Method and apparatus for supporting a plurality of different pre-cured composite stringers

Abstract

The name of the invention is a method and apparatus for supporting a plurality of different pre-cured composite stringers. A method and apparatus for supporting a plurality of different pre-cured composite stringers after forming and before curing is provided. The post-forming processing apparatus includes a base having a channel for receiving a cap portion of a different stringer. The apparatus also includes a support structure that extends at least partially within the channel. The support structure is configured to conform to the different cap portions and maintain the shape of the cap portions. For example, the support structure is made of a flexible material that conforms to any shape variations. In some examples, the support structure is made of a clamping material that reshapes with each of the pre-cured composite stringers. The post-forming processing apparatus is used to support different pre-cured composite stringers while various operations are performed on the stringers, such as stringer trimming, inspection, installation of pods and strips, and the like.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for supporting a plurality of different pre-cured composite stringers. Background Art

[0002] Aircraft utilize various parts, such as stringers, to resist bending, torsion, shear, and direct loads. Stringers are typically made of lightweight composite materials using, for example, tape or fabric having fibers embedded in a resin matrix. For example, the composite layup is machined in a forming tool to define the shape. The formed part is then transferred to a curing unit for curing. Until curing is complete, the stringer requires adequate support to maintain its shape. In addition to the cross-sectional profile that varies from one stringer to another, this shape is typically defined by in-plane and / or out-of-plane bending. Furthermore, the formed stringer may undergo various operations prior to curing, such as trimming, inspection, installation of additional parts, etc. This support for the uncured stringer is typically provided by either the forming tool or the curing tool, which limits the throughput of either of these tools and slows down the overall processing speed.

[0003] What are needed are new methods and apparatus for supporting a variety of different pre-cured composite stringers after forming and prior to curing. Summary of the Invention

[0004] A method and apparatus for supporting a plurality of different pre-cured composite stringers after forming and prior to curing are provided. The post-forming apparatus includes a base having a channel for receiving cap portions of the different stringers. The apparatus also includes a support structure extending at least partially within the channel. The support structure is configured to conform to the different cap portions and maintain the shape of the cap portions. For example, the support structure is made of a flexible material that conforms to any shape changes. In some examples, the support structure is made of a jamming material that is reshaped with each of the pre-cured composite stringers. The post-forming apparatus is used to support the different pre-cured composite stringers while performing various operations on the stringers, such as stringer trimming, inspection, installation of bladders and noodles, and the like.

[0005] In some examples, a post-forming apparatus for supporting pre-cured composite stringers is provided. The composite stringers include cap portions having different cross-sections between the pre-cured composite stringers. The post-forming apparatus includes a base, a support structure, and a cover. The base includes a channel having a channel width and a channel height. The channel width is greater than the width of the cap portion of the pre-cured composite stringer. The channel height is greater than the height of the cap portion of the pre-cured composite stringer. The support structure is at least partially within the channel and extends along the length of the channel. The support structure is configured to conform to each of the cap portions and maintain the cross-sectional shape of each of the cap portions when a corresponding one of the pre-cured composite stringers is supported by the post-forming apparatus. The cover is configured to be attached to the base such that the corresponding one of the pre-cured composite stringers is positioned between the cover and the base while being supported by the post-forming apparatus.

[0006] A method for manufacturing a composite stringer is also provided. The method includes forming a pre-cured composite stringer on a forming apparatus, the pre-cured composite stringer including a cap portion; and transferring the pre-cured composite stringer from the forming apparatus to a post-forming apparatus. The post-forming apparatus includes a base and a support structure, the base including a channel, and the support structure at least partially within the channel and extending along the length of the channel, conforming to the cap portion and maintaining the cross-sectional shape of the cap portion. The method also includes installing a bladder on the pre-cured composite stringer while the pre-cured composite stringer is positioned on the post-forming apparatus. The method includes installing a strip at an interface between the bladder and the pre-cured composite stringer and within a plane of a support surface of the base while the pre-cured composite stringer is positioned on the post-forming apparatus. The method also includes transferring the pre-cured composite stringer, along with the bladder and strip, from the post-forming apparatus to a curing apparatus, and curing the pre-cured composite stringer on the curing apparatus, thereby forming the composite stringer.

[0007] In some examples, the method includes transferring a precured composite stringer including a cap portion to a post-forming tool. The post-forming tool includes a base including a channel; and a support structure at least partially within the channel and extending along the length of the channel, and conforming to and maintaining a cross-sectional shape of the cap portion of the precured composite stringer. The method continues by removing the precured composite stringer from the post-forming tool and transferring another precured composite stringer including another cap portion to the post-forming tool. The support structure of the post-forming tool conforms to and maintains a cross-sectional shape of the cap portion of the precured composite stringer that is different from the cross-sectional shape of the cap portion of the precured composite stringer. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1A It is a process flow chart for manufacturing composite longitudinal beams.

