Patent Description:
Some gas turbine engines can include a number of different types of composite components, such as Ceramic Matrix Composite (CMC) components and Polymer Matrix Composite (PMC) components. In the process of manufacturing such composite components, and composite components generally, there is often a need to compact the components. Conventional manufacturing methods, such as a vacuum/ positive pressure debulk methods and press methods, have been effective for compacting composite components. However, conventional methods usually require complex equipment and tool moving solutions. Additionally, they can be cumbersome and imprecise in the way they apply pressure to the component.

Accordingly, improved compaction systems and methods of compacting composite components that address one or more of the challenges noted above would be useful.

<CIT> relates to a method and device for manufacturing an elongate beam member. The beam member is formed of a reinforcing fiber base material which has a web portion and at least a pair of flange portions extending to both sides via at least a branching point from the web portion.

In one aspect, a method is provided. The method includes positioning a laminate formed of plies on a tool of a compaction system. The laminate defines a cavity. The method also includes positioning a noodle relative to or in the cavity. Further, the method includes positioning a noodle ring relative to the noodle. In addition, the method includes moving a plunger to apply a force on the noodle ring so that the noodle ring compacts the noodle into the cavity.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements.

As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. For example, "upstream" refers to the direction from which the fluid flows and "downstream" refers to the direction to which the fluid flows.

For example, the approximating language may refer to being within a <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent margin in either individual values, range(s) of values, and/or endpoints defining range(s) of values.

Exemplary aspects of the present disclosure are directed to compaction systems and methods of compacting components, such as composite components for gas turbine engines. In one aspect, a method is provided for compacting a laminate. The laminate can form an entire portion of a composite component or a portion thereof. The laminate can be laid up on a tool of a compaction system or can be laid up elsewhere and subsequently positioned on the tool. The laminate is laid up in such a way that the laminate defines a cavity. The cavity can be a space between two diverging sections of the laminate, for example. With the laminate positioned on the tool, a noodle is positioned relative to or in the cavity. Generally, the noodle fills the cavity to improve the mechanical properties of a finished component. In some embodiments, prior to positioning the noodle relative to the cavity, a shaping tool can be moved into the cavity to shape the cavity to a desired shape. This may ensure the cavity is sized to receive the noodle.

With the noodle positioned relative to or in the cavity, a noodle ring is positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. For instance, if the noodle has a cross section with an airfoil shape, the noodle ring can likewise have a cross section with the same airfoil shape. The noodle ring can have a hollow interior, a look-through window, or can be transparent in whole or in part. In this way, when an operator is positioning the noodle ring relative to the noodle, the operator is able to visibly see the plies of the laminate and can take care not to damage the plies. In some embodiments, optionally, a sheet or film is placed between the noodle and the noodle ring.

With the noodle ring positioned in place, a plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity. Any suitable mechanical device, mechanism, or system can be used to move the plunger so that the noodle is ultimately compacted into the cavity. In addition to compacting the noodle into the cavity, the laminate or portions thereof can likewise be compacted when the plunger is moved during the compaction process.

The compaction systems and methods provided herein provide a number of advantages and benefits. For instance, the systems and methods provided herein allow for compaction of a component with minimal equipment and tool transportation, offering decreased process time and leaner processes, among other benefits. Further, the systems and methods provided herein provide the ability to apply pressure to specific portions of a laminate only, e.g., compacting a noodle into a cavity of a laminate. This may allow for improved compaction/composite part assembly and increased part yield. In addition, compaction of a composite component using the systems and methods disclosed herein can be more closely controlled than with conventional systems and techniques, such as bagging. For instance, the systems and methods provided herein can compact components with precise load or displacement-controlled compaction.

<FIG> provides a schematic cross-sectional view of a gas turbine engine in accordance with one example embodiment of the present subject matter. For the depicted embodiment of <FIG>, the gas turbine engine is a high-bypass turbofan jet engine <NUM>, referred to herein as "turbofan <NUM>. " As shown in <FIG>, the turbofan <NUM> defines an axial direction A (extending parallel to a longitudinal centerline <NUM> provided for reference), a radial direction R, and a circumferential direction extending in a plane orthogonal to the axial direction A three hundred sixty degrees around the longitudinal centerline <NUM>.

The turbofan <NUM> includes a fan section <NUM> and a core turbine engine <NUM> disposed downstream from the fan section <NUM>. The core turbine engine <NUM> includes a substantially tubular outer casing <NUM> that defines an annular core inlet <NUM>. The outer casing <NUM> encases, in serial flow relationship, a compressor section including a booster or low pressure (LP) compressor <NUM> and a high pressure (HP) compressor <NUM>; a combustion section <NUM>; a turbine section including a high pressure (HP) turbine <NUM> and a low pressure (LP) turbine <NUM>; and a jet exhaust nozzle section <NUM>. A high pressure (HP) shaft or spool <NUM> drivingly connects the HP turbine <NUM> to the HP compressor <NUM>. A low pressure (LP) shaft or spool <NUM> drivingly connects the LP turbine <NUM> to the LP compressor <NUM>.

The fan section <NUM> includes a variable pitch fan <NUM> having a plurality of fan blades <NUM> coupled to a disk <NUM> in a spaced apart manner. As depicted, the fan blades <NUM> extend outward from the disk <NUM> generally along the radial direction R. Each fan blade <NUM> is rotatable relative to the disk <NUM> about a pitch axis P by virtue of the fan blades <NUM> being operatively coupled to a suitable actuation member <NUM> configured to collectively vary the pitch of the fan blades <NUM> in unison. The fan blades <NUM>, disk <NUM>, and actuation member <NUM> are together rotatable about the longitudinal axis <NUM> by LP shaft <NUM>.

