Patent Description:
Manufacturing of large parts from flexible materials, such as composite materials, typically requires movement of the flexible materials throughout the manufacturing environment. Current means of moving flexible materials, such as pick and place apparatuses, utilize mechanical means such as suction cups to grip and hold the materials they are moving. In most applications, the suction cups are not completely distributed across the entire surface thus there can be draping of material between the suction cups. Additionally, these suctions cups are often ridged and not highly conformable and tend to result in some damage to the material.

Accordingly, those skilled in the art continue research and development in the field of transporting flexible materials.

<CIT>, in accordance with its abstract, states a composite vacuum bag material includes a flexible fabric of polymeric material having a void free layer of elastomer bonded to one side. The exposed fabric surface, treated with a release agent provide air passageways when applied against the surface of an article during vacuum bagging. Additionally, <CIT>, in accordance with column <NUM> lines <NUM> - <NUM>, states "As shown in the drawing, the composite vacuum bag material comprises a nonporous or void free elastomer layer or sheet bounded to one side of a woven or knitted fabric layer" (reference signs removed to aid clarity).

<CIT>, in accordance with its English language abstract, states an application tool for a flexible workpiece, in particular a fiber composite body, characterized in that the application tool is used as a combination tool for flatly receiving the flexible workpiece and for spatially shaping the received workpiece on an external shaping tool is designed, wherein the application tool has a controllably deformable as well as solidifiable and reconfigurable forming head. Additionally, <CIT>, in accordance with its English language translation, states in paragraph [<NUM>] that "In the variants shown, the forming member is designed as a vacuum mattress with a vacuum device. The vacuum mattress can deform under external shaping influences and can also be solidified and stiffened in the deformed position. For this purpose, the vacuum mattress has a gas-tight and flexible as well as stretch-resistant cover which is connected to the support body. The casing contains a filling made of granules, e.g. For example, particles made of plastic are pressure-resistant. The vacuum mattress further comprises a vacuum connection for connection to the vacuum device preferably arranged on the frame " (reference signs removed to aid clarity).

The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure.

Specifically, there is described herein, a pliable structure comprising: a first impermeable layer; a second impermeable layer opposed from the first impermeable layer to at least partially define an internal volume between the first impermeable layer and the second impermeable layer; a flow media layer disposed in the internal volume; and a core layer positioned in a layered configuration between the flow media layer and the second impermeable layer.

Also disclosed is a system for replicating a contour of a surface.

Specifically, there is described herein, a system for replicating a contour of a surface, the system comprising: a pliable structure as described previously; and a vacuum source fluidly coupled to the pliable structure with a vacuum tube.

Also disclosed is a method for replicating a contour of a surface.

Specifically, there is described herein, a method for replicating a contour of a surface, the method comprising: engaging an engagement surface of a pliable structure as described previously with the surface such that the engagement surface of the pliable structure assumes the contour of the surface; and drawing a vacuum from the pliable structure to lock the engagement surface of the pliable structure to the contour of the surface.

Advantageously, the pliable structure is one wherein the first impermeable layer comprises a polymeric material.

Preferably, the pliable structure is one wherein the first impermeable layer comprises rubber.

Preferably, the pliable structure is one wherein the second impermeable layer comprises a polymeric material.

Preferably, the pliable structure is one wherein the second impermeable layer comprises rubber.

Preferably, the pliable structure is one wherein the first impermeable layer and the second impermeable layer are compositionally alike.

Preferably, the pliable structure is one wherein the first impermeable layer and the second impermeable layer are compositionally different.

Preferably, the pliable structure is one wherein the first impermeable layer and the second impermeable layer enclose the internal volume.

Preferably, the pliable structure is one wherein the flow media layer comprises a biplanar mesh.

Preferably, the pliable structure is one wherein the flow media layer is a sheet.

Preferably, the pliable structure further comprises an engagement feature coupled to the second impermeable layer.

Preferably, the pliable structure is one wherein the engagement feature comprises an electrostatic feature.

Preferably, the pliable structure is one wherein the engagement feature comprises a suctioning feature.

