Patent Description:
Composite structures are widely used as high-strength, low-weight materials to replace metals, such as in aerospace applications. Vacuum-bagging is commonly used during manufacturing of composite structures. Complications arise when vacuum-bagging large composite structures, such as large fuselage structures requiring rotation, particularly during rotation as vacuum tubes typically become entangled and reduce efficacy of the vacuum draw.

Accordingly, those skilled in the art continue with research and development efforts in the field of improving vacuum-bagging large composite structures. <CIT> discloses a process for consolidating a fibre reinforced laminate using a mattress formed by at least two inflatable bladders, said mattress covering substantially the whole surface of the laminate, wherein each bladder of the mattress is connected to a source of pressurized gas and to a source of vacuum, and a first bladder of the mattress is inflated, while at the same time a second bladder of the mattress is deflated with vacuum. A rotating manifold is disclosed in <NPL>.

In an example, the disclosed rotating manifold includes an axle, a hub rotatable relative to the axle about an axis of rotation, and a compressed air line housed in the axle. The rotating manifold further includes a vacuum in fluid communication with the hub. The rotating manifold further includes a plurality of conduits connected to the hub. Each conduit of the plurality of conduits is in fluid communication with the vacuum line and houses a compressed air line arm in fluid communication with the compressed air line.

Also disclosed are systems for vacuum bagging a composite layup.

In an example, the disclosed system includes a rotating manifold. The rotating manifold includes an axle, a hub rotatable relative to the axle about an axis of rotation, and a compressed air line housed in the axle. The rotating manifold further includes a vacuum in fluid communication with the hub. The rotating manifold further includes a plurality of conduits connected to the hub. Each conduit of the plurality of conduits is in fluid communication with the vacuum line and houses a compressed air line arm in fluid communication with the compressed air line. The system further includes a vacuum source in fluid communication with the rotating manifold by way of the vacuum line.

Also discloses are methods for drawing vacuum through the disclosed system.

In an example, the disclosed method for drawing vacuum through the disclosed system includes steps of (<NUM>) drawing air though the compressed air line into the hub; (<NUM>) directing the air through the plurality of conduits via the hub; and (<NUM>) actuating a vacuum assembly to enable vacuum draw through the vacuum bag (<NUM>).

Also disclosed are methods for vacuum bagging a composite layup over a tool, such as a drum-shaped mandrel.

In an example, the disclosed method includes steps of (<NUM>) positioning a vacuum bag into engagement with the composite layup; (<NUM>) coupling a rotating manifold with the vacuum bag; and (<NUM>) drawing vacuum from the vacuum bag by way of the rotating manifold.

According to an aspect of the present disclosure a rotating manifold comprises:.

a vacuum line in fluid communication with the hub; and.

a plurality of conduits connected to the hub, wherein each conduit of the plurality of conduits is in fluid communication with the vacuum line and wherein each conduit of the plurality of conduits houses a compressed air line arm in fluid communication with the compressed air line.

Advantageously, the rotating manifold is one wherein the plurality of conduits are substantially equidistantly distributed about the hub.

Preferably, the rotating manifold is one wherein each conduit of the plurality of conduits radially extends from the hub.

Preferably, the rotating manifold is one wherein each conduit of the plurality of conduits comprises at least one of a tube, a hose, and a pipe.

Preferably, the rotating manifold is one wherein each conduit of the plurality of conduits is magnetically connected to the hub.

Preferably, the rotating manifold is one wherein each conduit of the plurality of conduits comprises a vacuum valve assembly.

Preferably, the rotating manifold is one wherein the vacuum valve assembly comprises a plunger.

Preferably, the rotating manifold is one wherein the vacuum valve assembly comprises a valve configured to control vacuum flow through the vacuum valve assembly.

Preferably, the rotating manifold is one wherein the valve is pneumatically actuatable between at least a first position and a second position.

Preferably, the rotating manifold is one wherein the vacuum valve assembly comprises an actuator.

Preferably, the rotating manifold further comprises a bearing located between the hub and the axle.

Preferably, the rotating manifold is one wherein the hub comprises a plurality of vacuum ports configured to engage the plurality of conduits.

Preferably, the rotating manifold is one wherein each vacuum port of the plurality of vacuum ports comprises a valve configured to selectively control vacuum flow through each conduit of the plurality of conduits.

According to another aspect of the present disclosure a system for vacuum bagging a composite layup, the system comprises:.

Advantageously, the system is one wherein each conduit of the plurality of conduits is connected to the hub with a magnet.

Preferably, the system is one wherein each conduit of the plurality of conduits comprises a vacuum valve assembly.

Preferably, the system is one wherein the vacuum source draws at least <NUM><NUM> / minute ( <NUM> cubic feet per minute).

Preferably, the system further comprises a vacuum bag on an outside surface of the composite layup.