Referring still to <FIG>, the disk <NUM> is covered by a rotatable front nacelle <NUM> aerodynamically contoured to promote an airflow through the plurality of fan blades <NUM>. Additionally, the fan section <NUM> includes an annular fan casing or outer nacelle <NUM> that circumferentially surrounds the fan <NUM> and/or at least a portion of the core turbine engine <NUM>. The nacelle <NUM> may be supported relative to the core turbine engine <NUM> by a plurality of circumferentially-spaced outlet guide vanes <NUM>. Moreover, a downstream section <NUM> of the nacelle <NUM> may extend over an outer portion of the core turbine engine <NUM> so as to define a bypass airflow passage <NUM> therebetween.

During operation of the turbofan <NUM>, a volume of air <NUM> enters the turbofan <NUM> through an associated inlet <NUM> of the nacelle <NUM> and/or fan section <NUM>. As the volume of air <NUM> passes across the fan blades <NUM>, a first portion of the air <NUM> as indicated by arrows <NUM> is directed or routed into the bypass airflow passage <NUM> and a second portion of the air <NUM> as indicated by arrow <NUM> is directed or routed into the annular core inlet <NUM> and into the LP compressor <NUM>. The pressure of the second portion of air <NUM> is then increased as it is routed through the high pressure (HP) compressor <NUM> and into the combustion section <NUM>, where it is mixed with fuel and burned to provide combustion gases <NUM>.

The combustion gases <NUM> are routed through the HP turbine <NUM> where a portion of thermal and/or kinetic energy from the combustion gases <NUM> is extracted via sequential stages of HP turbine stator vanes <NUM> that are coupled to the outer casing <NUM> and HP turbine rotor blades <NUM> that are coupled to the HP shaft or spool <NUM>, thus causing the HP shaft or spool <NUM> to rotate, thereby supporting operation of the HP compressor <NUM>. The combustion gases <NUM> are then routed through the LP turbine <NUM> where a second portion of thermal and kinetic energy is extracted from the combustion gases <NUM> via sequential stages of LP turbine stator vanes <NUM> that are coupled to the outer casing <NUM> and LP turbine rotor blades <NUM> that are coupled to the LP shaft or spool <NUM>, thus causing the LP shaft or spool <NUM> to rotate, thereby supporting operation of the LP compressor <NUM> and/or rotation of the fan <NUM>.

The combustion gases <NUM> are subsequently routed through the jet exhaust nozzle section <NUM> of the core turbine engine <NUM> to provide propulsive thrust. Simultaneously, the pressure of the first portion of air <NUM> is substantially increased as the first portion of air <NUM> is routed through the bypass airflow passage <NUM> before it is exhausted from a fan nozzle exhaust section <NUM> of the turbofan <NUM>, also providing propulsive thrust. The HP turbine <NUM>, the LP turbine <NUM>, and the jet exhaust nozzle section <NUM> at least partially define a hot gas path <NUM> for routing the combustion gases <NUM> through the core turbine engine <NUM>.

It will be appreciated that, although described with respect to turbofan <NUM> having core turbine engine <NUM>, the present subject matter may be applicable to other types of turbo machinery. For example, the present subject matter may be suitable for use with or in turboprops, turboshafts, turbojets, industrial and marine gas turbine engines, and/or auxiliary power units.

In some embodiments, components of turbofan <NUM> can be formed of a composite material. For example, components within hot gas path <NUM>, such as components of combustion section <NUM>, HP turbine <NUM>, and/or LP turbine <NUM>, can be formed of a Ceramic Matrix Composite (CMC) material, which is a non-metallic material having high temperature capability. For instance, turbine blades and turbine nozzles can be formed of CMC materials. Other components of turbine engine <NUM> also may be formed from CMC materials or other suitable composite materials, such as e.g., a Polymer Matrix Composite (PMC) material.

Exemplary matrix materials for such CMC components can include silicon carbide, silicon, silica, alumina, or combinations thereof. Ceramic fibers can be embedded within the matrix, such as oxidation stable reinforcing fibers including monofilaments like sapphire and silicon carbide (e.g., Textron's SCS-<NUM>), as well as rovings and yarn including silicon carbide (e.g., Nippon Carbon's NICALON®, Ube Industries' TYRANNO®, and Dow Corning's SYLRAMIC®), alumina silicates (e.g., Nextel's <NUM> and <NUM>), and chopped whiskers and fibers (e.g., Nextel's <NUM> and SAFFIL®), and optionally ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite). CMC materials may have coefficients of thermal expansion in the range of about <NUM>×<NUM>-<NUM> in/in/°F to about <NUM>×<NUM>-<NUM> in/in/°F in a temperature range of approximately <NUM>-<NUM>° F.