Preferably, the pliable structure further comprises a vacuum port in fluid communication with the internal volume.

Preferably, the pliable structure is one wherein the core layer comprises wood.

Preferably, the pliable structure is one wherein the core layer comprises foam.

Preferably, the pliable structure further comprises a second flow media layer positioned between the core layer and the second impermeable layer.

Advantageously, the method is one wherein the pliable structure comprises a vacuum port in fluid communication with an internal volume.

Preferably, the method further comprises disengaging the pliable structure from the surface.

Preferably, the method further comprises engaging the pliable structure with at least one uncured ply of composite material.

Preferably, the method is one wherein the engaging comprises suctioning the at least one uncured ply of composite material to the pliable structure.

Preferably, the method is one wherein the engaging comprises electro-statically adhering the at least one uncured ply of composite material to the pliable structure.

Preferably, the method is one wherein the pliable structure comprises: a first impermeable layer; a second impermeable layer opposed from the first impermeable layer to at least partially define an internal volume between the first impermeable layer and the second impermeable layer; and a flow media layer disposed in the internal volume.

Preferably, the method is one wherein the drawing comprises evacuation of air from the internal volume and locks the pliable structure such that shear slippage is inhibited or substantially inhibited between the first impermeable layer and the flow media layer.

Preferably, the method is one wherein the drawing comprises evacuation of air from the internal volume and locks the pliable structure such that shear slippage is inhibited or substantially inhibited between the second impermeable layer and the flow media layer.

Preferably, the method is one wherein the first impermeable layer comprises rubber.

Preferably, the method is one wherein the second impermeable layer comprises rubber.

Preferably, the method is one wherein the first impermeable layer and the second impermeable layer are compositionally alike.

Preferably, the method is one wherein the first impermeable layer and the second impermeable layer are compositionally different.

Preferably, the method is one wherein the flow media layer comprises a biplanar mesh.

Preferably, the method is one wherein the pliable structure comprises a core layer positioned in a layered configuration between the flow media layer and the second impermeable layer.

Preferably, the method is one wherein the pliable structure comprises a second flow media layer positioned between the core layer and the second impermeable layer.

Preferably, the method is one wherein the pliable structure comprises an engagement feature coupled to the second impermeable layer.

Preferably, the method is one wherein the engagement feature comprises an electrostatic feature.

Preferably, the method is one wherein the engagement feature comprises a suctioning feature.

Advantageously, the system is one wherein shear slippage is inhibited or substantially inhibited when a vacuum is drawn in the pliable structure.

Preferably, the system is one wherein the pliable structure comprises: a first impermeable layer; a second impermeable layer opposed from the first impermeable layer to at least partially define an internal volume between the first impermeable layer and the second impermeable layer; and a flow media layer disposed in the internal volume.

Preferably, the system is one wherein the first impermeable layer comprises rubber.

Preferably, the system is one wherein the second impermeable layer comprises rubber.

Preferably, the system is one wherein the first impermeable layer and the second impermeable layer are compositionally alike.

Preferably, the system is one wherein the first impermeable layer and the second impermeable layer are compositionally different.

Preferably, the system is one wherein the flow media layer comprises a biplanar mesh.

Preferably, the system is one wherein the pliable structure comprises a vacuum port in fluid communication with the internal volume.

Preferably, the system is one wherein the pliable structure comprises an engagement feature coupled to the second impermeable layer.

Preferably, the system is one wherein the engagement feature comprises an electrostatic feature.

Preferably, the system is one wherein the engagement feature comprises a suctioning feature.

Preferably, the system is one wherein the pliable structure comprises a core layer positioned in a layered configuration between the flow media layer and the second impermeable layer.

Preferably, the system is one wherein the core layer comprises wood.

Preferably, the system is one wherein the core layer comprises foam.

Preferably, the system further comprises controllable movement device coupled to the pliable structure.

Preferably, the system is one wherein the controllable movement device comprises a robotic arm.

Also disclosed is a method for transporting an uncured ply of composite material.

