Granted Patent B2

US 12,691,610 · App. 18/827,502 · Granted Jul 28, 2026

Inventors: Xiaoxi Wang (Mukilteo, WA); Jill Elisabeth Seebergh (Seattle, WA); Gary E. Georgeson (Tacoma, WA)

Assignee: THE BOEING COMPANY

B29C33/3821B29C35/0227B29C35/045B29C2035/046B29L2031/3076

Abstract

Claims (63)

1 . A method of curing a composite part, comprising:

introducing a blowing agent into an expandable material to place the expandable material in a charged state;

contacting the expandable material with an uncured composite part;

subjecting the expandable material and the uncured composite part to a first temperature such that the expandable material transitions from a charged state to an activated state;

maintaining the expandable material at the first temperature and in the charged state until the uncured composite part is a cured composite part;

cooling the expandable material and the cured composite part to a second temperature;

separating the expandable material from the cured composite material; and

exposing the expandable material to a recovery condition; and

wherein the expandable material comprises a polymer matrix configured to hold the blowing agent, and a flexible skin configured to:

encapsulate the polymer matrix; and

restrict escape of the blowing agent to control an expansion of the expandable material.

2 . The method of claim 1 , wherein:

the recovery condition comprises a third temperature and a period of from about 0.5 hours to about 48 hours;

the first temperature is from about 150° C. to about 300° C.;

the second temperature is from about 25° C. to about 90° C.; and

the third temperature is from about 25° C. to about 300° C.

3 . The method of claim 1 , further comprising storing the expandable material in the charged state after introducing a blowing agent into the expandable material.

4 . The method of claim 1 , wherein storing the expandable material in a charged state comprises a fourth temperature of from about 25° C. to about 35° C. for a time from about 24 hours to about 72 hours.

5 . The method of claim 1 , further comprising re-charging the expandable material after exposing the expandable material to the recovery condition.

6 . The method of claim 1 , wherein re-charging the expandable material comprises exposing the expandable material to a re-charging temperature for about 0.5 hours to about 2 hours.

7 . The method of claim 1 , wherein the expandable material comprises a plurality of pellets.

8 . The method of claim 1 , wherein the expandable material comprises a flexible carrier.

9 . A method of curing a composite part, comprising:

introducing a blowing agent into an expandable material to place the expandable material in a charged state;

contacting the expandable material with an internal cavity of an uncured composite part;

subjecting the expandable material and the internal cavity of the uncured composite part to a first temperature such that the expandable material transitions from a charged state to an activated state;

maintaining the expandable material at the first temperature and in the charged state until the uncured composite part is a cured composite part;

cooling the expandable material and the cured composite part to a second temperature; and

wherein the expandable material comprises a polymer matrix configured to hold the blowing agent, and a flexible skin configured to:

encapsulate the polymer matrix; and

restrict escape of the blowing agent to control an expansion of the expandable material.

10 . The method of claim 9 , further comprising:

separating the expandable material from the cured composite material; and

exposing the expandable material to a recovery condition.

11 . The method of claim 9 , wherein:

a recovery condition comprises a third temperature and a period of from about 0.5 hours to about 48 hours;

the first temperature is from about 150° C. to about 300° C.;

the second temperature is from about 25° C. to about 90° C.; and

the third temperature is from about 25° C. to about 300° C.

12 . The method of claim 9 , further comprising storing the expandable material in the charged state after introducing a blowing agent into the expandable material.

13 . The method of claim 9 , wherein storing the expandable material in a charged state comprises a fourth temperature of from about 25° C. to about 35° C. for a time from about 24 hours to about 72 hours.

14 . The method of claim 9 , further comprising re-charging the expandable material after exposing the expandable material to a recovery condition.

15 . The method of claim 9 , wherein re-charging the expandable material comprises exposing the expandable material to a re-charging temperature for about 0.5 hours to about 2 hours.

16 . The method of claim 9 , wherein the expandable material comprises a plurality of pellets.

17 . A method of curing a composite part, comprising:

introducing a blowing agent into an expandable material to place the expandable material in a charged state;

contacting the expandable material with an uncured composite part, wherein the uncured composite part is contained in a mold;

subjecting the expandable material and the uncured composite part to a first temperature such that the expandable material transitions from the charged state to an activated state;

maintaining the expandable material at the first temperature and in a charged state until the uncured composite part is a cured composite part;

cooling the expandable material and the cured composite part to a second temperature;

separating the expandable material from the cured composite material; and

exposing the expandable material to a recovery condition; and

wherein:

the expandable material comprises a polymer matrix configured to hold the blowing agent, and a flexible skin configured to:

encapsulate the polymer matrix; and

restrict escape of the blowing agent to control an expansion of the expandable material.

18 . The method of claim 17 , wherein the expandable material is in contact with an internal cavity of the uncured composite part.

19 . The method of claim 17 , wherein:

the recovery condition comprises a third temperature and a period of from about 0.5 hours to about 48 hours;

the first temperature is from about 150° C. to about 300° C.;

the second temperature is from about 25° C. to about 90° C.; and

the third temperature is from about 25° C. to about 300° C.

20 . The method of claim 17 , wherein the expandable material comprises a plurality of pellets.

Assignments (1)

Continuity (2)

References Cited (14)