<FIG> provides a perspective view of a turbine nozzle segment <NUM> according to an exemplary embodiment of the present subject matter. For this embodiment, the turbine nozzle segment <NUM> is formed of a CMC material, such as one or more of the CMC materials noted above. The turbine nozzle segment <NUM> is one of a number of nozzle segments that when connected together form an annular nozzle assembly of a gas turbine engine, such as e.g., the turbofan <NUM> of <FIG>. The nozzle segment <NUM> includes vanes <NUM>, such as e.g., stator vanes <NUM> of the turbofan <NUM> of <FIG>. Each vane <NUM> or airfoil extends between an outer and inner band <NUM>, <NUM>. The vanes <NUM> define a plurality of cooling holes <NUM>. Cooling holes <NUM> provide film cooling to improve the thermal capability of the vanes <NUM>. The cooling holes <NUM> can be fluidly connected to one or more fluid passageways that extend internally through the vanes <NUM>. Furthermore, as will be explained more fully below, one or more portions of the turbine nozzle segment <NUM> can be subjected to a compaction process.

<FIG> provides a schematic cross-sectional view of a compaction system <NUM> in the process of compacting a laminate <NUM> according to one example embodiment of the present subject matter. The laminate <NUM> can form a portion of a composite component, such as the turbine nozzle segment <NUM> of <FIG>. It will be appreciated that the compaction system <NUM> can be used to compact laminates of other components as well.

For the depicted embodiment of <FIG>, the laminate <NUM> has a first section <NUM> and a second section <NUM>. The first section <NUM> includes one or more plies <NUM> and the second section <NUM> includes one or more plies <NUM>. Generally, the first section <NUM> extends lengthwise along a first direction D1, e.g., a radial direction. At least a portion of the second section <NUM> extends lengthwise along the first direction D1 and at least a portion of the second section <NUM> extends lengthwise along a second direction D2, e.g., a circumferential direction. Accordingly, the second section <NUM> of the laminate <NUM> transitions from extending lengthwise along the first direction D1 to extending lengthwise along the second direction D2. The second direction D2 can be substantially orthogonal to the first direction D1.

The second section <NUM> transitions from extending lengthwise along the first direction D1 to the second direction D2 at a joint interface <NUM> of the laminate <NUM>. As one example, the joint interface <NUM> of the laminate may correspond with the joint interface between one of the vanes <NUM> and the outer band <NUM> of the turbine nozzle segment <NUM> of <FIG>. For instance, the portion of the second section <NUM> that extends lengthwise along the second direction D2 may form the outer band <NUM> or a portion thereof. The first section <NUM> and the portion of the second section <NUM> that extends lengthwise along the first direction D1 may form one of the vanes <NUM> or a portion thereof. As another example, the joint interface <NUM> of the laminate may correspond with the joint interface between one of the vanes <NUM> and the inner band <NUM> of the turbine nozzle segment <NUM> of <FIG>.

The laminate <NUM> defines a cavity <NUM>. For this embodiment, the cavity <NUM> is defined between the first section <NUM> and the second section <NUM> where the second section <NUM> transitions from extending lengthwise along the first direction D1 to extending lengthwise along the second direction D2, or stated another way, at the joint interface <NUM>. In this regard, the laminate <NUM> defines the cavity <NUM> at a location where the first section <NUM> and the second section <NUM> diverge. The cavity <NUM> has a triangular cross section in this example embodiment, but it will be appreciated that the cavity <NUM> may be defined to have other suitable cross-sectional shapes. A noodle <NUM> can be positioned in or relative to the cavity <NUM> and compacted therein by the compaction system <NUM> as will be described herein. The noodle <NUM> can be formed of a composite material, such as a CMC material. The noodle <NUM> can be formed of other suitable materials as well. The noodle <NUM> can be formed as a single part or can be formed as separate or distinct parts. Generally, the noodle <NUM> is positioned within the cavity <NUM> to fill the void, which provides improved mechanical properties to the finished component, among other benefits. In some embodiments, a slurry composition, e.g., a matrix material, can be inserted into the cavity <NUM> prior to the noodle <NUM> being compacted into the cavity <NUM>. This may facilitate a more complete filling of the cavity <NUM>, which may lead to improved mechanical properties of the finished component.

As further shown in <FIG>, the compaction system <NUM> includes a tool holder <NUM> that holds or supports a tool <NUM>. The tool <NUM> is contoured complementary to the shape of the laminate <NUM> so that the laminate <NUM> can be properly positioned in place for compaction. As depicted, the laminate <NUM> can be positioned relative to or placed over the tool <NUM>. When the laminate <NUM> is positioned in place on the tool <NUM>, a noodle ring <NUM> is positioned relative to the noodle <NUM>. Particularly, the noodle ring <NUM> is placed over at least a portion of the noodle <NUM>. The noodle ring <NUM> can be formed as a single part or can be formed as separate or distinct sections. Thus, in some embodiments, the noodle ring <NUM> is formed of a single, unitary component. In other embodiments, the noodle ring <NUM> is formed of at least two sections.

In some embodiments, the noodle ring <NUM> provides some means for an operator to look through the noodle ring <NUM>. In this way, when an operator is placing the noodle ring <NUM> in position relative to the noodle <NUM>, the operator can look through the noodle <NUM> and can visibly see a protruding portion <NUM> of the first section <NUM>. The protruding portion <NUM> is the portion of the first section <NUM> that protrudes above the second section <NUM> and noodle <NUM> along the first direction D1 as illustrated in <FIG>. As shown, when the noodle ring <NUM> is in place, the protruding portion <NUM> of the first section <NUM> of the laminate <NUM> overlaps with the noodle ring <NUM> along the first direction D1. With the protruding portion <NUM> of the first section <NUM> located, the operator can make sure not to contact the protruding portion <NUM> with the noodle ring <NUM> and can position the noodle ring <NUM> relative to the noodle <NUM> as shown in <FIG>. If contacted, the plies <NUM> forming the protruding portion <NUM> of the first section <NUM> can become damaged, e.g., delamination can occur.