[0009] Figure 1B is a process flow diagram for manufacturing a composite stringer according to other examples of the disclosure.

[0010] Figure 1C 、 1D and 1E are different examples of composite stringers.

[0011] Figure 2A is a schematic cross-sectional view of a post-forming processing device including a flexible support structure according to some examples of the disclosure.

[0012] Figure 2B is a schematic cross-sectional view of a post-forming processing device in Figure 2A according to some examples of the disclosure showing a flexible support structure conforming to a cap portion of a pre-cured composite stringer.

[0013] Figure 2C is a schematic cross-sectional view of a post-forming processing device in Figure 2A and 2B according to some examples of the disclosure showing a cover sealing against a base and enclosing a pre-cured composite stringer.

[0014] Figure 2D is a schematic cross-sectional view of a post-forming processing device including a flexible support structure and a flexible insert, both positioned in a channel, according to some examples of the disclosure.

[0015] Figure 2E is a schematic cross-sectional view of a post-forming processing device illustrating a tapered channel according to some examples of the disclosure.

[0016] Figure 2F is a schematic top view of a post-forming processing device illustrating a bladder seal according to some examples of the disclosure.

[0017] Figure 3A is a schematic cross-sectional view of a post-forming processing device including a pre-formed support structure made of a clamping material according to some examples of the disclosure.

[0018] Figure 3B is a schematic cross-sectional view of a post-forming processing device in Figure 3A according to some examples of the disclosure showing a flexible support structure engaging a pre-cured composite stringer.

[0019] Figure 3C is a schematic cross-sectional view of a post-forming processing device in Figure 3A and 3BSchematic cross-sectional view of the post-forming tooling apparatus in FIG, showing a cover sealing against a base and enclosing a pre-cured composite stringer.

[0020] Figure 4 is a process flow diagram corresponding to a method of manufacturing a composite stringer according to some examples of the present disclosure.

[0021] Figure 5A is a schematic illustration of a laminate layup placed on a tooling surface of a forming base and extending over a cavity according to some examples of the present disclosure.

[0022] Figure 5B is a schematic illustration of a laminate layup being formed into a pre-cured composite stringer by a forming apparatus according to some examples of the present disclosure.

[0023] Figure 5C is a schematic illustration of a pre-cured composite stringer supported by a post-forming tool according to some examples of the present disclosure.

[0024] Figure 5D is a schematic illustration of a bladder installed in a pre-cured composite stringer while the pre-cured composite stringer is supported by a post-forming tool according to some examples of the present disclosure.

[0025] Figure 5E is a schematic illustration of a noodle installed at the interface between a bladder and a pre-cured composite stringer while the pre-cured composite stringer is supported by a post-forming tooling apparatus according to some examples of the present disclosure.

[0026] Figure 5F is a schematic illustration of a cover sealed against a base of a post-molding tooling apparatus according to some examples of the present disclosure.

[0027] Figure 5G is a schematic illustration of a pre-cured composite stringer being transferred to a curing apparatus along with a bladder and a strip, according to some examples of the present disclosure.

[0028] Figure 5H is a schematic illustration of a composite stringer removed from a curing apparatus according to some examples of the present disclosure.

[0029] Figure 5I is a schematic illustration of an additional pre-cured composite stringer supported by a post-forming tool according to some examples of the present disclosure.

[0030] Figure 6A and 6B is a top schematic view of a post-forming tooling apparatus showing in-plane bending according to some examples of the present disclosure.

[0031] Figure 7is a process flow diagram corresponding to a method of supporting a pre-cured composite stringer in a post-forming tooling apparatus according to some examples of the present disclosure.

[0032] Figure 8 It is a process flow chart corresponding to the method of manufacturing and maintaining an aircraft.

[0033] Figure 9 A block diagram of an example of an aircraft is illustrated, according to some examples of the present disclosure. DETAILED DESCRIPTION

[0034] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the concepts presented. In some examples, the concepts presented may be practiced without some or all of these specific details. In other cases, well-known process operations are not described in detail so as not to unnecessarily obscure the concepts being described. Although some concepts will be described in conjunction with specific examples, it should be understood that these examples are not intended to be limiting.

