Integral double bag for vacuum bagging a composite part and method of using the same

Abstract

Composite parts such as plastic laminates are formed using a pre-assembled, integral double bag to vacuum bag the part. The double bag is formed of two sheets of bag material that are cut to pre-determined width dimensions, with the width of one sheet being less than that of the other. The bag sheets are prealigned and then attached to each other by spaced apart bonds between the sheets which hold the bag sheets in registered relationship to each other when the double bag is placed over the part and sealed to a tool base. The attachment bonds may be formed by ultrasonic welding, heat sealing or an adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a fragmentary, plan view of a lay-up part on a tool base covered by a double vacuum bag according to the prior art.

FIG. 1B is a transverse cross section of the assembly shown in FIG. 1A.

FIG. 2 is a cross sectional view similar to FIG. 1B, but showing an integral double bag in accordance with the present invention.

FIG. 3 is an enlarged, fragmentary view of the area surrounded by the dotted line designated by the numeral 36 in FIG. 2.

FIG. 4 is a fragmentary, plan view of the bagged lay-up assembly shown in FIG. 2.

FIG. 5 is a diagmratic view of equipment used to perform a method for high volume production of the integral double bag of the present invention.

FIG. 6 is a plan view of an integral double bag produced using the method used in FIG. 5.

FIG. 7 is a flow chart showing the basic steps of a method for forming a composite part using the double bagging method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1A and 1B show a prior art arrangement for vacuum bagging a composite part which may comprise, for example, a plastic laminate lay-up part 12. The part 12 is mounted on a tool base 14 and is typically covered with various relief films, peel plies and breather layers. In the illustrated example, only a breather ply 20 is shown for sake of simplicity. The breather layer 20 is used to maintain a “breather” path throughout an overlying, inner bag 16 to a vacuum source (not shown) so that air and volatiles can escape and continuous pressure can be applied to the part 12. The breather layer 20 normally comprises a synthetic fiber material and/or any fiberglass fabric which extends past the outer edges of the part 12. As previously indicated, a release film or peel ply (not shown) may be placed over the part 12, followed by a bleeder which absorbs the resin from the part 12 and a separator layer (not shown) which functions to resist or prevent resin flow.

The peripheral edges of the inner bag 16 are sealed to the tool base 14 by means of an adhesive seal 26 in the form of a strip that may comprise, for example, zinc chromate. Seal 24 is commercially available in roll form as “peel and stick” tape which is applied first to the tool base 14, following which an upper, non-adhesive layer is peeled away to reveal an adhesive that adheres to the bottom side of the inner bag 16 to form an air tight seal.

An outer bag 18 overlies the inner bag 16 and is attached to the tool base 14 by means of a second seal 22, also in the form of an adhesive strip of zinc chromate. A breather strip 26 is placed over the tool base 14 between seals 22 and 24. Vacuum ports (not shown) are installed in the inner and outer bags 16, 18 to allow air to be evacuated from each of the bags 16, 18.

The prior art double bag construction described above reduces the possibility of a vacuum failure due to tearing of the bag material or loosening of the seals, since if either of the bags 16, 18 fails, the other bag maintains the necessary compaction pressure produced by the remaining bag vacuum. The forgoing double bag construction, while effective in reducing the possibility of vacuum loss within the bag, is particularly time consuming to setup and install, and requires a considerable amount of space on the tool base 14 around the part 12 in order to be effectively sealed. In part, this is because each of the bags 16, 18 must be separately cut, registered and installed on the tool base in multiple operations. For example, after the breather ply 20 is installed, a sheet of bag material forming the inner bag 16 is placed over the tool base and then adhered to the inner seals 24. Next, an operator must trim the outer edges of the inner bag 16 to size. Then, a second sheet of bag material forming the outer bag 18 is placed over the tool base, overlying the inner bag 16. The edges of the outer bag 18 are adhered to the outer seals 22, following which the outer edges of the bag material must be trimmed to the desired dimensions.

Referring now to FIGS. 2-4, the present invention provides an integral double bag construction and bagging method in which an integral double bag 28 is formed from inner and outer bags 30, 32 that are attached to each other by a plurality of spaced apart bonds 34. These attaching bonds 34 are formed between the opposing inner faces of the bag sheet material and preferably located in central regions of the bags 30, 32, spaced inwardly from the outer edges of the bags. In the illustrated example, the bonds 34 are aligned in two spaced apart rows (FIG. 4) in which the individual bonds 34 in each row are also spaced apart. This spacing arrangement allows air to quick freely flow within the space formed between bags 30, 32 yet holds the two bags 30, 32 in precise registration relative to each other while not interfering with the seals that attach the outer edges 42, 44 to the tool base 14. In effect, the attachment bonds 34 function to prealign the edges of the inner and outer bags. The bonds 34 may be formed by ultrasonic welding or heat sealing, for example in which small areas of the sheet material forming bags 30, 32 are brought into contact and effectively melted together. Alternatively, the bonds 34 may be formed by the introduction of adhesive material between bags 30, 32.