According to some examples of the present disclosure, a method for transporting an uncured ply of composite material comprises: positioning the uncured ply of composite material on a tool; engaging a pliable structure as described above with the uncured ply of composite material; drawing a vacuum from the pliable structure to lock the pliable structure to a shape of the uncured ply of composite material, thereby preventing shear of the first impermeable layer and second impermeable layer of pliable structure relative to the flow media layer; adhering the uncured ply of composite material to the pliable structure; disengaging the uncured ply of composite material from the tool while retaining a contour of the tool; and placing the uncured ply of composite material onto a prior placed ply of composite material or a second tool while retaining a contour of the tool.

Advantageously, the method further comprises preventing shear of the first impermeable layer and second impermeable layer of the pliable structure relative to the flow media layer along a slip plane by drawing a vacuum through the internal volume.

Preferably, the method further comprises preventing shear of the first impermeable layer and second impermeable layer of the pliable structure relative to the flow media layer along a slip plane by drawing a vacuum normal to the first impermeable layer through the internal volume.

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.

Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according the present disclosure are provided below.

In one or more examples, the pliable structure <NUM> (<FIG>), system <NUM> (<FIG> and <FIG>), method <NUM> (<FIG>), and method <NUM> (<FIG>) may be used to facilitate manufacturing of composite parts, i.e., workpieces. In some examples, composite parts, such as carbon fiber reinforcement polymer parts, are initially laid-up in multiple layers that together are referred to as a laminate or "preform. " Individual fibers within each layer of the laminate are aligned parallel with each other, but different layers may exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The laminate may include a viscous resin that solidifies in order to harden the laminate into a composite part (e.g., for use in an aircraft). In some examples, the pliable structure <NUM>, system <NUM>, method <NUM>, and method <NUM> may be used to facilitate manufacturing of composite parts comprised of thermoplastic resins.

Referring to <FIG>, disclosed is a pliable structure <NUM>. The pliable structure <NUM> includes various layers in a layered or sandwich configuration. The pliable structure <NUM> includes a first impermeable layer <NUM>. The first impermeable layer <NUM> is impermeable or substantially impermeable to fluids, including air. In some examples, the first impermeable layer <NUM> comprises a polymeric material. In other examples, the first impermeable layer <NUM> comprises rubber. In some specific, nonlimiting examples, the first impermeable layer <NUM> comprises a Mosites™ rubber sheet.

Still referring to <FIG>, the pliable structure <NUM> includes a second impermeable layer <NUM> opposed from the first impermeable layer <NUM>. The opposing sandwich relationship between the first impermeable layer <NUM> and the second impermeable layer <NUM> at least partially defines an internal volume <NUM> between the first impermeable layer <NUM> and the second impermeable layer <NUM>. In some examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> enclose the internal volume <NUM>.

In some examples, the second impermeable layer <NUM> comprises a polymeric material. In other examples, the second impermeable layer <NUM> comprises rubber. In some examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> are compositionally alike such that they comprise the same material. In yet other examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> are compositionally different.

The pliable structure <NUM> may include an engagement feature <NUM>. In some examples, the engagement feature <NUM> is coupled to the second impermeable layer <NUM>. The engagement feature <NUM> may assist in engaging a flexible material <NUM> with the pliable structure <NUM>. In some examples, the engagement feature <NUM> comprises an electrostatic feature <NUM>. In other examples, the engagement feature comprises <NUM> a suctioning feature <NUM>.

Still referring to <FIG>, the pliable structure <NUM> includes a flow media layer <NUM> disposed in the internal volume <NUM>. In some examples, the flow media layer <NUM> comprises a biplanar mesh. In other examples, the flow media layer <NUM> is a sheet of material, such as a biplanar mesh.

Referring to <FIG>, the pliable structure includes a vacuum port <NUM>. The vacuum port <NUM> may be coupled with the first impermeable layer <NUM> or the second impermeable layer <NUM>. The vacuum port <NUM> is in fluid communication with the internal volume <NUM> of the pliable structure <NUM> such that when a vacuum is drawn, air is evacuated from the internal volume <NUM> of the pliable structure <NUM>.

