Magnetic compaction blanket for composite structure curing

• US 10,639,857 B1
• Filed: 08/01/2016
• Issued: 05/05/2020
• Est. Priority Date: 02/08/2013
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hafenrichter, Joseph Lawrence, Hull, John Ralph
• Primary Examiner(s): Tucker, Philip C
• Assistant Examiner(s): Slawski, Brian R
• Application Number:
  US15/225,617
• Time in Patent Office: Days
• Field of Search: 156 94, 1562722, 156297, 1563071, 156391, 1565833, 219243
• CPC Class Codes: B25B 11/002 Magnetic work holders
• CPC Class Codes: B29C 37/0075 using release sheets
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/785 using magnetic forces to hold at least one of the parts to be joined magnetic work holders in general B25B11/002
• CPC Class Codes: B29C 73/10 using patches sealing on the surface of the article B29C73/14 takes precedence
• CPC Class Codes: B29C 73/12 Apparatus therefor, e.g. for applying B29C73/30 takes precedence
• CPC Class Codes: B29C 73/30 for local pressing or local heating
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B32B 2037/1081 using a magnetic force
• CPC Class Codes: B32B 7/025 Electric or magnetic properties
• CPC Class Codes: F16B 2200/83 Use of a magnetic material

Abstract

A method and apparatus for reworking a structure. A compaction blanket comprising a number of magnets is placed on the structure. A heat source is applied on the compaction blanket, wherein the compaction blanket is between the heat source and a rework of the structure and heat is conducted from the heat source through the compaction blanket to heat the rework.

Claims

1. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force; and

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure;

wherein the support structure comprises a magnetic backplane and wherein the plurality of magnets is magnetically coupled to the magnetic backplane and is attached to the magnetic backplane by an adhesive.

2. The apparatus of claim 1, wherein the magnetic backplane is flexible.

3. The apparatus of claim 1, wherein the magnetic backplane comprises a material selected from the group of magnetic materials consisting of a metal sheet, a ferromagnetic metal sheet with slits therein, a metal mesh, steel shot, and ferromagnetic powder.

4. The apparatus of claim 1, wherein the plurality of magnets is embedded in a flexible non-magnetic material comprising the support structure.

5. The apparatus of claim 4, wherein the flexible non-magnetic material is silicone.

6. The apparatus of claim 1, wherein the plurality of magnets is selected from the group of permanent magnets consisting of rare-earth magnets, iron-boron neodymium magnets, samarium cobalt magnets, and ferrite magnets.

7. The apparatus of claim 1, wherein the magnetic compaction structure comprises a material selected from the group of magnetic materials consisting of a metal sheet, a metal mesh, and a second compaction blanket.

8. The apparatus of claim 1, wherein the heat source is selected from a heat blanket placed on the compaction blanket and a heated gas.

9. The apparatus of claim 8, wherein the compaction blanket is a first magnetic compaction blanket and the plurality of magnets is a first number of magnets.

10. The apparatus of claim 9,

wherein the heat source is a heat blanket;

and further comprising;

a magnetic sheet positioned such that the heat blanket is between the magnetic sheet and the first magnetic compaction blanket and magnetic attraction between the magnetic sheet and the first magnetic compaction blanket pulls the magnetic sheet toward the first magnetic compaction blanket to compress the heat blanket between the magnetic sheet and the first magnetic compaction blanket.

11. The apparatus of claim 9,

wherein the heat source is a heat blanket;

and further comprising;

a compression wrap positioned such that the heat blanket is between the compression wrap and the first magnetic compaction blanket and the compression wrap compresses the heat blanket between the compression wrap and the first magnetic compaction blanket.

12. The apparatus of claim 9,

wherein the heat source is a heat blanket;

and further comprising;

a second magnetic compaction blanket comprising a second number of magnets positioned such that the heat blanket is between the second magnetic compaction blanket and the first magnetic compaction blanket and magnetic attraction between the second magnetic compaction blanket and the first magnetic compaction blanket pulls the second magnetic compaction blanket toward the first magnetic compaction blanket to compress the heat blanket between the second magnetic compaction blanket and the first magnetic compaction blanket.

13. The apparatus of claim 1, further comprising:

a magnetic holder tool having the compaction blanket placed thereon, wherein the magnetic holder tool is configured to place the compaction blanket on the material and to be removed from the compaction blanket after placing the compaction blanket on the material.

14. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force; and

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure;

wherein the plurality of magnets is embedded in a flexible non-magnetic material comprising the support structure.

15. The apparatus of claim 14, wherein the support structure comprises a flexible magnetic backplane.

16. The apparatus of claim 14, wherein the heat source is selected from a heat blanket placed on the compaction blanket and a heated gas.

17. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force;

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure; and

a magnetic holder tool having the compaction blanket placed thereon, wherein the magnetic holder tool is configured to place the compaction blanket on the material and to be removed from the compaction blanket after placing the compaction blanket on the material.

18. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force; and

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure;

wherein the compaction blanket is a first magnetic compaction blanket, the plurality of magnets is a first number of magnets, and the heat source is a heat blanket; and

a magnetic sheet positioned such that the heat blanket is between the magnetic sheet and the first magnetic compaction blanket and magnetic attraction between the magnetic sheet and the first magnetic compaction blanket pulls the magnetic sheet toward the first magnetic compaction blanket to compress the heat blanket between the magnetic sheet and the first magnetic compaction blanket.

19. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force; and

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure;

wherein the compaction blanket is a first magnetic compaction blanket, the plurality of magnets is a first number of magnets, and the heat source is a heat blanket; and

a compression wrap positioned such that the heat blanket is between the compression wrap and the first magnetic compaction blanket and the compression wrap compresses the heat blanket between the compression wrap and the first magnetic compaction blanket.

20. An apparatus comprising:

a support structure;

a plurality of magnets attached to the support structure and arranged to form a compaction blanket;

a magnetic compaction structure configured to magnetically attract the compaction blanket with a desired amount of force; and

a heat source applied on the compaction blanket such that heat is conducted from the heat source to cure a material positioned between the compaction blanket and the magnetic compaction structure;

wherein the compaction blanket is a first magnetic compaction blanket, the plurality of magnets is a first number of magnets, and the heat source is a heat blanket; and

a second magnetic compaction blanket comprising a second number of magnets positioned such that the heat blanket is between the second magnetic compaction blanket and the first magnetic compaction blanket and magnetic attraction between the second magnetic compaction blanket and the first magnetic compaction blanket pulls the second magnetic compaction blanket toward the first magnetic compaction blanket to compress the heat blanket between the second magnetic compaction blanket and the first magnetic compaction blanket.