Preferably, the system further comprises a tool.

Preferably, the system is one wherein the tool is a drum-shaped mandrel.

According to yet another aspect of the present disclosure a method of vacuum bagging a composite layup over a drum-shaped mandrel, the method comprises:
positioning a vacuum bag into engagement with the composite layup;
coupling a rotating manifold with the vacuum bag; and
drawing vacuum from the vacuum bag by way of the rotating manifold.

Advantageously, the method is one wherein the rotating manifold comprises:.

Preferably, the method is one wherein the coupling comprises positioning the plurality of conduits into engagement with the vacuum bag.

Preferably, the method further comprises applying the composite layup to an outside surface of the drum-shaped mandrel prior to the positioning.

Preferably, the method further comprises rotating the drum-shaped mandrel simultaneously with the drawing.

A method for drawing vacuum through the system comprises:.

actuating a vacuum valve assembly to enable vacuum draw through the vacuum bag.

Other examples of the disclosed rotating manifolds, systems, and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

The following detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings.

Referring to <FIG>, disclosed is a rotating manifold <NUM>. The rotating manifold <NUM> is designed for high volume vacuum bagging for compaction of composite materials. The rotating manifold <NUM> may include a modular high volume plenum system utilizing a rotational plenum design where high volume vacuum draw is distributed with compressed air to a plurality of pneumatically actuated vacuum valve assemblies via a plurality of conduits. In one example, the subcomponents of the modular high volume plenum system are held together via magnets for easy assembly and disassembly.

Still referring to <FIG>, in one or more examples, the rotating manifold <NUM> includes a hub <NUM> and a compressed air line <NUM> housed in the axle <NUM>, see <FIG>. The hub <NUM> is rotatable relative to the compressed air line <NUM> about an axis of rotation A, see <FIG>. In one example, the compressed air line <NUM> is housed in an axle <NUM> such that the hub <NUM> is rotatable relative to the axle <NUM> and a center axis A defined by the axle <NUM>, see <FIG>. The axle <NUM> may be of any desired diameter for use with the rotating manifold <NUM>. In one example, the axle <NUM> is approximately <NUM>" in diameter. Further, in one example, the hub <NUM> may be rotatable about the axle <NUM> via a bearing <NUM> located on an outside surface of the hub <NUM>. The hub <NUM> may be rotatable about the axle <NUM> via both the bearing <NUM> and a second bearing 114b located on an outside surface of the hub <NUM>, see <FIG>.

The compressed air line <NUM> passes through the hub <NUM> and is in fluid communication with the compressed air manifold <NUM> which is housed inside the compressed air hub <NUM>. The compressed air line <NUM>, see <FIG>, may extend beyond the axle <NUM> and may further extend perpendicular to the axle <NUM> via a rotational compressed air elbow fitting <NUM>. The rotational compressed air elbow fitting <NUM> may be configured to maintain necessary supply of compressed air through the compressed air line <NUM>.

Referring to <FIG>, in one or more examples, the axle <NUM> further includes a vacuum line <NUM> in fluid communication with the hub <NUM>. The vacuum line <NUM> is configured to selectively draw vacuum through the hub <NUM>. In one example, the vacuum line <NUM> is housed within the axle <NUM>, see <FIG>, such that it surrounds the compressed air line <NUM>. The vacuum line <NUM> may pivot to extend perpendicular to the axle <NUM> to couple with a vacuum source <NUM>. The compressed air line <NUM> and vacuum line <NUM> are both housed inside the axle <NUM> and may both have a center axis A.

Referring to <FIG>, <FIG>, and <FIG>, in one or more examples, the hub <NUM> may further be coupled with a compressed air hub <NUM>. The compressed air hub <NUM> houses a compressed air manifold <NUM>. The compressed air manifold <NUM> includes a plurality of ports <NUM> in fluid communication with the compressed air line <NUM>. Each port <NUM>' of the plurality of ports <NUM> may be individually controllable such that each may distribute compressed air based upon automated or manual control.

Referring to <FIG>, the rotating manifold <NUM> further includes a plurality of conduits <NUM> connected to the hub <NUM>. Each conduit <NUM>' of the plurality of conduits <NUM> is in fluid communication with the vacuum line <NUM> such that each is configured to draw vacuum. Further, each conduit <NUM>' of the plurality of conduits <NUM> includes a compressed air line arm <NUM>' that is in fluid communication with the compressed air line <NUM> via the compressed air manifold <NUM>, see <FIG>. In one example, each conduit <NUM>' of the plurality of conduits <NUM> radially extends from the hub <NUM>. Each conduit <NUM>' of the plurality of conduits <NUM> may comprise an elastic material, such as a rubber material. In one example, each conduit <NUM>' of the plurality of conduits <NUM> may be at least one of a tube, a hose, and a pipe. In one or more examples, the plurality of conduits <NUM> are substantially equidistantly distributed about the hub <NUM>. Further, in another example, each conduit <NUM>' of the plurality of conduits <NUM> is magnetically connected to the hub <NUM>.