The pliable structure <NUM> further includes a core layer <NUM> positioned in a layered configuration between the flow media layer <NUM> and the second impermeable layer <NUM>. The core layer <NUM> may be any desirable thickness and stiffness needed. In some examples, the core layer <NUM> comprises wood, such as balsa wood, or any other wood having desirable flexibility to conform to a contour of a surface <NUM>. In other examples, the core layer <NUM> comprises foam.

Still referring to <FIG>, the pliable structure <NUM> may further comprise a second flow media layer <NUM> positioned between the core layer <NUM> and the second impermeable layer <NUM>. The second flow media layer <NUM> may include a permeable layer such as a sheet of biplanar mesh.

Referring to <FIG> and <FIG>, disclosed is a system <NUM> for replicating a contour of a surface <NUM>. The surface <NUM> of a tool <NUM>, mandrel, or any other mold. The system <NUM> includes a pliable structure <NUM>.

The pliable structure <NUM> includes a first impermeable layer <NUM>. The first impermeable layer <NUM> is impermeable or substantially impermeable to fluids, including air. In some examples, the first impermeable layer <NUM> comprises a polymeric material. In other examples, the first impermeable layer <NUM> comprises rubber.

In one or more examples, the pliable structure <NUM> of the system <NUM> includes a second impermeable layer <NUM> opposed from the first impermeable layer <NUM>. The opposing sandwich relationship between the first impermeable layer <NUM> and the second impermeable layer <NUM> at least partially defines an internal volume <NUM> between the first impermeable layer <NUM> and the second impermeable layer <NUM>. In some examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> enclose the internal volume <NUM>.

In some examples, the second impermeable layer <NUM> comprises a polymeric material. In other examples, the second impermeable layer <NUM> comprises rubber. In one example, the first impermeable layer <NUM> and the second impermeable layer <NUM> are compositionally alike such that they comprise the same material. In yet other examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> are compositionally different.

The pliable structure <NUM> may include an engagement feature <NUM>, see <FIG>. In some examples, the engagement feature <NUM> is coupled to the second impermeable layer <NUM>. The engagement feature <NUM> may assist in engaging a flexible material <NUM> with the pliable structure <NUM>. In some examples, the engagement feature <NUM> comprises an electrostatic feature <NUM>. In other examples, the engagement feature comprises <NUM> a suctioning feature <NUM>.

The pliable structure <NUM> includes a flow media layer <NUM> disposed in the internal volume <NUM>. In some examples, the flow media layer <NUM> comprises a biplanar mesh. In other examples, the flow media layer <NUM> is a sheet of material, such as a biplanar mesh.

In one or more examples, the pliable structure <NUM> of the system <NUM> includes a vacuum port <NUM>. The vacuum port <NUM> may be coupled with the first impermeable layer <NUM> or the second impermeable layer <NUM>. The vacuum port <NUM> is in fluid communication with the internal volume <NUM> of the pliable structure <NUM>.

As illustrated in <FIG>, the pliable structure <NUM> of the system <NUM> may further comprise a second flow media layer <NUM> positioned between the core layer <NUM> and the second impermeable layer <NUM>. The second flow media layer <NUM> may include a permeable layer such as a sheet of biplanar mesh. In some examples, the second flow media layer <NUM> is in the form of a sheet.

Referring to <FIG>, the system <NUM> includes a vacuum source <NUM>. The vacuum source <NUM> is fluidly coupled to the pliable structure <NUM> with a vacuum tube <NUM>. The vacuum tube <NUM> is coupled to the vacuum port <NUM> of the pliable structure <NUM>. In some examples, shear slippage is inhibited or substantially inhibited when a vacuum is drawn in the pliable structure <NUM>.

Referring to <FIG> and <FIG>, the system <NUM> may further include a controllable movement device <NUM> coupled to the pliable structure <NUM>. In some examples, the controllable movement device <NUM> includes a robotic arm <NUM> configured to control movement of the pliable structure <NUM> from one location, such as a tool <NUM>, to another location for moving a flexible material <NUM> to a tool <NUM>.

