D space that a design may exist within and represents the maximum height, width, and length of a design and also represents the 3D coordinate location of that 3D space. The structural parameters can include structural load cases. For example, an integrated heat sink supports its own weight and stands up to some handling loads such that if a mechanic or technician were to accidently bump into or grab the integrated heat sink, the integrated heat sink would not be rendered ineffective or partially destroyed. The thermal inputs represent factors that affect the heat transfer during the curing process. For example, the thermal input factors can include, but are not limited to, air flow in an autoclave or a press, a mass of a part tool in an oven or an autoclave, whether or not other parts are in the autoclave or the oven for the purposes of a batch cure, part material, tool material, etc. The functional generative process uses these inputs to automate an iterative thermal topology optimization process and output geometry from data inputs.

In some examples, the modeling and simulation tool uses the thermal inputs to model a composite cure and the heat transfer associated with the cure. Heat transfer can occur at different rates across the face of the tool. This is because certain inputs such as "mass of tool," "mass of part," or "access to circulating air" can vary across the face of the tool. If heat transfer is occurring at a slower rate than desired, this is functionally a "cold spot" where a discrete temperature on a select point location of the part-tool interface is lower than the overall average temperature of the part-tool interface. Similarly, if heat transfer is occurring at an accelerated rate which is higher than desired, this is functionally a "hot spot" where a discrete temperature at a select point location of the part-tool interface is higher than the overall average temperature of the part-tool interface.

Computer <NUM> can be coupled with additive manufacturing device <NUM>. These thermal inputs can be imposed on a design space to automatically generate integrated heat sink geometry on the back side (non-functional side) of tool <NUM> that dissipates heat away from a composite part form surface of tool <NUM> during formation of composite part <NUM>.

As shown in <FIG>, composite part <NUM> is mounted on tool <NUM> during composite part <NUM> formation. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on composite part <NUM>. For example, a thermal profile will show peaks and valleys in temperature which are effectively indicative of peaks and valleys in thermal energy across the face of the tool during cure. In some cases, these hot spots will deleteriously affect cure kinetics resulting in low degree of cure, porosity and voiding, untenable resin flow if cross-linking doesn't occur at an appropriate rate, etc. By strategically generating integrated heat sink geometry and strategic placement of that integrated heat sink or integrated heat sinks, these thermal peaks and valleys are eliminated or effectively mitigated to the point where the profile of thermal energy across the face of the tool during cure is effectively uniform.

Although <FIG> shows one integrated heat sink <NUM>, there may be more than one depending on the thermal analysis for the particular composite part <NUM> being manufactured. Vacuum bag <NUM> is arranged on top surface of composite part <NUM> to provide a vacuum environment for composite part <NUM> to complete forming, such as finish bonding or curing depending on the type and/or process by which composite part <NUM> is being manufactured.

<FIG> shows different examples of an AM integrated heat sink that can be used as integrated heat sink <NUM> in <FIG>. The particular type, construction, materials, and shape of the integrated heat sink are optimized based on the particular composite part <NUM> being manufactured.

<FIG> show different thermal analysis results for an integrated heat sink according to examples of the present disclosure. <FIG> shows parametric optimum results <NUM> and <FIG> shows topological optimum results <NUM> for an integrated heat sink. <FIG> shows additional integrated heat sink examples that were formed using a topological optimization process according to examples of the present disclosure.

<FIG> shows a similar arrangement of system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on composite part <NUM>. Additional integrated heat sinks <NUM> and <NUM> are shown encircled by dashed lines in <FIG> and at an edge of composite part <NUM> and tool <NUM>. Additional integrated heat sinks <NUM> and <NUM> can take the any of the forms as shown by alternative integrated heat sink <NUM>, alternative integrated heat sink <NUM>, and alterative integrated heat sink <NUM>, for example. Alternative forms of additional integrated heat sinks <NUM> and <NUM> can also be used based on the thermal characteristics of composite part <NUM>. Vacuum bag <NUM> is arranged on top surface of composite part <NUM> to provide a vacuum environment for composite part <NUM> to complete forming, such as finish bonding or curing depending on the type and/or process by which composite part <NUM> is being manufactured.