Referring to <FIG> and <FIG>, in one or more examples, each conduit <NUM>' of the plurality of conduits <NUM> includes a vacuum valve assembly <NUM>. <FIG> and <FIG> illustrate perspective views of the vacuum valve assembly <NUM> portion of the rotating manifold. The vacuum valve assembly <NUM> may include a movable sealing member, such as a plunger <NUM>. The plunger <NUM> is configured to move between at least two positions to block or allow vacuum draw based upon an actuator <NUM>. The vacuum valve assembly <NUM> may further include a valve <NUM> configured to control vacuum flow through the vacuum valve assembly <NUM>. In one example, the valve <NUM> is pneumatically actuatable between at least a first position and a second position. In another example, the valve <NUM> is a pneumatic compressed air valve that controls an actuator <NUM> to actuate the plunger <NUM>. Upon pressure from the compressed air line <NUM>, the valve <NUM> supplies air pressure to actuate the actuator <NUM> for releasing the plunger <NUM> to an open position to allow vacuum draw from the vacuum line <NUM>.

Referring to <FIG>, in one or more examples, the hub <NUM> includes a plurality of vacuum ports <NUM> configured to engage the plurality of conduits <NUM>. In one example, each vacuum port <NUM>' of the plurality of vacuum ports <NUM> includes a valve <NUM> configured to selectively control vacuum flow through each conduit <NUM>' of the plurality of conduits <NUM>. The valve <NUM> may be automated or manually controlled.

Referring to <FIG>, also disclosed is a system <NUM> for vacuum bagging a composite layup <NUM>. The system <NUM> is designed for effective compaction of large composite structures, and particularly for fuselage structures for aircrafts. The composite layup <NUM> includes at least one ply of composite material (e.g., a composite ply) placed on (e.g., over) a tool <NUM>. The composite layup <NUM> can include any number (e.g., one or more) of composite plies. The composite material includes a reinforcement material embedded in a polymeric matrix material. In one or more examples, the composite material is pre-impregnated ("pre-preg") thermoset composite material.

Still referring to <FIG>, the system <NUM> includes a rotating manifold <NUM>. the rotating manifold <NUM> includes a hub <NUM> and a compressed air line <NUM> housed in the hub <NUM>. The hub <NUM> is rotatable relative to the compressed air line <NUM> about an axis of rotation A. In one example, the compressed air line <NUM> is housed in an axle <NUM> such that the hub <NUM> is rotatable relative to the axle <NUM> and a center axis A defined by the axle <NUM>, see <FIG>. In one example, the hub <NUM> is rotatable about the axle <NUM> via a bearing <NUM> located on an outside surface of the hub <NUM>. The hub <NUM> may be rotatable about the axle <NUM> via both the bearing <NUM> and a second bearing 114b located on an outside surface of the hub <NUM>, see <FIG>.

Referring to <FIG>, in one or more examples, the axle <NUM> further includes a vacuum line <NUM> in fluid communication with the hub <NUM> via the axle <NUM>. The vacuum line <NUM> is configured to selectively draw vacuum through the hub <NUM> by way of the vacuum source <NUM>. In one example, the vacuum line <NUM> is housed within the axle <NUM>, see <FIG>, such that it surrounds the compressed air line <NUM>.

The rotating manifold <NUM> of the system <NUM> further includes a plurality of conduits <NUM> connected to the hub <NUM>. Each conduit <NUM>' of the plurality of conduits <NUM> is in fluid communication with the compressed air line <NUM>. In one example, each conduit <NUM>' of the plurality of conduits <NUM> is connected to the hub <NUM> with a magnet. In another example, each conduit <NUM>' of the plurality of conduits <NUM> comprises a vacuum valve assembly <NUM>.

The system <NUM> further includes a vacuum source <NUM> in fluid communication with the rotating manifold <NUM> by way of the hub <NUM> via vacuum line <NUM> within the axle <NUM>. The vacuum source <NUM> may draw any amount of vacuum suitable for the intended application, such as a high flow vacuum draw. In one example, the vacuum source <NUM> draws at least <NUM><NUM>/minute ( <NUM> cubic feet per minute).