[0035] introduce

[0036] Composite longerons and other shaped composite structures are used in many applications, such as aircraft, land vehicles, and the like. The manufacture of these composite structures involves various handling and processing of pre-cured formed parts, such as trimming, inspection, bladder installation, and the like. Prior to curing, these formed parts require adequate support to maintain shape, which can be challenging due to the variations in shapes and sizes of these pre-cured parts. For example, modern aircraft use hundreds of different composite longerons having different sizes, cross-sectional shapes, in-plane curvatures, and / or out-of-plane curvatures. Providing dedicated supports for each type of these composite longerons is challenging and expensive, adding to the already large number of specialized tools used in the manufacture of composite longerons.

[0037] Figure 1A and 1B Two process flow diagrams representing different examples of manufacturing composite stringers and corresponding tools for various operations are illustrated. Figure 1A and 1B To provide some background and a general overview of the key components, tools, and steps, see the following examples. In both examples, the process begins with a forming device 510 forming a composite layup 502, thereby forming a pre-cured composite stringer 190. A curing device 540 then cures the pre-cured composite stringer 190, thereby forming a composite stringer 198. The pre-cured composite stringer 190 and the composite stringer 198 have substantially the same shape, but different materials and mechanical properties. For example, the resin of the pre-cured composite stringer 190 is not fully cross-linked or cross-linked as well as the resin of the composite stringer 198. As such, the pre-cured composite stringer 190 is still capable of changing shape and requires support prior to curing.

[0038] The forming device 510 and the curing device 540 are specifically shaped to accommodate the specific design of the composite stringer 198. Therefore, after the forming operation is completed and before the curing operation begins, one or both of the forming device 510 and the curing device 540 can be used to support the pre-cured composite stringer 190, which corresponds to Figure 1A . However, this approach occupies one or both of the forming apparatus 510 and the curing apparatus 540 for operations that are not core to the functions of these apparatuses. Furthermore, many of these operations, and even the storage of the pre-cured composite stringer 190, may take a significant amount of time. As a result, the throughput of one or both of the forming apparatus 510 and the curing apparatus 540 may be limited by these intermediate operations and storage associated with the pre-cured composite stringer 190.

[0039] refer to Figure 1B The post-forming processing apparatus 100 is configured to receive the pre-cured composite stringer 190 after it has been formed / shaped. The post-forming processing apparatus 100 is also configured to support the pre-cured composite stringer 190 until the curing operation. The post-forming processing apparatus 100 effectively reduces the burden on the forming apparatus 510 and the curing apparatus 540, thereby increasing their processing throughput. The post-forming processing apparatus 100 is configured to perform various operations on the pre-cured composite stringer 190 and, in some examples, to store the pre-cured composite stringer 190.

[0040] However, if the post-forming tooling is specifically and permanently shaped to fit the shape of each specific composite stringer, the number of such post-forming tooling will be the same as the number of different stringers. This approach is undesirable from a space and cost perspective and complicates the overall process due to the large number of additional tools required. Furthermore, due to design variations, specifically and permanently shaped post-forming tooling may not always be stackable, which complicates their storage. It should also be noted that the supply base is limited based on the complexity of the post-forming tooling. Moreover, the 3D geometry increases the complexity of shuttling the stringers back and forth. Finally, the 3-D geometry may increase weight, which can hinder manual operation for various reasons, including maintenance.

[0041] Figure 1C 、 1DDesign variations of composite stringers - or more specifically, pre-cured composite stringers 190 - are shown in FIGS. 1A-1E. In each example, the pre-cured composite stringer 190 includes a flange portion 196 that defines a contact surface 197. The contact surface 197 is used to connect the composite stringer formed from the pre-cured composite stringer 190 to other parts, such as a composite skin of an aircraft. These other parts define the shape of the contact surface 197. In some examples, the contact surface 197 is planar. Optionally, the contact surface 197, and more generally the entire stringer, has out-of-plane curvature.

[0042] Each pre-cured composite stringer 190 also includes a cap portion 191 that interconnects and is positioned between the flange portions 196. The cap portion 191 extends away from the contact surface 197, which defines a stringer cavity 192. The cap portion 191 is defined by a height (H) of the cap portion 191, which is defined as the maximum deviation from the contact surface 197. The cap portion 191 is also defined by a width (W) of the cap portion 191, which is defined as the gap between the flange portions 196.

