Method and Apparatus for Forming Contoured Composite Laminates

Patent metadata

Field	Value
Publication number	US-2016354982-A1
Application number	US-201615240529-A
Country	US
Kind code	A1
Filing date	Aug 18, 2016
Priority date	May 16, 2014
Publication date	Dec 8, 2016
Grant date	—

Abstract

A composite laminate such as a hat-type stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

First claim

What is claimed is:

1 . Apparatus for forming plies of material onto a mandrel having contours, comprising:
a ply sweeper for sweeping the plies onto the contours of the mandrel; a presser independently displaceable relative to the ply sweeper for pressing a portion of the plies against the mandrel; and at least one powered actuator coupled with the presser for displacing the presser relative to the ply sweeper.

2 . The apparatus of claim 1 , wherein the ply sweeper includes a tube having a plurality of slots therein and fingers defined between the slots configured to engage and press the plies against the contours of the mandrel.

3 . The apparatus of claim 1 , wherein:
the powered actuator includes a pneumatic cylinder having a cylinder rod, and a coupling connecting an end of the cylinder rod with the presser.

4 . The apparatus of claim 3 , wherein the coupling includes a slot in the presser and a pivotal connection slidable within the slot.

5 . The apparatus of claim 1 , wherein:
the presser includes a plurality of presser sections attached to each other and arranged end-to-end, and each of the presser sections is formed of a flexible material allowing the presser to conform to the contours of the mandrel.

6 . The apparatus of claim 1 , wherein the presser includes:
a rib connected to the powered actuator, and a pair of flexible wings extending outwardly from the rib and engageable with the mandrel.

7 . Apparatus for forming composite plies on a mandrel contoured along its length and having a cap, a pair of webs and a pair of flanges configured to form a hat-shaped stringer, comprising:
a frame; a ply sweeper mounted on the frame and configured to sweep the composite plies down onto and over the pair of webs of the mandrel; a presser mounted on the frame and extendable relative to the ply sweeper, the presser being configured to press a portion of the composite plies against the cap of the mandrel; and at least one linear actuator mounted on the frame and coupled with the presser for extending the presser relative to the ply sweeper.

8 . The apparatus of claim 7 , wherein:
the ply sweeper includes a tube having a plurality of slots therein and fingers defined between the slots configured to engage and press the composite plies against the webs of the mandrel.

9 . The apparatus of claim 7 , wherein the linear actuator is a pneumatic cylinder mounted on the frame and having a displaceable piston rod coupled with the presser.

10 . The apparatus of claim 7 , wherein:
the ply sweeper includes opposing sets of spaced apart, flexible fingers having fingertips, and the presser is extendable by the linear actuator beneath the fingertips.

11 . The apparatus of claim 7 , wherein:
the presser includes a plurality of presser sections attached together and arranged end-to-end, and the presser is formed of a flexible material allowing the presser to conform to the contoured length of the mandrel.

12 . The apparatus of claim 7 , further comprising:
a coupling between the linear actuator and the presser allowing the presser to conform to the contour of the mandrel.

13 . The apparatus of claim 12 , wherein the coupling includes a slot in the presser and a pivotal connection slidable within the slot connecting the presser with the linear actuator.

14 . The apparatus of claim 7 , wherein the presser includes a rib connected to the linear actuator and a pair of flexible wings extending outwardly from the rib and engageable with the pair of webs of the mandrel.

15 . A method of forming a composite stiffener contoured along its length, comprising:
placing at least one composite ply over a mandrel; positioning a ply sweeper and a presser above the mandrel; extending the presser relative to the ply sweeper using a linear actuator; clamping a portion of the composite ply against the mandrel, including moving the presser and the ply sweeper toward the mandrel until the presser forces the portion of the composite ply against the mandrel; and sweeping the composite ply down over the mandrel while the portion of the composite ply is clamped against the mandrel.

16 . The method of claim 15 , wherein extending the presser includes extending a pair of piston rods.

17 . The method of claim 16 , further comprising:
retracting the pair of piston rods as the ply sweeper sweeps the composite ply down over the mandrel.

18 . The method of claim 15 , further comprising:
attaching a plurality of presser sections together end-to-end; and pivotally coupling the presser with the linear actuator to allow the presser to conform to the contoured length of the mandrel.

19 . The method of claim 15 , wherein clamping a portion of the composite ply against the mandrel includes applying a force to the presser using the linear actuator.

20 . The method of claim 15 , wherein clamping a portion of the composite ply against the mandrel includes centering the presser on the mandrel using flexible features on the presser.

Assignees

• Boeing Co

Inventors

• Prause Richard Alexander
• Modin Andrew Elmer

Classifications

• B29K2105/0881

  unidirectional · CPC title

• B29K2307/04

  Carbon · CPC title

• B29C70/34 Primary

  and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} · CPC title

• B29L2009/00

  Layered products · CPC title

• B29C70/543

  Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08) · CPC title