US 12,275,201 B2
Methods and apparatuses for forming composite parts from multi-ply prepreg composite charges
Andrew E. Modin, Charleston, SC (US); Dorekia Martin, Ladson, SC (US); Richard E. Heath, Mt. Pleasant, SC (US); Eric C. Anderson, St. Charles, MO (US); Caleb J. Handolescu, Ladson, SC (US); Richard Alexander Prause, Charleston, SC (US); Michael C. Hargrove, Goose Creek, SC (US); and Justin H. Register, Charleston, SC (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Jul. 23, 2021, as Appl. No. 17/384,440.
Claims priority of provisional application 63/089,453, filed on Oct. 8, 2020.
Prior Publication US 2022/0118720 A1, Apr. 21, 2022
Int. Cl. B29C 70/44 (2006.01); B29C 70/54 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/44 (2013.01) [B29C 70/54 (2013.01); B29L 2031/3076 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a composite part from a multi-ply prepreg composite charge, the method comprising steps of:
reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure;
placing the multi-ply prepreg composite charge, having a first shape, in the chamber;
reducing pressure inside the chamber below the atmospheric pressure;
while maintaining the pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing the pressure inside the bladder to the atmospheric pressure, so that:
the bladder comprises a first bladder volume and a second bladder volume;
a forming tool is positioned between the first bladder volume and the second bladder volume;
the multi-ply prepreg composite charge is compressed between the bladder and the forming tool; and
the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape; and
curing the multi-ply prepreg composite charge, having the second shape, by recirculating hot air between the first bladder volume and the second bladder volume to heat the multi-ply prepreg composite using the bladder.