Referring to <FIG>, disclosed is a method <NUM> for replicating a contour of a surface <NUM>. The method <NUM> may be performed using the pliable structure <NUM> as shown and described herein. In one or more examples, the method <NUM> includes engaging <NUM> an engagement surface <NUM> of the pliable structure <NUM> with the surface <NUM> such that the engagement surface <NUM> of the pliable structure <NUM> assumes the contour of the surface <NUM>. The pliable structure <NUM> comprises a vacuum port <NUM> in fluid communication with an internal volume <NUM>.

In one or more examples, the pliable structure <NUM> of the method <NUM> includes a second impermeable layer <NUM> opposed from the first impermeable layer <NUM>. The opposing sandwich relationship between the first impermeable layer <NUM> and the second impermeable layer <NUM> at least partially defines an internal volume <NUM> between the first impermeable layer <NUM> and the second impermeable layer <NUM>. In some examples, the first impermeable layer <NUM> and the second impermeable layer <NUM> enclose the internal volume <NUM>.

Illustrated in <FIG>, the pliable structure <NUM> includes a flow media layer <NUM> disposed in the internal volume <NUM>. In some examples, the flow media layer <NUM> comprises a biplanar mesh. In other examples, the flow media layer <NUM> is a sheet of material, such as a biplanar mesh.

In one or more examples, the pliable structure <NUM> of the method <NUM> includes a vacuum port <NUM>. The vacuum port <NUM> may be coupled with the first impermeable layer <NUM> or the second impermeable layer <NUM>. The vacuum port <NUM> is in fluid communication with the internal volume <NUM> of the pliable structure <NUM>.

As illustrated in <FIG>, the pliable structure <NUM> of the method <NUM> may further comprise a second flow media layer <NUM> positioned between the core layer <NUM> and the second impermeable layer <NUM>. The second flow media layer <NUM> may include a permeable layer such as a sheet of biplanar mesh. In some examples, the second flow media layer <NUM> is in the form of a sheet.

Referring back to <FIG>, the method <NUM> includes drawing <NUM> a vacuum from the pliable structure <NUM> to lock the engagement surface <NUM> of the pliable structure <NUM> to the contour of the surface <NUM>. The drawing <NUM> may be performed via a vacuum source <NUM> coupled to the pliable structure <NUM> via a vacuum tube <NUM> and vacuum port <NUM> of the pliable structure <NUM>. The drawing <NUM> includes evacuation of air within the internal volume <NUM> of the pliable structure <NUM> such that a vacuum is generated and the pliable structure <NUM> is locked in a configuration. In one or more examples, the drawing <NUM> locks the pliable structure <NUM> such that shear slippage is inhibited or substantially inhibited between the first impermeable layer <NUM> and the flow media layer <NUM>. In other examples, the drawing <NUM> locks the pliable structure <NUM> such that shear slippage is inhibited or substantially inhibited between the second impermeable layer <NUM> and the flow media layer <NUM>. The drawing <NUM> locks the pliable structure <NUM> by evacuation of air from the internal volume <NUM>, thus increasing friction among the layers of the pliable structure <NUM> and inhibiting shear slippage.

Still referring to <FIG>, the method <NUM> includes disengaging <NUM> the pliable structure <NUM> from the surface <NUM>. The disengaging <NUM> may be performed via a controllable movement device <NUM>. In some examples, the controllable movement device <NUM> includes a robotic arm <NUM>, see <FIG>.

Still referring to <FIG>, the method <NUM> engaging <NUM> the pliable structure <NUM> with a flexible material <NUM>. In some examples, the flexible material <NUM> includes at least one uncured ply of composite material <NUM>. In other examples, the flexible material <NUM> includes more than one uncured ply of composite material <NUM>. In some examples, the engaging <NUM> includes suctioning <NUM> the flexible material <NUM>, or at least one uncured ply of composite material <NUM>, to the pliable structure <NUM>. In other examples, the engaging <NUM> includes electro-statically adhering <NUM> the at least one uncured ply of composite material <NUM> to the pliable structure <NUM>.

