Method and device for manufacturing a structural element in composite material with a Z-shaped profile

Patent metadata

Field	Value
Publication number	US-12559255-B2
Application number	US-202118037469-A
Country	US
Kind code	B2
Filing date	Nov 23, 2021
Priority date	Nov 23, 2020
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

A method is described for manufacturing a structural element in composite material extending along a straight or curvilinear longitudinal direction, having a Z-shaped cross section and comprising, in its final configuration, a central web and two flanges extending at a given final angle from opposite end portions of the web in respective directions opposite to one another; the method including the steps of: arranging a plurality of layers of composite material on a shaped portion of a forming mold; laminating the layers on the shaped portion so that the web is arranged, at least partially, in its final configuration, that a first flange is arranged in its final configuration at the final angle with respect to the portion of the web arranged in its final configuration, and that a second flange is arranged in its initial configuration at an initial angle distinct from, and greater than, said final angle with respect to the portion of the web arranged in its final configuration; moving a movable portion of the forming mold, which is movable with respect to a fixed portion of the forming mold, from a rest position to a bending position; displacing the second flange from the initial configuration into a final configuration in which it is at said final angle with respect to the portion of the web arranged in its final configuration; the step d) of displacing being carried out by means of the step c) of moving.

First claim

The invention claimed is:

1 . Method for manufacturing a structural element in composite material extending along a straight or curvilinear longitudinal direction, having a cross section Z-shaped with respect to the longitudinal direction and comprising, in its final configuration, a central web and two flanges extending at a given final angle from opposite end portions of the web in respective directions opposite to one another; the method including the steps of:
a) arranging a plurality of layers of composite material on a shaped portion of a forming mold; b) laminating said plurality of layers on the shaped portion so that the web is arranged, at least partially, in its final configuration, that a first flange is arranged in its final configuration at said final angle with respect to the portion of the web arranged in its final configuration, and that a second flange is arranged in its initial configuration at an initial angle distinct from, and greater than, said final angle with respect to the portion of the web arranged in its final configuration; c) moving a movable portion of said forming mold, which is movable with respect to a fixed portion of said forming mold, from a rest position to a bending position, the fixed portion and the movable portion defining, together, the shaped portion, the shaped portion being defined partly by an external forming surface of the fixed portion and partly by an external forming surface of the movable portion; d) displacing said second flange from the initial configuration into a final configuration in which it is at said final angle with respect to the portion of the web arranged in its final configuration; the step b) of laminating being carried out by arranging the second flange at the movable portion; the step d) of displacing being carried out by means of the step c) of moving; wherein the step a) of arranging is carried out by positioning the second flange at the movable portion; and wherein the step c) of moving comprises releasing an elastic return means from a deformed condition to an undeformed condition.

2 . The method as claimed in claim 1 , wherein the step c) of moving comprises the step of:
e) pushing the second flange by means of the movable portion; and wherein the step d) of displacing includes the step of: f) folding the second flange from the initial configuration to the final configuration by means of the movement of the movable portion from the rest position to the folding position.

3 . The method as claimed in claim 1 , wherein the step c) of moving comprises driving a fluid-dynamic or electrodynamic actuator.

4 . The method as claimed in claim 1 , and further comprising the steps of:
e) arranging an abutment body against said plurality of layers so that at least said web is interposed between the abutment body and the shaped portion; and f) moving the abutment body towards the shaped portion to compact at least said web; and wherein the step d) of displacing is carried out by pushing the second flange, by means of the movable portion-( 6 ), until it abuts against the abutment body.

5 . Device for the manufacture of a structural element in composite material extending along a straight or curvilinear longitudinal direction, having a cross section Z-shaped with respect to the longitudinal direction comprising a plurality of layers of composite material and having, in its final configuration, a central web and two flanges extending at a given final angle from opposite end portions of the web in respective directions opposite to one another;
said device comprising a forming mold having a shaped portion configured to support the plurality of layers of composite material, which are configured to be arranged on the shaped portion and to be laminated together on the shaped portion and in such a way that, in use, the web is arranged, at least partially, in its final configuration, that a first flange is arranged in its final configuration at said final angle with respect to the portion of the web arranged in its final configuration, and that a second flange is arranged in its initial configuration at an initial angle distinct from, and greater than, said final angle with respect to the portion of the web arranged in its final configuration; said device, and in particular said forming mold, comprising a fixed portion and a movable portion, which is movable with respect to the fixed portion, the portion fixed portion and the movable portion defining, together, said shaped portion, the shaped portion being defined partly by an external forming surface of the fixed portion and partly by an external forming surface of the movable portion; the second flange being configured to be arranged and laminated at the movable portion; said movable portion being configured to be moved from a rest position to a bending position to move the second flange from the initial configuration to the final configuration; and elastic return means interposed between the fixed portion and the movable portion and configured to be released from a deformed position to an undeformed position to drive the movement of the movable portion from the rest position to the bending position.

6 . Device as claimed in claim 5 , and comprising a fluid-dynamic or electrodynamic actuator drivable to move the movable portion from the rest position to the bending position.

Assignees

• Leonardo Spa

Inventors

• Gallo Nicola
• Corvaglia Stefano Giuseppe
• Miani Nicola
• Monopoli Luca
• Ruberto Antonio
• Barile Marco

Classifications

• B64C1/064

  Stringers; Longerons · CPC title

• B64C2001/0072

  from composite materials · CPC title

• B64C1/06

  Frames; Stringers; Longerons {; Fuselage sections} · CPC title

• B29L2031/3082

  Fuselages · CPC title

• B29C70/541

  Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30) · CPC title