In some embodiments, the noodle ring <NUM> can define a hollow interior <NUM>, e.g., as shown in <FIG>. The hollow interior <NUM> allows an operator to look through the noodle ring <NUM> to ensure the protruding portion <NUM> of the first section <NUM> is not contacted when the noodle ring <NUM> is positioned in place. In other embodiments, the noodle ring <NUM> or a portion thereof can be formed of a transparent material. For instance, in some embodiments, the noodle ring <NUM> can include a look-through window. In other embodiments, the entire noodle ring <NUM> can be formed of a transparent material.

The noodle ring <NUM> can be shaped complementary to the noodle <NUM>. Particularly, the noodle ring <NUM> can have a cross section shaped complementary to a cross section of the noodle <NUM>. Stated another way, an outline of the noodle ring <NUM> can be shaped complementary to an outline of the noodle <NUM>. In this way, when a force is applied to the noodle ring <NUM> during compaction, the noodle ring <NUM> can apply a force on the entire noodle <NUM> during compaction.

<FIG> provides a perspective view of an example noodle ring <NUM> positioned relative to a noodle (the noodle is not shown in <FIG>). In <FIG>, a plunger of the compaction system <NUM> is shown transparent for illustrative purposes. As depicted, the noodle ring <NUM> has a cross section shaped like an airfoil or vane, such as a vane <NUM> of the turbine nozzle segment <NUM> of <FIG>. The cross-sectional shape of the noodle ring <NUM> can match or be complementary to the cross-sectional shape of the noodle, which is positioned below the noodle ring <NUM> and not visible in <FIG>.

<FIG> provides a perspective view of another example noodle ring <NUM> positioned relative to a noodle (the noodle is not shown in <FIG>). For this embodiment, the noodle ring <NUM> has a main body <NUM>. The main body <NUM> has a cross section shaped complementary to a cross section of the noodle, which is positioned below the noodle ring <NUM> and not visible in <FIG>. Moreover, for this embodiment, the noodle ring <NUM> has a first stabilizing member <NUM> extending outward from the main body <NUM>. The first stabilizing member <NUM> couples the noodle ring <NUM> to at least one of a band debulk cap (not shown in <FIG>) and the tool <NUM>. The noodle ring <NUM> also has a second stabilizing member <NUM> extending outward from the main body <NUM>. The second stabilizing member <NUM> couples the noodle ring <NUM> to at least one of a band debulk cap (not shown in <FIG>) and the tool <NUM>. The first stabilizing member <NUM> and the second stabilizing member <NUM> extend outward from the main body <NUM> in opposite directions from one another. However, in other embodiments, the first stabilizing member <NUM> and the second stabilizing member <NUM> need not extend in opposite directions from one another.

The first stabilizing member <NUM> defines one or more openings <NUM> that are sized to receive fasteners, such as threaded bolts. Threaded bolts can extend through the first stabilizing member <NUM> and into corresponding threaded openings defined by the tool <NUM>, for example. Similarly, the second stabilizing member <NUM> defines one or more openings <NUM> that are sized to receive fasteners, such as threaded bolts. Threaded bolts can extend through the second stabilizing member <NUM> and into corresponding threaded openings defined by the tool <NUM>, for example. Such bolts or other fasteners can be used to secure the noodle ring <NUM> to the tool <NUM>, which may ensure that the noodle ring <NUM> remains in place during compaction. In this manner, the noodle ring <NUM> can be coupled to the tool <NUM>. Using the first and second stabilizing members <NUM>, <NUM> to secure the main body <NUM> of the noodle ring <NUM> on opposing sides thereof can provide enhanced stability to the noodle ring <NUM> during compaction.

Returning to <FIG>, with the noodle ring <NUM> positioned in place relative to the noodle <NUM>, optionally, a band debulk cap <NUM> can be moved in place to secure the noodle ring <NUM> in place relative to the noodle <NUM> as shown in <FIG>. A latch system <NUM> can be used to secure the band debulk cap <NUM> in place. For this embodiment, the latch system <NUM> includes latch clamps <NUM> that connect with the tool holder <NUM>. Each latch clamp <NUM> is movable between a clamped position and an unclamped position. In the clamped position, a given latch clamp <NUM> secures the band debulk cap <NUM> in place. In the unclamped position, a given latch clamp <NUM> does not secure the band debulk cap <NUM> in place. In addition to securing the noodle ring <NUM> relative to the noodle <NUM>, the band debulk cap <NUM> may also secure the laminate <NUM> in place relative to the tool <NUM>.

Further, optionally, a film or protective sheet <NUM> can be positioned between the noodle <NUM> and the noodle ring <NUM>, e.g., along the first direction D1. This may allow for the noodle ring <NUM> to be removed more easily after compaction and can prevent foreign objects on the noodle ring <NUM>, which may be reusable, from being transferred to the noodle <NUM>. In addition, the protective sheet <NUM> can extend such that it is positioned between the band debulk cap <NUM> and the second section <NUM> of the laminate <NUM> that extends lengthwise along the second direction D2. The protective sheet <NUM> can prevent the plies <NUM> from being damaged by the band debulk cap <NUM> during compaction. The protective sheet <NUM> can be formed of any suitable material. As one example, the protective sheet <NUM> can be formed of a Room-Temperature Vulcanizing (RTV) rubber material.