<FIG> shows a similar arrangement of composite part system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM>, which may be for example additional integrated heat sinks, are arranged at an edge of composite part <NUM> and tool <NUM>. Additional supports <NUM> and <NUM> of tool <NUM>, which can be additional integrated heat sinks or have integrated heat sink-like properties, can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM> can also be used based on the thermal characteristics of tool <NUM>. For example, additional supports <NUM> and <NUM>, that function as additional integrated heat sinks, are created using the optimization process which uses structural and thermal inputs as discussed above. The structural inputs on the non-functional surface of the tool opposite the surface that contacts the composite part are limited. In this case, an integrated heat sink must only support its own weight plus any limited handling loads seen when moving the tool about in a shop or lab. For an integrated heat sink on supports, the structural inputs are different and thus the integrated heat sink geometry will functionally be different. Structural supports must not only support their own weight but the weight of the tool and the part during curing and thus more mass will be used to create these supports. As more mass is used, the opportunity for surface area maximization differs from that of an integrated heat sink which only must use mass to support its own weight. Vacuum bag <NUM> is arranged on top surface of composite part <NUM> to provide a vacuum environment for composite part <NUM> to complete forming, such as finish bonding or curing depending on the type and/or process by which composite part <NUM> is being manufactured. Vacuum pump <NUM> provides a vacuum environment to vacuum bag <NUM> through vacuum couplers <NUM>, <NUM> that are attached to vacuum ports <NUM>, <NUM>, respectively, arranged on first lateral portion <NUM> and second lateral portion <NUM>, respectively. In the example shown in <FIG>, vacuum ports <NUM>, <NUM> are arranged to a top surface of vacuum bag <NUM>, for example at areas offset from a center part contacting surface <NUM>.

<FIG> shows a similar arrangement of composite part system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM> can be arranged at an edge of tool <NUM> and can be in the form of additional integrated heat sinks or have integrated heat sink-like properties. Additional supports <NUM> and <NUM> can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM> can also be used based on the thermal characteristics of tool <NUM>. Vacuum bag <NUM> is arranged on top surface of composite part <NUM> to provide a vacuum environment for composite part <NUM> to complete forming, such as finish bonding or curing depending on the type and/or process by which composite part <NUM> is being manufactured. Vacuum pump <NUM> provides a vacuum environment to vacuum bag <NUM> through vacuum couplers <NUM>, <NUM> that are attached to vacuum ports <NUM>, <NUM>, respectively, arranged on first lateral portion <NUM> and second lateral portion <NUM>, respectively. In the example shown in <FIG>, vacuum ports <NUM>, <NUM> are arranged to a top surface of vacuum bag <NUM>, for example at areas offset from vacuum bag <NUM> and composite part <NUM>, near central part contacting surface <NUM>.

<FIG> shows a similar arrangement of system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used for tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM> can be arranged at an edge of tool <NUM>. Additional supports <NUM> and <NUM> can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM> can also be used based on the thermal characteristics of tool <NUM>. Caul/pressure intensifier <NUM> is arranged within vacuum bag <NUM> and on a top surface of composite part <NUM> is provide additional pressure for completion of the manufacture (i.e., bonding and/or curing) of composite part <NUM>. Caul/pressure intensifier <NUM> can be used as a replacement of the vacuum pump configuration of <FIG>. As discussed above, a bag is a flexible material which conforms to the shape of the laid up composite material. On the bag side of a cured composite (in an autoclave or oven), a caul is used to create a smooth and more uniform surface that has tight profile tolerance requirements. A caul is typically a plate which mimics the bag side shape of the part. In places where there is a much more severe concavity (such as a c-channel, L or T profile with an up-standing leg, etc.), a plate cannot be used to achieve the effects of a caul plate. In that case, a pressure intensifier which mimic the volume inside the concavity is used to provide to appropriate rigid surface to intensify pressure where a bag cannot.

