System and method for forming a composite stiffener

Patent metadata

Field	Value
Publication number	US-2024326352-A1
Application number	US-202418740695-A
Country	US
Kind code	A1
Filing date	Jun 12, 2024
Priority date	Apr 5, 2021
Publication date	Oct 3, 2024
Grant date	—

Abstract

A method for forming a composite stiffener includes locating a composite sheet on a support surface such that a first sheet-portion of the composite sheet is supported on the support surface and a second sheet-portion of the composite sheet extends beyond the support surface. The method includes separating the second sheet-portion from the first sheet-portion to at least partially form a composite charge. The method includes transferring the composite charge onto a layup surface of a layup tool, wherein the layup surface comprises a curvature along a longitudinal tool-axis of the layup tool. The method includes selectively positioning the layup tool relative to a compaction device such that a compaction force, applied to the composite charge by the compaction device, is normal to the layup surface. The method includes compacting the composite charge on the layup surface to form a portion of the composite stiffener.

First claim

What is claimed is:

1 . A method for forming a composite stiffener, the method comprises:
locating a composite sheet on a support surface such that a first sheet-portion of the composite sheet is supported on the support surface and a second sheet-portion of the composite sheet extends beyond the support surface; separating the second sheet-portion from the first sheet-portion to at least partially form a composite charge; transferring the composite charge onto a layup surface of a layup tool, wherein the layup surface comprises a curvature along a longitudinal tool-axis of the layup tool; selectively positioning the layup tool relative to a compaction device such that a compaction force, applied to the composite charge by the compaction device, is normal to the layup surface; and compacting the composite charge on the layup surface to form a portion of the composite stiffener.

2 . The method of claim 1 , further comprising repeating the steps of locating, separating, transferring, selectively positioning, and compacting to sequentially form and locate a plurality of composite charges on the layup surface in a stacked configuration that forms the composite stiffener.

3 . The method of claim 1 , wherein the step of selectively positioning comprises selectively adjusting an angular orientation of the layup surface relative to the compaction device.

4 . The method of claim 3 , wherein the step of selectively positioning further comprises selectively locating the layup surface relative to the compaction device.

5 . The method of claim 1 , further comprising varying a speed of the steps of separating based, at least in part, on a speed of the step of selectively positioning.

6 . The method of claim 1 , further comprising varying a speed of the steps of compacting based, at least in part, on a speed of the step of selectively positioning.

7 . The method of claim 1 , further comprising a step of separating a third sheet-portion of the composite sheet from the second sheet-portion to form the composite charge.

8 . The method of claim 7 , wherein the step of separating the second sheet-portion from the first sheet-portion comprising cutting the composite sheet along a separation line.

9 . The method of claim 8 , wherein the step of separating the third sheet-portion from the second sheet-portion comprising cutting the composite sheet along a second separation line.

10 . The method of claim 9 , wherein each of the separation line and the second separation line is continuous.

11 . The method of claim 9 , wherein each of the separation line and the second separation line is nonlinear.

12 . The method of claim 9 , wherein each of the separation line and the second separation line is continuous and nonlinear.

13 . The method of claim 1 , further comprising selectively locating a first one of a plurality of layup tools adjacent to the support surface.

14 . The method of claim 13 , further comprising performing the steps of locating, separating, transferring, selectively positioning, and compacting to form a portion of a first one of a plurality of composite stiffeners.

15 . The method of claim 14 , further comprising moving the first one of a plurality of layup tools away from the support surface after performing the steps of locating, separating, transferring, selectively positioning, and compacting.

16 . The method of claim 15 , further comprising selectively locating a second one of the plurality of layup tools adjacent to the support surface.

17 . The method of claim 16 , further comprising performing the steps of locating, separating, transferring, selectively positioning, and compacting to form a portion of a second one of the plurality of composite stiffeners.

18 . The method of claim 1 , wherein the locating the composite sheet comprises locating a composite sheet comprising reinforcing fiber and a resin material on the support surface.

19 . The method of claim 1 , wherein the locating the composite sheet comprises locating a composite sheet comprising carbon fiber and an epoxy resin on the support surface.

20 . A method for forming a composite stiffener, the method comprises:
locating a composite sheet on a support surface, the composite sheet comprising reinforcing fiber and a resin material; separating a second sheet-portion of the composite sheet from a first sheet-portion of the composite sheet; separating a third sheet-portion of the composite sheet from the second sheet-portion of the composite sheet to form a composite charge; transferring the composite charge onto a layup surface of a layup tool, wherein the layup surface comprises a curvature along a longitudinal tool-axis of the layup tool; selectively positioning the layup tool relative to a compaction device such that a compaction force, applied to the composite charge by the compaction device, is normal to the layup surface; and compacting the composite charge on the layup surface to form a portion of the composite stiffener.

Assignees

• Boeing Co

Inventors

• Dong Shuonan
• Oviir Marko
• Boroughs Nicholas A

Classifications

• B64C1/064

  Stringers; Longerons · CPC title

• B29L2031/3076

  Aircrafts (blades, propellers B29L2031/08) · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B64F5/10

  Manufacturing or assembling aircraft, e.g. jigs therefor · CPC title