The compaction system <NUM> also includes a plunger <NUM>. For this embodiment, the plunger <NUM> and the band debulk cap <NUM> can be formed as separate components as shown in <FIG>. In alternative embodiments, the plunger <NUM> and the band debulk cap <NUM> can be formed as a single component. Notably, the plunger <NUM> is movable, e.g., along the first direction D1. As will be explained in detail herein, the plunger <NUM> can be moved such that the plunger <NUM> applies a force F1 on the noodle ring <NUM> so that the noodle ring <NUM> in turn compacts the noodle <NUM> into the cavity <NUM>. Moreover, when the plunger <NUM> is moved, e.g., downward along the first direction D1 toward the laminate <NUM>, the applied force F1 also compacts the laminate <NUM> generally. For instance, the plunger <NUM> can apply a force on the band debulk cap <NUM> and the band debulk cap <NUM> can in turn compact the portion of the second section <NUM> that extends lengthwise along the second direction D2. The plunger <NUM> can be moved by any suitable mechanism, device, or system. Various examples are provided below.

For the depicted embodiment of <FIG>, the plunger <NUM> can be moved along the first direction D1 to compact the laminate <NUM> by torqueing or tightening one or more fasteners. For instance, as shown, one or more bolts <NUM> can be tightened or loosened to control the position of the plunger <NUM> along the first direction D1 (e.g., a vertical direction). For example, to move the plunger <NUM> toward the laminate <NUM> along the first direction D1, the bolts <NUM> can be tightened. Conversely, to move the plunger <NUM> away from the laminate <NUM> along the first direction D1, e.g., after compaction, the bolts <NUM> can be loosened. The bolts <NUM> can be inserted through holes defined by the plunger <NUM> and into blind holes defined by the band debulk cap <NUM>. The plunger <NUM> and/or the band debulk cap <NUM> can include threading so that threads of the bolts <NUM> can threadingly engage the plunger <NUM> and/or the band debulk cap <NUM>. In other embodiments, it will be appreciated that the bolts <NUM> can engage other structures in addition or alternatively to the plunger <NUM> and/or the band debulk cap <NUM>. For instance, the bolts <NUM>, or more broadly fasteners, can engage the tool <NUM> and/or the tool holder <NUM>.

In some embodiments, the compaction system <NUM> includes a single bolt for controlling the position of the plunger <NUM> and thus the applied force on the laminate <NUM>. In other embodiments, the compaction system <NUM> includes multiple bolts for controlling the position of the plunger <NUM> and thus the applied force on the laminate <NUM>. In such embodiments, the bolts can be strategically positioned so that the applied force F1 is more evenly distributed to the laminate <NUM> and/or noodle <NUM>. For instance, in some embodiments, bolts can be positioned on opposite sides of the noodle ring <NUM>, e.g., as shown in <FIG>. It will also be appreciated that different bolts can be tightened to different degrees so that more or less force is applied to a specific portion of the laminate <NUM>. In this way, the force applied on different portions of the laminate <NUM> can be controlled.

<FIG> provides a schematic cross-sectional view of another example compaction system <NUM> in the process of compacting a laminate <NUM> according to one example embodiment of the present subject matter. The compaction system <NUM> of <FIG> is configured in a similar manner as the compaction system <NUM> of <FIG> except as provided below. For this embodiment, the band debulk cap <NUM> defines spring chambers <NUM> in which springs <NUM> are positioned. The springs <NUM> are at least partially received within the spring chambers <NUM> and extend lengthwise along the first direction D1 to engage the plunger <NUM>.

When a press or other mechanical system applies a force, as represented by the arrow P1 in <FIG>, the plunger <NUM> is moved toward the laminate <NUM> along the first direction D1. When this occurs, the springs <NUM> are compressed by the plunger <NUM>. The plunger <NUM> eventually engages the noodle ring <NUM> and the band debulk cap <NUM> to compact the noodle <NUM> into the cavity <NUM> and the laminate <NUM> generally. When the force applied by the press or other mechanical system is reduced or no longer applied to the plunger <NUM>, the springs <NUM> bias the plunger <NUM> upward or away from the laminate <NUM> along the first direction D1. Although two springs <NUM> are shown in <FIG>, it will be appreciated that the compaction system <NUM> of <FIG> can include more or less than two springs in some embodiments. The press or mechanical system that moves the plunger <NUM> can be any suitable system, such as a jackscrew or other suitable press machine.

<FIG> provides a schematic cross-sectional view of yet another example compaction system <NUM> in the process of compacting a laminate <NUM> according to an example embodiment of the present subject matter. The compaction system <NUM> of <FIG> is configured in a similar manner as the compaction system <NUM> of <FIG> except as provided below.

For this embodiment, the compaction system <NUM> includes a press system <NUM>. The press system <NUM> includes a bridge <NUM> removably coupled with or fixed to the tool <NUM>. The bridge <NUM> can be fixed to other structures as well. The press system <NUM> also includes a leadscrew <NUM> that is threadingly engaged with a cross bar of the bridge <NUM> as shown in <FIG>. The leadscrew <NUM> can be rotated so that a press <NUM> of the leadscrew <NUM> engages the plunger <NUM>. In this way, the plunger <NUM> can be moved toward the laminate <NUM> along the first direction D1. The plunger <NUM> can engage the noodle ring <NUM> and apply a force F1 thereto. The force F1 applied to the noodle ring <NUM> by the plunger <NUM> causes the noodle ring <NUM> to drive or compact the noodle <NUM> into the cavity <NUM> defined by the laminate <NUM>. The leadscrew <NUM> can be driven or torqued manually by an operator or in automated manner by a torque system, such as an electric motor. The leadscrew <NUM> can be rotated in the opposite direction to move the press <NUM> away from the plunger <NUM> after a compaction cycle or when compaction is complete.