Each of the bags 30, 32 is formed from a sheet of flexible material such as nylon, kapton, or PVA (polyvinyl alcohol) for example. The sheets may be first trimmed to their final width dimensions, following which the sheet forming the inner bag 30 is placed in registered, face-to-face contact with the sheet forming the outer bag 32. The longitudinal center lines of bags 30, 32 are aligned before they are bonded so that the outer edges 54 of the inner bag 30 are equally spaced from the corresponding outer edges 52 from the outer bag 32. Thus, it may be appreciated that when the bag assembly 28 is installed over the part 12 onto the tool base 14, the width dimensions of the inner and outer bags 30, 32 have been pre-cut to final dimensions. If desired, the edges 50, 52 of the double bag 28 can be cut to final dimensions after the bonds 34 are formed, but prior to installing the bag 28 on the base 14.

After the integral double bag 28 is formed as described above, a breather ply 40 is installed over the part 12, but unlike the breather ply 20 used in the prior art method (FIGS. 1A, 1B), the outer edges 35 of the breather ply 40 are shorter owing to the fact that an inner seal 50 which secures the outer margins 52 of the inner bag 30 are positioned more closely to the part 12. An outer seal 48 bonds and seals the outer margin 44 of the outer bag 32 to the tool base. Another breather ply 46 covers the tool base 14 between the inner and outer seals 42, 48. The widths of the inner and outer seals 42, 48 as well as the width of the breather ply 46 are reduced in dimension compared to the corresponding components in the prior art (FIGS. 1A, 1B) and are more closely inwardly spaced, toward the part 12. As a result, a narrower tool base 14 may be utilized, resulting in materials savings and reduction in oven cycling times since the thermal mass of the tool base 14 is reduced.

The reduction in width of the seals 42, 48 and the breather layer 46 as well as their placement closer to the part 12 is a result of the fact that the width dimension of the bags 30, 32 are effectively pre-determined before the bag assembly 28 is disposed over the tool base. In addition, the relative spacing between the outer edges 52, 54 of the inner and outer bags 30, 32 is likewise pre-determined since the bag assembly 28 is assembled as an integral unit before it is placed on the tool base 14.

In use, after the breather layer 40 and other layers have been placed over the part 12 according to the applicable bagging schedule, the pre-assembled double bag 28 is disposed over the part 12 and the margins 42 of the inner bag 30 are pressed onto the inner seals 50 which seal the inner bag 30 to the base 14. Then, the outer margins 44 of the outer bag 32 are brought into contact with the outer seal 40 in order to seal the outer bag 32 to the base. Vacuum ports (not shown) may be pre-installed in the sheets forming the inner and outer bags 30, 32 before the integral double bag is placed on the tool base. Alternatively, depending upon the installation, the vacuum ports may be installed in the inner and outer bags 30, 32 after the integral double bag 28 has been placed on the tool base 14.

Only two sides of the integral double bag 28 are shown in FIGS. in 2-4. The remaining two ends of the double bag 28 may be sealed to the tool base 14 in the same manner as described above, or using the and trimming technique described with reference to FIG. 1A and 1B.

The integral double bag 28 may be manually fabricated for “one-off” or low volume production. However, the integral double bag construction of the present invention lends itself to high volume production, and in this connection reference is now made to FIGS. 5 and 6. The sheet material from which the double bag 28 is made may be fed from rolls 56, 58 of material in which the width of one roll 56, 58 is less than the other. The rolls 56, 58 are aligned such that the sheets are centered a common centerline 38. The sheets 60, 62 are fed through rollers 64 which bring the faces of the sheets together. A bonding machine, such as an ultrasonic welder 66, forms a series of bonds 34 along the length of the sheets 60, 62 as the latter are fed as a bonded double sheet to a sheer 68 which cuts the final double bag 28 to the desired length.

Reference is now made to FIG. 7 which depicts the basic steps of a double bagging method using the integral double bag of the present invention. At step 70, a sheet of material defining the outer bag 32 is cut to the desired width. A second sheet of material defining the inner bag 30 is cut to the desired width at step 72. Then, at step 74, the two sheets that have been cut to the width are aligned along a common centerline and then bonded together at spaced apart, central locations as previously described.