<FIG> shows a similar arrangement of system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM> are arranged at an edge of tool <NUM>. Additional supports <NUM> and <NUM> can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM>, which may be for example integrated heatsinks, can also be used based on the thermal characteristics of tool <NUM>. Caul/pressure intensifier <NUM> is arranged within outer vacuum bag <NUM> and inner vacuum bag <NUM> and on a top surface of composite part <NUM> is provide additional pressure for completion of the manufacture (i.e., bonding and/or curing) of composite part <NUM>.

<FIG> shows a similar arrangement of system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM> are arranged at an edge of tool <NUM>. Additional supports <NUM> and <NUM> can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM> can also be used based on the thermal characteristics of tool <NUM>. A press, which is typically hydraulically actuated, can be used provide additional pressure to cure the composite part <NUM>. The press comprises an actuator <NUM>, however depending on the size of the press, multiple actuators may exist. Actuator <NUM> is connected to and moves heat press upper platen <NUM> that is arranged on a top surface of composite part <NUM> and provides additional pressure for completion of the manufacture (i.e., bonding and/or curing) of composite part <NUM>. Heat press upper platen <NUM> can be used as a replacement of the vacuum pump configuration of <FIG>.

<FIG> shows a similar arrangement of system <NUM> of the arrangement of <FIG> with the addition of example integrated heat sinks according to examples of the present disclosure. As shown in <FIG>, composite part <NUM> is mounted on tool <NUM>. Integrated heat sink <NUM>, which can be created using the same manufacturing process that was used to form tool <NUM> and at the same time or at a different time, is mounted to an underside surface of tool <NUM> and provides a thermal sink for tool <NUM> and composite part <NUM>, resulting in an evenly spread thermal surface on tool <NUM> and composite part <NUM>. Additional supports <NUM> and <NUM> are arranged at an edge of tool <NUM>. Additional supports <NUM> and <NUM> can take the any of the forms as shown in <FIG>, <FIG>, or <FIG>, for example. Alternative forms of additional supports <NUM> and <NUM> can also be used based on the thermal characteristics of tool <NUM>. A press, which is typically hydraulically actuated, can be used provide additional pressure to cure the composite part <NUM>. The press comprises an actuator <NUM>, however depending on the size of the press, multiple actuators may exist. Actuator <NUM> is connected to and moves heat press upper platen <NUM> that is arranged on a top surface of composite part <NUM> and provides additional pressure for completion of the manufacture (i.e., bonding and/or curing) of composite part <NUM>. Heat press upper platen <NUM> can be used as a replacement of the vacuum pump configuration of <FIG>.

Integrated heat sink geometry in plumbed cavity can incorporate turbulator features to break up fluid boundary layer, which aids in thermal conductivity at wall/tool surface. For example, in some cases, the tooling configuration of a composite part could be considered "hard" on one side where there is a tool directly against the face of the part and "soft" on the other side of the part where a bag is directly against the part. On the bag side of the part, air is free to flow against the surface of the part. When a part has hard tooling on either side such as in the case of a heat press, compression molding, resin transfer molding, etc., airflow across the surface of the part is not present for convective heat transfer. In this case, a plumbed cavity beneath the tooling surface is filled with a liquid, such as water or oil, and the fluid is circulated through the cavity via a pump to enable convective heat transfer. For example, turbulator geometry examples are shown in <FIG>. Additional turbulator geometry can be generated through similar functional generative design and associated thermal optimization processes described above. This geometry can exist within the plumbed cavity to break up laminar fluid flow and enable more efficient heat transfer through the tool wall. Shape, placement, complexity of integrated heat sink geometry is tailorable and is to be placed to mitigate hot spots on part-tool thermal profile. A turbulator can be printed in place to mitigate fluid boundary effects seen in laminar or near laminar flow. The thermal boundary layer of a fluid decreases as laminar flow of a fluid is broken up. As the boundary layer decreases, it increases the wall temperature gradient and increases surface heat transfer rate. A laminar flow of fluid results in a greater thermal boundary layer and decreases heat transfer rate. This results in the previously stated "peaks" in thermal energy and thus issues with cure kinetics such as low degree of cure, porosity, etc. This feature can provide a controlled, but expedient cooling feature after laminate consolidation to increase manufacturing rate.