<FIG> provides a schematic cross-sectional view of a further compaction system <NUM> in the process of compacting a laminate <NUM> according to an example embodiment of the present subject matter. The compaction system <NUM> of <FIG> is configured in a similar manner as the compaction system <NUM> of <FIG> except as provided below.

For this embodiment, the compaction system <NUM> includes a press system <NUM> having a mandrel <NUM> and a bolt <NUM> threadingly received within the mandrel <NUM>. As depicted, the mandrel <NUM> is received within an opening defined by the plunger <NUM>. The bolt <NUM> can be a cap screw bolt, for example. The bolt <NUM> can be rotated within the mandrel <NUM> so that the plunger <NUM> is moved toward the laminate <NUM> along the first direction D1. The plunger <NUM> can engage the noodle ring <NUM> and apply a force F1 thereto. The force F1 applied to the noodle ring <NUM> by the plunger <NUM> causes the noodle ring <NUM> to drive or compact the noodle <NUM> into the cavity <NUM> defined by the laminate <NUM>. The bolt <NUM> can be driven or torqued manually by an operator or in automated manner by a torque system, such as an electric motor. The bolt <NUM> can be rotated in the opposite direction to reduce the force F1 that the plunger <NUM> applies to the noodle ring <NUM>, e.g., after a compaction cycle or when compaction is complete.

<FIG> provides a schematic cross-sectional view of a further example compaction system <NUM> in the process of compacting a laminate <NUM> according to an example embodiment of the present subject matter. The compaction system <NUM> of <FIG> is configured in a similar manner as the compaction system <NUM> of <FIG> except as provided below.

For this embodiment, the compaction system <NUM> includes a piston system <NUM> for compacting the laminate <NUM>. As shown, the piston system <NUM> includes a piston housing <NUM> defining a piston chamber <NUM>. The piston housing <NUM> can form a part of a bridge, such as the bridge <NUM> of <FIG>. A piston <NUM> is received within the piston chamber <NUM> of the piston housing <NUM> and is movable, e.g., along the first direction D1. A piston rod <NUM> is coupled with the piston <NUM>. The piston rod <NUM> extends between a first end and a second end, e.g., along the first direction D1. The first end of the piston rod <NUM> is coupled with the piston <NUM>. The piston rod <NUM> is coupled with the plunger <NUM> at its second end. Accordingly, when the piston <NUM> is moved within the piston chamber <NUM>, the plunger <NUM> is likewise moved.

The piston <NUM> is hydraulically controlled in this example embodiment. It will be appreciated that the piston <NUM> can be controlled in other suitable manners as well. As depicted, the piston housing <NUM> defines a first inlet <NUM> and a first drain <NUM> that provide an ingress and an egress for working fluid WF to flow into and out of a first side S1 of the piston chamber <NUM>. The piston housing <NUM> also defines a second inlet <NUM> and a second drain <NUM> that provide an ingress and an egress for working fluid WF to flow into and out of a second side S2 of the piston chamber <NUM>. The first and second sides S1, S2 of the piston chamber <NUM> are fluidly separated by the piston <NUM>. The piston system <NUM> includes a control valve <NUM> for controlling the flow of working fluid WF to the piston chamber <NUM>. For this example embodiment, the control valve is a three-way valve.

A controller <NUM> communicatively coupled with the control valve <NUM> can control the control valve <NUM> to selectively allow working fluid WF to flow from a fluid source <NUM> to the first side S1 of the piston chamber <NUM> and to prevent working fluid WF from flowing to the second side S2 of the piston chamber <NUM>. The controller <NUM> can include one or more processors and one or more memory devices. The one or more memory devices can include a non-transitory computer readable storage medium, for example. The one or more memory devices can store information accessible by the one or more processors, including computer-readable instructions that can be executed by the one or more processors. The instructions can be any set of instructions that, when executed by the one or more processors, cause the one or more processors to perform operations, such as controlling the control valve <NUM>. The controller <NUM> can be configured as shown in <FIG> and described in the accompanying text.

By supplying working fluid WF to the first side S1 of the piston chamber <NUM> and preventing working fluid from flowing to the second side S2, the piston <NUM> can be moved downward toward the laminate <NUM> along the first direction D1. The controller <NUM> can also control the control valve <NUM> to selectively allow working fluid WF to flow from the fluid source <NUM> to the second side S2 of the piston chamber <NUM> and to prevent working fluid WF from flowing to the first side S1 of the piston chamber <NUM>. By supplying working fluid WF to the second side S2 of the piston chamber <NUM> and preventing working fluid from flowing to the first side S1, the piston <NUM> can be moved upward away from the laminate <NUM> along the first direction D1.

A sensor <NUM> (e.g., a pressure sensor) can be positioned within or attached to the noodle ring <NUM>. The sensor <NUM> can be communicatively coupled with the controller <NUM> and can provide feedback signals indicating the applied pressure placed on the noodle ring <NUM> by the plunger <NUM>. The controller <NUM> can control the control valve <NUM>, and thus the flow of working fluid WF to the piston chamber <NUM>, based at least in part on the received feedback signals.

