Method of consolidating pre-preg material ply layers

Abstract

An induction heating compaction system is provided. The system includes an induction heating member and a compaction member. The induction heating member is configured to generate an electromagnetic field at a select frequency. The select frequency causes at least one of the fibers and matrix in pre-preg material to heat up. The compaction member has at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member. The compaction member includes a cooling assembly that is configured and arranged to extract heat from the pre-preg material, while compacting the pre-preg material.

1 . A method of consolidating pre-preg material ply layers, the method comprising:
 laying-up at least one first pre-preg material ply layer over at least one second pre-preg material ply layer on a contoured surface of a forming tool;   inductively heating an area of at least one of fibers or matrix in the at least one first pre-preg material ply layer to soften the matrix in the heated area with an induction heater of a compaction member;   compacting the heated area of the at least one first pre-preg material ply layer during the lay-up of the at least one first pre-preg material ply layer over the at least one second pre-preg material ply layer;   while compacting the heated area, extracting heat energy from the at least one first pre-preg material ply layer and the at least one second pre-preg material ply layer with a cooling member within the compaction member; and   joining the at least one first pre-preg material ply layer and the at least one second pre-preg material ply layer in a compact state.   
     
     
         2 . The method of  claim 1 , further comprising solidifying the at least one first pre-preg material layer and the at least one second pre-preg material ply layer in the compact state. 
     
     
         3 . The method of  claim 1 , further comprising
 automatically laying up at least a portion of the at least one first pre-preg material ply layer over the at least one second pre-preg material ply layer.   
     
     
         4 . The method of  claim 1 , further comprising generating induction heat of a given frequency to apply heat energy to the at least one of the fibers or matrix in the at least one first pre-preg material ply layer with the induction heater. 
     
     
         5 . The method of  claim 1 , further comprising shielding at least some elements of the compaction member from heating effects of the induction heating. 
     
     
         6 . The method of  claim 1 , further comprising actively cooling the compaction member that compacts the heated area to extract the heat energy from the at least one first pre-preg material ply layer and the at least one second pre-preg material ply layer. 
     
     
         7 . The method of  claim 1 , wherein compacting the heated area of the at least one first pre-preg material ply layer comprises applying a force to the at least one first pre-preg material ply layer with a compaction roller of the compaction member. 
     
     
         8 . The method of  claim 1 , wherein compacting the heated area of the at least one first pre-preg material ply layer comprises applying a force to the at least one first pre-preg material ply layer with a compaction foot of the compaction member. 
     
     
         9 . The method of  claim 1 , wherein extracting heat from the at least one first pre-preg material ply layer and the at least one second pre-preg material ply layer comprises cooling the at least one first pre-preg material ply layer and the at least one second pre-preg material ply layer with at least one of cooling passages or heat sink material of the compaction member. 
     
     
         10 . The method of  claim 9 , further comprising flowing at least one of a gas or a liquid through a flow path of the cooling passages. 
     
     
         11 . A method of consolidating pre-preg material, the method comprising:
 laying-up at least one first pre-preg material over a surface of a forming tool;   laying-up at least one second pre-preg material over the at least one first pre-preg material and the forming tool;   inductively heating a portion of the at least one second pre-preg material with an induction heater of a compaction member;   compacting the portion of the at least one second pre-preg material over the at least one first pre-preg material;   while compacting the portion of the at least one second pre-preg material, extracting heat energy from the portion of the at least one second pre-preg material with a cooling member of the compaction member.   
     
     
         12 . The method of  claim 11 , further comprising at least one of joining or solidifying the at least one first pre-preg material and the at least one second pre-preg material in a compact state. 
     
     
         13 . The method of  claim 11 , wherein compacting the portion of the at least one second pre-preg material comprises applying a force to the at least one second pre-preg material with one of a compaction roller or a compaction foot of the compaction member. 
     
     
         14 . The method of  claim 11 , wherein extracting heat from the at least one second pre-preg material comprises cooling the at least one second pre-preg material with cooling passages defined within the compaction member. 
     
     
         15 . The method of  claim 11 , further comprising directing an electromagnetic field at a select frequency at the portion of the at least one second pre-preg material from the induction heater positioned within compaction member. 
     
     
         16 . The method of  claim 11 , wherein extracting heat energy from the at least one second pre-preg material comprises transferring the heat energy from the at least one second pre-preg material to a portion of the cooling member within the compaction member. 
     
     
         17 . The method of  claim 11 , further comprising inductive heating and extracting heat energy from the portion of the at least one second pre-preg material with the same component of the compaction member. 
     
     
         18 . A method of consolidating material, the method comprising:
 laying-up a material over a surface of a forming tool;   laying-up another material comprising fibers and matrix over the material and the forming tool;   inductively heating a portion of the another material with an induction heater of a compaction member; and   compacting the heated area of the another material solely with the compaction member while extracting heat from the another material with a cooling member within the compaction member.   
     
     
         19 . The method of  claim 18 , further comprising directing an electromagnetic field at a select frequency at the portion of the another material from the induction heater positioned within compaction member. 
     
     
         20 . The method of  claim 18 , further comprising actively cooling the another material with the cooling member.