<FIG> show an integrated heat sink geometry in plumbed cavity <NUM>, <NUM> that incorporate turbulator features, shown in <FIG>, to break up fluid boundary layer, which aids in thermal conductivity at wall/tool surface, in an exploded side view <NUM> and an unexploded side view <NUM>, respectively, according to examples of the present disclosure. For example, turbulator geometry examples are shown in <FIG>. The integrated heat sink, according to this and other examples, is formed using a tool having male tool component <NUM> and female tool component <NUM> that are pressed together to form the layers of the integrated heat sink. Female tool component <NUM> comprises female tool surface <NUM> that contacts the integrated heat sink and male tool component <NUM> comprises male tool surface <NUM> that contacts the integrated heat sink. The integrated heat sink comprises first plumbed cavity <NUM> and second plumbed cavity <NUM>, which are both fluid exposed to the integrated heat sink geometry. Part <NUM> of the integrated heat sink is arranged between first plumbed cavity <NUM> and second plumbed cavity <NUM>. The shape, placement, complexity of integrated heat sink geometry is tailorable and is to be placed to mitigate hot spots on part-tool thermal profile. Turbulator can be printed in place to mitigate fluid boundary effects seen in laminar or near laminar flow. This feature can provide a controlled but expedient cooling feature after laminate consolidation to increase manufacturing rate.

<FIG> show example integrated heat sink geometry with turbulator features <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, respectively, according to examples of the present disclosure. The shapes of the turbulator features can exist within the plumbed cavity. The plumbed cavities are shown in <NUM> and <NUM>. The geometry of the various turbulator features that exists within the plumbed cavity, which function to break up laminar flow into turbulent flow and thus decrease the thermal boundary layer at the wall, which increases the wall temperature gradient and increases surface heat transfer rate. The geometry of the turbulator can be modified to tailor the boundary layer thickness and thus tailor the surface heat transfer rate across the surface area of the tool.

If the part-tool thermal profile were to change due to a manufacturing decision such as tool placement or orientation in autoclave/oven, modular multi-piece tooling would easily allow for a tooling component swap to mitigate hot spots associated with a new thermal profile. This modularity feature allows additional integrated heat sink geometry to be added with only a tool modular modification rather than the design and manufacture of a completely new tool.

<FIG> shows a method <NUM> for manufacturing a heat sink, according to examples of the present disclosure. The features shown in <FIG> are similar to those shown in <FIG>. At <NUM> integrated heat sink <NUM> is shown being formed by applying pressure to a forming tool comprising male tool part <NUM> and first female tool part <NUM>. At <NUM>, during thermal analysis, such as the thermal analysis of <FIG>, thermal hot spot <NUM> is determined that may require further thermal mitigation. At <NUM>, second female tool part <NUM> is applied over first female tool part <NUM>. At <NUM>, second female tool part <NUM> is shown with an additional or revised integrated heat sink component <NUM> that provides further thermal mitigation to thermal hot spot <NUM>. For example, the existing tool may need to be re-worked, which may require the addition of a heat sink because (a) the tool did not previously include a heat sink or (b) the thermal inputs have changed which alter the expected heat transfer and thus require the addition of a heat sink. For instance, the mass and/or material of a part could change if the same tool that was previously used to cure a laminate panel is now used to cure a honeycomb structure which also incorporates doubler plies for additional stiffness. At <NUM>, pressure is applied to a top surface of second female tool part <NUM> to form the integrated heat sink with additional or revised integrated heat sink component <NUM> of thermal hot spot. In this and other examples, a tool which did not have an integrated heat sink built into the large mass of the tool at the location of a discrete hot spot or cold spot. To rework the tool, a large mass of the tool is excised, this area of the tool design is modified to include an integrated heat sink, and this portion of the reworked design is printed in place on top of the tool to replace the excised material.