<FIG> provides a flow diagram of a method (<NUM>) of compacting a laminate according to an exemplary embodiment of the present subject matter. Any of the example compaction systems provided herein can be used to compact a laminate using method (<NUM>). Other compaction systems can be used to compact a laminate using method (<NUM>) as well.

At (<NUM>), the method (<NUM>) includes positioning a laminate on a tool of a compaction system. The laminate positioned on the tool can formed of one or more plies. The laminate can be positioned on the tool by laying up the plies of the laminate directly on the tool or the laminate can be laid up elsewhere and subsequently positioned on the tool. Further, the laminate can define a cavity. In some instances, the laminate is laid up in such a way that the laminate defines a cavity. For instance, <FIG> depicts an example laminate <NUM> positioned on the tool <NUM> of the compaction system <NUM>. As illustrated, the laminate <NUM> defines cavity <NUM>. The cavity <NUM> is defined between the first section <NUM> and the second section <NUM> of the laminate <NUM> at the joint interface <NUM>.

At (<NUM>), the method (<NUM>) optionally includes shaping the cavity of the laminate to a desired shape. For instance, shaping the cavity of the laminate to the desired shape can include pressing a shaping tool into the cavity of the laminate to shape the cavity. The shaping tool can be mounted to the plunger of the compaction system, for example.

By way of example, <FIG> provides a schematic cross-sectional view of a compaction system <NUM> in the process of shaping a cavity <NUM> of a laminate <NUM> to a desired shape. As depicted, a shaping tool <NUM> is mounted to the plunger <NUM>. For instance, the plunger <NUM> can include a chuck that holds the shaping tool <NUM>. The shaping tool <NUM> includes a shaping end <NUM> that is shaped complementary to the desired shape of the cavity <NUM>. To achieve the desired geometry of the cavity <NUM>, the plunger <NUM> with the shaping tool <NUM> mounted thereto can be moved toward the laminate <NUM> along the first direction D1. The plunger <NUM> can be moved along the first direction D1 in any suitable manner, e.g., by tightening bolts <NUM> as shown in <FIG>. The plunger <NUM> can move the shaping end <NUM> of the shaping tool <NUM> into the cavity <NUM>. In this way, the shaping end <NUM> of the shaping tool <NUM> can shape the cavity <NUM> by pressing on the laminate <NUM>. For instance, in <FIG>, the shaping end <NUM> can press on the first section <NUM> and the second section <NUM> to form the cavity <NUM> to the desired geometry so that a noodle can be positioned therein.

In some implementations, optionally, the method (<NUM>) can include inserting a slurry into the cavity prior to the noodle being compacted into the cavity. The slurry can be composed of a matrix material, such as a ceramic matrix material. The inserted slurry composition may facilitate a more complete filling of the cavity, which may lead to improved mechanical properties of the finished component.

At (<NUM>), the method (<NUM>) includes positioning a noodle relative to or in the cavity. The noodle is positioned relative to or in the cavity so that the noodle is received within the cavity during the compaction process. In some implementations, the noodle is positioned such that at least a portion of the noodle is positioned within the cavity. For instance, as shown in <FIG>, noodle <NUM> is shown positioned in the cavity <NUM> of the laminate <NUM>. The noodle can be formed of any suitable material, such as a CMC material. The noodle can be positioned manually by an operator or automatically, e.g., by a piston-controlled noodle insertion tool. For instance, a noodle insertion tool can be mounted to the plunger <NUM> of the compaction system <NUM> of <FIG>. For instance, a chuck of the plunger <NUM> can hold the noodle insertion tool. The noodle can be mounted to the noodle insertion tool. The plunger <NUM> can be controlled to move toward the laminate <NUM> along the first direction D1 by the controller <NUM>. The noodle insertion tool can position the noodle <NUM> relative to the cavity <NUM>.

At (<NUM>), the method (<NUM>) includes positioning a noodle ring relative to the noodle. For instance, in some implementations, the noodle ring can be positioned directly on the noodle. In other implementations, a sheet or film can be placed between the noodle ring and the noodle. For example, protective sheet <NUM> is shown positioned between the noodle ring <NUM> and the noodle <NUM>, e.g., along the first direction D1. In some implementations, the noodle ring is formed as a single component. In other implementations, the noodle ring is formed of at least two sections.

In some implementations, with the noodle ring <NUM> positioned in place, optionally, a band debulk cap can be secured in place by a latch system to retain the noodle ring <NUM> in place during compaction, e.g., as shown in <FIG>. In other implementations, the noodle ring <NUM> can include a main body and one or more stabilizing members extending outward from the main body, e.g., as shown in <FIG>. The stabilizing members can be mounted to the tool upon which the laminate is positioned, for example. In some implementations, the main body includes at least one pair of stabilizing members that extend in opposite directions from the main body. The main body can have an outline or cross section shaped complementary to the noodle. The noodle ring can be coupled with the tool via one or more fasteners extending through openings in the stabilizing members and corresponding openings in the tool, e.g., as shown in <FIG>.

The noodle ring can be positioned manually by an operator. In some implementations, the noodle ring defines a hollow interior, includes a look-through window, and/or is transparent in whole or in part. Such features may allow an operator to see the laminate while positioning the noodle ring relative to the noodle. This can prevent damage to the laminate. Furthermore, in some implementations, the noodle ring can be positioned automatically, e.g., by a piston-controlled plunger with a noodle ring positioning tool mounted thereto. The noodle ring can be mounted to the noodle ring positioning tool and can be released by the tool when the noodle ring is positioned relative to the noodle.

