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EP-4140683-B1 - FORMING APPARATUS, METHODS, AND SYSTEMS

EP4140683B1EP 4140683 B1EP4140683 B1EP 4140683B1EP-4140683-B1

Inventors

  • WILLDEN, KURTIS S.
  • ROBINS, BRIAN G.

Dates

Publication Date
20260506
Application Date
20220609

Claims (15)

  1. A method (700) for forming a composite part (375), the method (700) comprising: positioning (710) a composite ply (312) over a forming surface (310) of a forming tool (308); sweeping (720) a forming feature (104) into engagement with the composite ply (312) to yield a formed ply (318), the sweeping (720) forms the composite ply (312) to one of the forming tool (308) and a previously formed ply (318') on the forming tool (308); and securing (730) the formed ply (318) relative to the forming tool (308), wherein the securing (730) comprising engaging a clamping assembly (500) with the formed ply (318), wherein the clamping assembly (500) comprises a bladder (118); the method further comprising engaging (740) a support member (106) with the formed ply (318).
  2. The method (700) of Claim 1, wherein the clamping assembly (500) comprising a clamping member (510).
  3. The method according to Claim 1 or 2, wherein the bladder (118) is inflatable, and wherein inflation of the bladder (118) facilitates securing (730) of the formed ply (318).
  4. The method (700) according to any one of Claims 1 to 3, wherein the securing (730) comprising moving the clamping assembly (500) into engagement with the formed ply (318).
  5. The method (700) according to any one of Claims 1 to 4, further comprising retracting (750) the clamping assembly (500).
  6. The method (700) according to any one of Claims 2 to 5, wherein the forming tool (308) defines a recessed portion (306).
  7. The method (700) according to any one of Claims 2 to 6, further comprising forming (725) the composite ply (312) across the forming surface (310) of the forming tool (308).
  8. The method (700) of Claims 1 to 7, further comprising retracting (760) the support member (106).
  9. The method (700) according to any one of Claims 1 to 8, further comprising positioning (770) a second composite ply (312) over the formed ply (318).
  10. A composite forming apparatus (100) comprising: a forming feature (104) for deforming a composite ply (312) over a forming surface (310) of a forming tool (308); and a clamping assembly (500) for securing the composite ply (312) relative to the forming tool (308), wherein the clamping assembly (500) comprising a clamping member (510), wherein the clamping assembly (500) comprising a bladder (118); the composite forming apparatus (100) further comprising a ply support member (106), the ply support member (106) being movably engageable with the forming tool (308).
  11. The composite forming apparatus (100) according to claim 10, wherein the clamping assembly (500) comprising a cam assembly (512).
  12. The composite forming apparatus (100) according to claim 10 or 11, wherein the clamping assembly (500) comprising a spring (514).
  13. The composite forming apparatus (100) according to any one of Claims 10 to 12, wherein the forming tool (308) defines a recessed portion (306), and wherein the clamping assembly (500) is movably engageable with the recessed portion (306).
  14. The composite forming apparatus (100) according to any one of Claims 10 to 14, further comprising: an end effector (102), coupled to the forming feature (104), wherein the end effector (102) moves the forming feature (104) relative to the forming tool (308) to deform the composite ply (312) over the forming surface (310) of the forming tool (308).
  15. A composite forming system (300) comprising: a movement mechanism (302); an end effector (102) that is coupled to the movement mechanism (302); a forming feature (104) that is coupled to the end effector (102); and a clamping assembly (500) that is movably engageable with a forming tool (308), wherein: the end effector (102) selectively moves the forming feature (104) relative to a forming surface (310) of the forming tool (308) to apply a compaction force (144) to a composite ply (312); the movement mechanism (302) selectively moves the end effector (102) relative to the forming surface (310) of the forming tool (308) to deform a portion of the composite ply (312) over a portion of the forming surface (310) using the forming feature (104); and the clamping assembly (500) selectively secures the composite ply (312) relative to the forming tool (308), wherein the clamping assembly (500) comprises a clamping member (510), wherein the clamping assembly (500) comprises a bladder (118); the composite forming system further comprising a ply support member (106), the ply support member (106) being movable relative to the forming tool (308).

Description

FIELD The present application relates to manufacturing of composite parts and, more particularly, to apparatus, methods, and systems for forming of composite parts. BACKGROUND Formed composite structures are commonly used in applications where light weight and high strength are desired, such as in aircraft and vehicles. Often, these applications utilize contoured parts that must be formed and then cured. Conventional formation of composite structures, particularly relatively large composite structures or composite structures having a complex contour, requires extensive manual labor prior to curing. For example, composite fiber plies (e.g., pre-impregnated fiber plies or dry fabric) are laid by hand over a shaped forming tool or mandrel. The part is then cured, often by heating and pressure. Each composite ply adds volume to the laminate such that the resulting shape is complementary to the mandrel or matches the shape of the forming tool. However, manual layup of the fiber plies is time consuming and laborious. Some known composite manufacturing processes attempt to automate a portion of the formation operation. As an example, a drape forming process includes heating a laminate stack of pre-impregnated fiber plies ("composite charge") and forcing it around a mandrel with the use of a vacuum bag or rubber bladder. However, this method has achieved limited success on thick laminates or structures with more complex shapes. As another example, a compactor may be used to compress the composite charge against a tool surface during fabrication. However, this method often requires supplemental manual formation after compaction when the tool surface and resulting structure is contoured. Accordingly, while such methods may be effective at forming relatively small and thin composite structures or composite structures with relatively simple shapes, they may be inefficient when applied to forming large composite structures or composite structures with more complex shapes. Accordingly, those skilled in the art continue with research and development efforts in the field of composite manufacturing and, more particularly, to the manufacture of relatively large and/or relatively complex composite structures. Document US 2006/017200 A1, according to its abstract, states methods and systems for manufacturing fiber-reinforced resin parts. A method for manufacturing a fiher-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface. Document EP 2 783 840 A1, according to its abstract, states method of manufacturing a composite structure comprising: providing a mould having an inner surface with a close to vertical portion, placing a fibre layer on the mould inner surface on the close to vertical portion and arranging one or more clamping elements on top of the fibre layer with the close to vertical portion such that the clamping elements create a pressing force on the fibre layer against the mould. The method further comprises removing the clamping elements, placing a new fibre layer overlying a previous fibre layer and arranging the clamping elements on top of the new fibre layer. Optionally the steps of removing clamping elements, placing fibre layers and rearranging clamping elements may be repeated until a stack of fibre layers is formed. Further according to the abstract, the document states a mould for manufacturing a composite structure. Figures 2a, 2b and 2c show a sequence of three stages of an example of a method of manufacturing a blade root half or a blade shell in the mould of figure 1. Figure 2a shows the stage of placing a third fibre layer. In this example, two fibre layers were previously distributed on the mould inner surface and a third fibre layer is already distributed in practically the whole mould inner surface with the exception of the vertical or close to vertical portion. The metallic element has been temporarily removed and the third fibre layer is being placed on the vertical or close to vertical portion of the mould. In practice, a stack of fibres may also be formed in which several layers have different orientations. The mould of the example shown in figure 3 is directed to longitudinal distribution of fibre layers. A method of manufacturing a composite structure is provided. The method comprises providing a mould having an inner surface with a close to vertical portion, placing a fibre layer on the mould inner surface on the close to vertical portion and arranging one or more clamping elements on top of the fibre layer with the c