Referring to <FIG>, disclosed is a method <NUM> for transporting an uncured ply of composite material <NUM>. In some examples, the method <NUM> includes positioning <NUM> the uncured ply of composite material <NUM> on a tool <NUM>. The tool <NUM> may have complex geometry or curvature. In some examples, the tool <NUM> has a previously laid uncured ply of composite material <NUM> prior to the positioning <NUM>.

Still referring to <FIG>, the method includes engaging <NUM> the pliable structure <NUM> with the uncured ply of composite material <NUM>. After the engaging <NUM>, the <NUM> further includes drawing <NUM> a vacuum from the pliable structure <NUM> to lock the pliable structure <NUM> to a shape of the uncured ply of composite material <NUM>, thereby preventing shear of the first impermeable layer <NUM> and second impermeable layer <NUM> of pliable structure <NUM> relative to the flow media layer <NUM>. The drawing <NUM> a vacuum locks the pliable structure <NUM> by evacuation of air from the internal volume <NUM>, thus increasing friction among the layers of the pliable structure <NUM> and inhibiting shear slippage.

Still referring to <FIG>, the method <NUM> includes adhering <NUM> the uncured ply of composite material <NUM> to the pliable structure <NUM>. The adhering <NUM> may be achieved with an engagement feature <NUM>. In some examples, the adhering <NUM> includes suctioning with a suctioning feature <NUM>. In other examples, the adhering <NUM> includes electro-statically adhering with an electrostatic feature <NUM>.

The method <NUM> may further include disengaging <NUM> the uncured ply of composite material <NUM> from the tool <NUM> while retaining a contour of the tool <NUM>. The disengaging <NUM> may be automated and may be performed by a controllable movement device <NUM>, such as a robotic arm <NUM>. In one or more examples, the method <NUM> further includes placing <NUM> the uncured ply of composite material <NUM> onto a prior placed ply of composite material or a second tool while retaining a contour of the tool <NUM>.

Still referring to <FIG>, the method <NUM> further includes preventing <NUM> shear of the first impermeable layer <NUM> and second impermeable layer <NUM> of the pliable structure <NUM> relative to the flow media layer <NUM> along a slip plane <NUM> by drawing a vacuum through the internal volume <NUM>. In other examples, the method <NUM> further includes preventing <NUM> shear of the first impermeable layer <NUM> and second impermeable layer <NUM> of the pliable structure <NUM> relative to the flow media layer <NUM> along a slip plane <NUM> by drawing a vacuum normal to the first impermeable layer <NUM> through the internal volume <NUM>. Drawing a vacuum locks the pliable structure <NUM> by evacuation of air from the internal volume <NUM>, thus increasing friction among the layers of the pliable structure <NUM> and inhibiting shear slippage.

Examples of the present disclosure may be described in the context of aircraft manufacturing and illustrative method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. During pre-production, illustrative 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 illustrative 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 illustrative 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..

Structure(s) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and illustrative method <NUM>. For example, components or subassemblies corresponding to component and subassembly manufacturing (block <NUM>) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft <NUM> is in service (block <NUM>). Also, one or more examples of the structure(s), method(s), or combination thereof may be utilized during production stages production, component and subassembly manufacturing (block <NUM>) and system integration (<NUM>), for example, by expediting or substantially expediting assembly of or reducing the cost of aircraft <NUM>. Similarly, one or more examples of the structure or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft <NUM> is in service (block <NUM>) and/or during maintenance and service (block <NUM>).

Claim 1:
A pliable structure (<NUM>) comprising:
a first impermeable layer (<NUM>);
a second impermeable layer (<NUM>) opposed from the first impermeable layer (<NUM>) to at least partially define an internal volume (<NUM>) between the first impermeable layer (<NUM>) and the second impermeable layer (<NUM>);
a flow media layer (<NUM>) disposed in the internal volume (<NUM>); and
a core layer (<NUM>) positioned in a layered configuration between the flow media layer (<NUM>) and the second impermeable layer (<NUM>).