Referring to <FIG>, the system <NUM> includes a vacuum bag <NUM>. In one example, the vacuum bag <NUM> is positioned on an outside surface of the composite layup <NUM>. The vacuum bag <NUM> includes an impermeable layer <NUM>. The impermeable layer <NUM> is substantially impermeable to fluids, including air. In one example, the impermeable layer <NUM> comprises a polymeric material. In another example, the impermeable layer 242comprises rubber. In one specific, non-limiting example, the impermeable layer <NUM> comprises a Mosites™ rubber sheet. The vacuum bag <NUM> further includes a flow media layer <NUM>. In on example, the flow media layer <NUM> comprises a biplanar mesh. In another example, the flow media layer <NUM> is a sheet of material, such as a biplanar mesh.

Referring to <FIG> and <FIG>, in one or more example, the system <NUM> further includes a tool <NUM>. The tool <NUM> may be any size or configuration based upon the desired structure. In one example, the tool <NUM> may be a mandrel. In one specific example, the tool <NUM> is a drum-shaped mandrel <NUM>.

Referring to <FIG>, disclosed is a method <NUM> of vacuum bagging a composite layup <NUM> over a drum-shaped mandrel <NUM>. The method <NUM> includes positioning <NUM> a vacuum bag <NUM> into engagement with the composite layup <NUM>. The vacuum bag <NUM> includes an impermeable layer <NUM>. The impermeable layer <NUM> is substantially impermeable to fluids, including air. In one example, the impermeable layer <NUM> comprises a polymeric material. In another example, the impermeable layer 242comprises rubber. In one specific, non-limiting example, the impermeable layer <NUM> comprises a Mosites™ rubber sheet. The vacuum bag <NUM> further includes a flow media layer <NUM>. In on example, the flow media layer <NUM> comprises a biplanar mesh. In another example, the flow media layer <NUM> is a sheet of material, such as a biplanar mesh.

Still referring to <FIG>, the method <NUM> includes coupling <NUM> a rotating manifold <NUM> with the vacuum bag <NUM>. The rotating manifold <NUM> includes a hub <NUM> and a compressed air line <NUM> housed in the hub <NUM>. The rotating manifold <NUM> of the method <NUM> further includes a plurality of conduits <NUM> in fluid communication with the compressed air line <NUM> by way of the hub <NUM>, wherein the hub <NUM> is rotatable relative to the compressed air line <NUM>. In one example, the coupling <NUM> comprises positioning the plurality of conduits <NUM> into engagement with the vacuum bag <NUM>.

The method <NUM> further includes drawing <NUM> vacuum from the vacuum bag <NUM> via the vacuum source <NUM> by way of the rotating manifold <NUM>. Referring to <FIG>, the method <NUM> further includes applying <NUM> the composite layup <NUM> to an outside surface of the drum-shaped mandrel <NUM> prior to the positioning <NUM>. In one or more examples, the method <NUM> further includes rotating <NUM> the drum-shaped mandrel <NUM> simultaneously with the drawing <NUM>.

Referring to <FIG>, in one or more examples, disclosed is a method <NUM> for drawing vacuum through the system <NUM>. In one example, the method <NUM> includes drawing <NUM> air though the compressed air line <NUM> into the hub <NUM>. The method <NUM> further includes directing <NUM> the air through the plurality of conduits <NUM> via the hub <NUM>. The method <NUM> further includes actuating <NUM> the vacuum valve assembly <NUM> to enable vacuum draw through the vacuum bag <NUM>. Upon actuating <NUM>, vacuum may be drawn via each vacuum valve assembly <NUM> in fluid communication with the vacuum line <NUM> by way of the vacuum source <NUM>.

Examples of the present disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. During pre-production, service method <NUM> may include specification and design (block <NUM>) of aircraft <NUM> and material procurement (Block <NUM>). During production, component and subassembly manufacturing (Block <NUM>) and system integration (Block <NUM>) of aircraft <NUM> may take place. Thereafter, aircraft <NUM> may go through certification and delivery (Block <NUM>) to be placed in service (Block <NUM>). While in service, aircraft <NUM> may be scheduled for routine maintenance and service (Block <NUM>). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft <NUM>.

Each of the processes of service method <NUM> may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown in <FIG>, aircraft <NUM> produced by service method <NUM> may include airframe <NUM> with a plurality of high-level systems <NUM> and interior <NUM>. Examples of high-level systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft <NUM>, the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc..

Claim 1:
A rotating manifold (<NUM>) comprising:
an axle (<NUM>);
a hub (<NUM>) rotatable relative to the axle (<NUM>) about an axis of rotation (A);
a compressed air line (<NUM>) housed in the axle (<NUM>); a vacuum line (<NUM>) in fluid communication with the hub (<NUM>); and
a plurality of conduits (<NUM>) connected to the hub (<NUM>), wherein each conduit (<NUM>') of the plurality of conduits (<NUM>) is in fluid communication with the vacuum line (<NUM>) and wherein each conduit (<NUM>') of the plurality of conduits (<NUM>) houses a compressed air line arm (<NUM>') in fluid communication with the compressed air line (<NUM>).