In the above-described examples, the integrated heat sink geometry can be exposed to air circulating in the closed system of an oven or autoclave, or to ambient air surrounding a heat press. Alternatively, a bond jig or mold with internal plumbed cavities for water, oil, or other fluids could allow for integrated heat sink geometry to be fluid cooled rather than air cooled. For compression or injection molded parts (typically thermoplastic), ambient air-cooled, and internally plumbed fluid cooled examples are both applicable. Internally plumbed cooling enables a more consistent and rapid cool down without worry for warpage or crystallization, and thus can increase rate and add a means of cost savings through economy of scale. Benefits of the above-described tool include, but are not limited to, more consistent glass transition temperature (Tg) and Degree of Cure measurements across the face of a composite panel, and more predictable rheological behavior during cure. AM also enables other benefits such as weight optimization and integral vacuum ports to mitigate leak risk. AM also enables reimagined integrated heat sink shapes to optimize surface area and increase cooling.

<FIG> shows a flowchart <NUM> for a method of forming a composite part using a tool with an integrated heat sink according to examples of the present disclosure. The method comprises placing the composite part on a top surface of the tool during manufacture, as in <NUM>. For example, as shown in <FIG>, composite part <NUM> is arranged on a top surface of tool <NUM>. The method further comprises providing at least a partial vacuum to the component part, as in <NUM>. Continuing with the example of <FIG>, vacuum bag <NUM> is arranged on a top surface of composite part <NUM> and vacuum pump <NUM> supplies at least a partial vacuum. The method further comprises dissipating heat away from the composite part by the integrated heat sink toward a surface opposite the top surface, as in <NUM>. A shape of the integrated heat sink is based on a thermal topology optimization process of the tool; and curing the composite part. Continuing with the example of <FIG>, integrated heat sink <NUM> provides a thermal pathway to remove heat from tool <NUM> during formation of composite part <NUM>.

<FIG> shows a flowchart <NUM> for a method for additive manufacturing of a tool for forming a composite part with an integrated heat sink according to examples of the present disclosure. The method comprises obtaining a digital representation of a tool to be additively manufactured, as in <NUM>. In some examples, the digital representation of the tool is a computer-aided design drawing. For example, as shown in <FIG>, computer <NUM> is used to obtain the digital representation of tool <NUM>.

The method further comprises performing, using one or more hardware processors, a first thermal topology optimization process of the digital representation using one or more thermal computer models, as in <NUM>. In some examples, the first thermal topology optimization process is based on one or more parameters for heat transfer efficiency and maximizing surface area of the tool where the integrated heat sink is applied. Continuing with the example of <FIG>, computer <NUM> performs a thermal topology optimization process using one or more thermal models.

The method further comprises determining, using the one or more hardware processors, a first thermal hot spot of the tool after manufacture using the first thermal topology optimization process, as in <NUM>. Continuing with the example of <FIG>, computer <NUM> determines thermal hot spot <NUM> of tool <NUM>. The method further comprises creating, a first digital representation of a first integrated heat sink that is configured to mitigate the first thermal hot spot based on the first thermal topology optimization process, as in <NUM>. Continuing with the example of <FIG>, computer <NUM> creates the first digital representation of the first integrated heat sink, such as the various integrated heat sinks discussed above. The method further comprises generating the tool and the first integrated heat sink using an additive manufacturing tool wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool, as in <NUM>. A shape of the first integrated heat sink is based on the first thermal topology optimization process of the tool. In some examples, the tool and the first integrated heat sink are generated at the same time. In some examples, the tool and the first integrated heat sink are generated at different times. In some examples, the tool, the first integrated heat sink, or both the tool and the first integrated heat sink comprise one or more fluidic pathways for additional heat dissipation.

The method can further comprise performing, using the one or more hardware processors, a second thermal topology optimization process of the tool during or after manufacture; determining, using the one or more hardware processors, a second thermal hot spot of the tool during or after manufacture; creating, a second digital representation of a second integrated heat sink that is configured to mitigate the second thermal hot spot based on the second thermal topology optimization process; and generating the second integrated heat sink using an additive manufacturing tool, as in <NUM>.