The integral double bag 28 having been pre-assembled for use in vacuum bagging a particular part 12, the part 12 is mounted on the tool base 14 at step 76. Inner and outer seals 42, 48 are placed on the tool base, as shown in step 78. Release films, bleeder plies, peel plies, etc are then placed over the part according to a bagging schedule that will depend upon the nature of the particular part 12 being formed. Next, at step 82, breather plies 40, 46 are installed, following which the double bag 28 is placed on the tool base 14 covering the part 12. The outer margins 42 of the inner bag 30 are pressed onto the inner seal 50, thereby sealing the inner bag 30 at step 86. Similarly, as shown at step 88, the outer margins 44 of the outer bag 32 are pressed onto the outer seals 48, thereby sealing the outer bag 32. Not shown in FIG. 7 is the installation of vacuum ports in the inner and outer bags 30, 32 respectively. The integral double bag 28 having been installed on the tool base 14 and connected with a suitable vacuum source, vacuum is applied at step 90 which creates a vacuum inside both the inner and outer bags 30, 32 respectively, producing the necessary compaction pressure which both forces the plies of the part 12 together and urges resin to flow through the plies.

Although this invention has been described with respect to certain exemplary embodiments, it is to be understood that the specific embodiments are for purposes of illustration and not limitation, as other variations will occur to those of ordinary skill in the art.

Claims

1. A method of forming a composite part, comprising the steps of: (A) forming an inner bag;(B) forming an outer bag;(C) attaching the inner bag to the outer bag to form a double bag assembly;(D) placing the bag assembly over a tool holding the composite part;(E) sealing the bag assembly to the tool; and,(F) drawing a vacuum in the inner and outer bags.

2. The method of claim 1, wherein: step (A) includes forming the inner bag to have a width, andstep (B) includes forming the outer bag to have a width greater than the width of the inner bag.

3. The method of claim 1, further comprising the step of: (G) placing the outer bag over the inner bag before step (C) is performed

4. The method of claim 1, wherein step (C) is performed by welding parts of the inner bag to the outer bag.

5. The method of claim 1, wherein step (C) is performed by introducing an adhesive between the inner and outer bags.

6. The method of claim 1, wherein step (E) includes: sealing the inner bag to the tool, and sealing the outer bag to the tool.

7. The method of claim 1, wherein step (E) includes forming an inner seal between the inner bag and the tool, and forming an outer seal between the outer bag and the tool.

8. The method of claim 7, further comprising the step of: (G) introducing a breather layer between the inner and outer seals

9. The method of claim 1, further comprising the step of: (G) aligning the inner and out bags relative to each other before step (C) is performed.

10. A method of manufacturing a double bag for use in vacuum bagging a composite part, comprising the steps of: (A) forming a first flexible sheet having a width;(B) forming a second flexible sheet having a width less than the width of the first sheet;(C) pre-aligning the first and second sheets relative to each other; and(D) attaching the first and second sheets together at spaced apart locations.

11. The method of claim 10, wherein at least one of steps (A) and (B) is performed by cutting a sheet to a width of preselected dimensions.

12. The method of claim 10, wherein step (D) is performed by welding portions of the first sheet to portions of the second sheet.

13. The method of claim 10, wherein: step (A) includes drawing sheet material from a first roll,step (B) includes drawing sheet material from a second roll,step (C) includes bringing the sheets of material from the first and second rolls into face-to-face relationship to each other, andstep (D) is performed while the sheets of material from the first and second rolls are in face-to-face relationship.

14. The method of claim 13, wherein the bonding is performed by welding.

15. The method of claim 10, wherein step (A) includes cutting the first sheet to a first preselected width dimension.

16. The method of claim 15, wherein step (B) includes cutting the second sheet to second preselected width dimension.

17. The method of claim 10, wherein step (C) includes symmetrically positioning the first and second sheets along a common centerline.

18. A method of vacuum bagging a composite part, comprising the steps of: (A) forming an integral double bag;(B) placing the integral double bag over the part; and,(C) sealing the double bag to a tool holding the part.

19. The method of claim 18, wherein step (A) includes: cutting first and second sheets of a flexible material to first and second widths, respectively, wherein the first width is greater than the second width, andjoining the first and second sheets to each other.

20. The method of claim 18, wherein step (C) in performed by: sealing edges of the second sheet to the tool, and then, sealing the edges of the first sheet to the tool.

21. An integral double bag for use in vacuum bagging a composite part held on a base, comprising: a first sheet of flexible material having a width and defining a first bag; and,a second sheet of flexible material having a width less than the width of the first sheet and defining a second bag,wherein the first and second sheets are integrally joined together to maintain the sheets in prealigned relationship to each other

22. The integral double bag of claim 21, wherein: the first and second sheets each include spaced apart opposite edges defining the respective width of the sheet, andthe opposite edges of the first sheet overlap the corresponding edges of the second sheet substantially equally.

23. The double bag of claim 21, wherein the first and second sheets each includes spaced apart opposite edges equidistant from a common centerline.

24. The double bag of claim 21, wherein the first and second sheets are joined by a plurality of spaced apart bonds between the first and second sheets.

25. The double bag of claim 24, wherein the bonds are located in central regions of the first and second sheets.