In some further implementations, as noted, the noodle ring can be formed in sections. In such implementations, the sections of the noodle ring can be moved into place or positioned relative to the noodle by an automated system at a non-vertical angle, e.g., at a forty-five degree angle relative to the first direction D1. For instance, an automated system <NUM> is shown in <FIG>. The automated system <NUM> can include one or more robotic arms <NUM> or other suitable devices. In this example embodiment, the robotic arms <NUM> can move a first section SC1 and a second section SC2 of the noodle ring <NUM> in place. The first and second sections SC1, SC2 can form respective halves of the noodle ring <NUM>. The robotic arms <NUM> can be controlled by a controller <NUM>, for example. The controller <NUM> can be configured as shown in <FIG> and described in the accompanying text. Positioning the sections SC1, SC2 of the noodle ring <NUM> at a non-vertical angle relative to the first direction D1 can prevent the noodle ring from crushing or otherwise damaging the protruding portion <NUM> of the laminate <NUM>. In some implementations, the sections SC1, SC2 of the noodle ring <NUM> are positioned or moved toward the laminate <NUM> by at least a fifteen degree offset relative to the first direction D1 and at least a fifteen degree offset relative to the second direction D2.

At (<NUM>), the method (<NUM>) includes moving a plunger to apply a force on the noodle ring so that the noodle ring compacts the noodle into the cavity. For instance, a plunger of the compaction system can be moved toward the laminate. The plunger can be moved by any suitable system, mechanism, or device. For instance, in some implementations, the plunger <NUM> can be moved by tightening one or more bolts <NUM> as shown in <FIG>. In some implementations, the plunger <NUM> can be moved by a press system <NUM> as shown in <FIG>. In some implementations, the plunger <NUM> can be moved by a piston system <NUM> as shown in <FIG>. In some implementations, the plunger <NUM> can be moved by other suitable mechanical systems, e.g., as represented in <FIG>. For instance, the plunger <NUM> can be a plate movable by a jackscrew or an arbor press.

As shown in <FIG>, the plunger <NUM> can be moved toward the laminate <NUM> along the first direction D1 and can engage the noodle ring <NUM>. With the noodle ring <NUM> engaged, the plunger <NUM> applies a force F1 on the noodle ring <NUM>. The noodle ring <NUM> in turn applies a force on the protective sheet <NUM>, which in turn applies a force on the noodle <NUM>. The force on the noodle <NUM> compacts the noodle <NUM> into the cavity <NUM>. In view of these applied forces, the noodle <NUM> can be satisfactorily compacted into the cavity <NUM>. The plunger <NUM> can also engage the band debulk cap <NUM>, which in turn can apply a force on the protective sheet <NUM>, which in turn can apply a force on the portion of the second section <NUM> that extends lengthwise along the second direction D2.

After compacting the laminate <NUM> and the noodle <NUM> into the cavity <NUM> of the laminate <NUM>, the plunger <NUM> can be moved away from the laminate <NUM> along the first direction D1. The laminate can be removed from the tool <NUM> and the compaction process can be repeated with subsequent laminates.

<FIG> provides a block diagram of an example computing system <NUM> that can be used to implement methods and systems described herein according to example embodiments of the present subject. The computing system <NUM> is one example of a suitable computing system for implementing the computing elements described herein.

As shown in <FIG>, the computing system <NUM> can include one more computing device(s) <NUM>. The controllers described herein can be embodied as one of the computing device(s) <NUM>. The one or more computing device(s) <NUM> can include one or more processor(s) <NUM> and one or more memory device(s) <NUM>. The one or more processor(s) <NUM> can include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, or other suitable processing device. The one or more memory device(s) <NUM> can include one or more computer-readable medium, including, but not limited to, non-transitory computer-readable medium or media, RAM, ROM, hard drives, flash drives, and other memory devices, such as one or more buffer devices.

The one or more memory device(s) <NUM> can store information accessible by the one or more processor(s) <NUM>, including computer-readable instructions <NUM> that can be executed by the one or more processor(s) <NUM>. The instructions <NUM> can be any set of instructions that, when executed by the one or more processor(s) <NUM>, cause the one or more processor(s) <NUM> to perform operations. The instructions <NUM> can be software written in any suitable programming language or can be implemented in hardware. The instructions <NUM> can be any of the computer-readable instructions noted herein.

The memory device(s) <NUM> can further store data <NUM> that can be accessed by the processor(s) <NUM>. For example, the data <NUM> can include one or more table(s), function(s), algorithm(s), model(s), equation(s), etc. according to example embodiments of the present disclosure.

The one or more computing device(s) <NUM> can also include a communication interface <NUM> used to communicate, for example, with other components of the compaction system <NUM> or other systems or devices. The communication interface <NUM> can include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

Although the figures and the accompanying text disclose exemplary systems and methods for compacting composite components, such as CMC and PMC components, the systems and methods disclosed herein are applicable to compacting other types of components as well.

Claim 1:
A method, comprising:
positioning a laminate formed of plies on a tool of a compaction system, the laminate defining a cavity;
positioning a noodle relative to or in the cavity;
positioning a noodle ring relative to the noodle; and
moving a plunger to apply a force on the noodle ring so that the noodle ring compacts the noodle into the cavity.