In some examples, any of the methods of the present disclosure may be executed by a computing system. <FIG> illustrates an example of such a computing system <NUM>, in accordance with some examples. The computing system <NUM> may include a computer or computer system 1601A, which may be an individual computer system 1601A or an arrangement of distributed computer systems. The computer system 1601A includes one or more analysis module(s) <NUM> configured to perform various tasks according to some examples, such as one or more methods disclosed herein. To perform these various tasks, the analysis module <NUM> executes independently, or in coordination with, one or more processors <NUM>, which is (or are) connected to one or more storage media <NUM>. The processor(s) <NUM> is (or are) also connected to a network interface <NUM> to allow the computer system 1601A to communicate over a data network <NUM> with one or more additional computer systems and/or computing systems, such as 1601B, 1601C, and/or 1601D (note that computer systems 1601B, 1601C and/or 1601D may or may not share the same architecture as computer system 1601A, and may be located in different physical locations, e.g., computer systems 1601A and 1601B may be located in a processing facility, while in communication with one or more computer systems such as 1601C and/or 1601D that are located in one or more data centers, and/or located in varying countries on different continents).

The storage media <NUM> can be implemented as one or more non-transitory computer-readable or machine-readable storage media. The storage media <NUM> can be connected to or coupled with a thermal analysis machine learning module(s) <NUM>. Note that while in the example of <FIG> storage media <NUM> is depicted as within computer system 1601A, in some examples, storage media <NUM> may be distributed within and/or across multiple internal and/or external enclosures of computing system 1601A and/or additional computing systems. Storage media <NUM> may include one or more different forms of memory including semiconductor memory devices such as dynamic or static random access memories (DRAMs or SRAMs), erasable and programmable read-only memories (EPROMs), electrically erasable and programmable read-only memories (EEPROMs) and flash memories, magnetic disks such as fixed, floppy and removable disks, other magnetic media including tape, optical media such as compact disks (CDs) or digital video disks (DVDs), BLURAY® disks, or other types of optical storage, or other types of storage devices. Note that the instructions discussed above can be provided on one non-transitory computer-readable or machine-readable storage medium, or alternatively, can be provided on multiple computer-readable or machine-readable storage media distributed in a large system having possibly plural nodes. Such non-transitory computer-readable or machine-readable storage medium or media is (are) considered to be part of an article (or article of manufacture). The storage medium or media can be located either in the machine running the machine-readable instructions or located at a remote site from which machine-readable instructions can be downloaded over a network for execution.

It should be appreciated that computing system <NUM> is only one example of a computing system, and that computing system <NUM> may have more or fewer components than shown, may combine additional components not depicted in the example of <FIG>, and/or computing system <NUM> may have a different configuration or arrangement of the components depicted in <FIG>. The various components shown in <FIG> may be implemented in hardware, software, or a combination of both hardware and software, including one or more signal processing and/or application specific integrated circuits.

Further, the steps in the processing methods described herein may be implemented by running one or more functional modules in an information processing apparatus such as general-purpose processors or application specific chips, such as ASICs, FPGAs, PLDs, or other appropriate devices. These modules, combinations of these modules, and/or their combination with general hardware are all included within the scope of protection of the disclosure.

Thermal analysis and/or material or part constraint data, models and/or other interpretation aids may be refined in an iterative fashion; this concept is applicable to examples of the present methods discussed herein. This can include use of feedback loops executed on an algorithmic basis, such as at a computing device (e.g., computing system <NUM>, <FIG>), and/or through manual control by a user who may make determinations regarding whether a given step, action, template, model, or set of curves has become sufficiently accurate for the evaluation of the signal(s) under consideration.

Claim 1:
A tool (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) for forming a composite part (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>), the tool comprising:
a support surface, optionally a top surface (<NUM>), that supports the composite part during forming, the support surface comprising a first lateral portion (<NUM>, <NUM>) and a second lateral portion (<NUM>, <NUM>) arranged on either side of a central part contacting surface (<NUM>, <NUM>);
a first integrated heat sink (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) arranged on an opposite surface of the support surface, wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool;
a first vacuum port (<NUM>, <NUM>) arranged at a first location on the first lateral portion; and
a second vacuum port (<NUM>, <NUM>) arranged at a second location on the first lateral portion, wherein the first vacuum port and the second vacuum port provide access to a vacuum pump (<NUM>, <NUM>) to provide at least a partial vacuum to the support surface during composite part formation.