[0043] Referring to FIGS. 1A-1E, Figure 1C In some examples, the cap portion 191 is formed by straight walls. Optionally, in some examples, the cap portion 191 is formed by continuous curved walls, for example, as shown in FIG. 1E. Figure 1E Figure 1D FIG. 1D illustrates an example in which the cap portion 191 is formed by a combination of straight walls and curved walls. Figure 1C 1D FIGS. 1A-1E illustrate that the pre-cured composite stringers 190 shown in these figures require different types of support from the post-forming machining device 100. In addition, Figure 1C 1D FIGS. 1A-1E illustrate that the pre-cured composite stringers 190 are not stackable. Thus, if permanent rigid supports are used for these pre-cured composite stringers, these supports will also not be stackable. For purposes of distinguishing pre-cured composite stringers, Figure 1E the examples shown in FIGS. 1A-1D can be referred to as first pre-cured composite stringers 190. The example shown in FIG. 1E can be referred to as a further pre-cured composite stringer 199. Machining different types of pre-cured composite stringers using the same post-forming machining device 100 is described below with reference to FIGS. 2A-2E. Figure 4

[0044] The described methods and devices are used to support a variety of different pre-cured composite stringers, such as Figures 1A-1C ​​​​The composite stringer shown in FIG. More specifically, a common post-forming apparatus is configured to support pre-cured composite stringers having cap portions having different cross-sectional profiles. Specifically, the post-forming apparatus includes a channel and a support structure extending at least partially within the channel. The support structure is configured to conform to each of the differently shaped cap portions of the pre-cured composite stringer and maintain the shape of the cap portions while providing support. In some examples, the support structure is made of a flexible material that conforms to any shape of the cap portion. Alternatively, the support structure is made of a clamping material and is reshaped along with each of the pre-cured composite stringers.

[0045] In examples of the present disclosure, the disclosed post-forming tooling apparatus is used to support various pre-cured composite stringers while performing various operations on these stringers, such as stringer trimming, inspection, and installation of bladders and strips. Furthermore, in some examples, the disclosed post-forming tooling apparatus is used to store pre-cured composite stringers. Overall, adding the disclosed post-forming tooling apparatus to the overall process flow allows for increased processing throughput of other equipment, such as forming and curing equipment. Overall, the disclosed post-forming tooling apparatus provides high-speed automation of stringer installation by bridging the gap between forming and curing equipment with these post-forming tooling apparatuses.

[0046] The described method also includes incorporating alignment fittings to ensure proper alignment between the stringer and the bladder for dead-end fitting. The offset of the bladder helps provide proper support and function during curing. For example, in some cases, the bladder terminates inside the edge of the part. Specific examples include door structures, window structures, and converging structures (e.g., aircraft structures with very pointed ends).

[0047] It should be noted that the cavity is the tool used to form the stringer, housing the stringer and the bladder. If the bladder does not extend past the stringer, it will interfere with the tool or leave an unacceptably large gap inside the tool. Since the bladder is aligned and locked to the stringer during the kitting stage, it is beneficial to index the bladder in the correct position to avoid rework at a later stage.

[0048] Additionally, some bladders receive one or more layers of material wrapped around them before being inserted into corresponding stringers. In some examples, the assembly includes a glass ply aligned with the ends of the stringers to provide corrosion protection inside the stringers. In other examples, the assembly includes a carbon wrap that adds strength to the stringers. In these latter examples, the bladder wrap is aligned with the stringers.

[0049] Example of post-molding processing equipment

[0050] Figure 2A FIG2 is a schematic cross-sectional view of a post-molding tool 100 for supporting a pre-cured composite stringer 190 according to some examples. The post-molding tool 100 includes a base 110, a support structure 120, and an optional cover 130. In some examples, the post-molding tool 100 does not have the cover 130, or is used without the cover 130, at least in some operations.

[0051] The base 110 is formed from a rigid material such as carbon fiber, aluminum, or a pultruded polyester / glass solution. The base 110 includes a support surface 114 that faces the hood 130 when the hood 130 is present. The support surface 114 is configured to seal against the hood 130 and, in some examples, includes one or more sealing features. During operation of the post-molding apparatus 100, the support surface 114 serves to support the flange portion 196 of the stringer 190, for example, by compressing the flange portion 196 between the support surface 114 and the hood. In some examples, the support surface 114 is planar. Generally, the support surface 114 conforms to the shape of the flange portion 196 of the stringer 190.

[0052] The base 110 also includes a channel 112 that extends partially through the base 110 and has an opening 113. The opening 113 separates two portions of the support surface 114. Figure 2A As shown, the channel 112 has a channel width (CW) and a channel height (CH). The channel width (CW) is measured in a direction parallel to the support surface 114 (along the Y axis). The channel height (CH) is measured in a direction perpendicular to the support surface 114 (along the Z axis). In some examples, the channel width (CW) is measured along the length (X axis (e.g., see FIG. 1 ) of the base 110. Figure 2F )) is constant. In the same or other examples, the channel height (CH) is constant along the length (X-axis) of the base 110. In some examples, the channel width (CW) is constant along the channel height (Z-axis), e.g., Figure 2A This type of channel 112 may be referred to as a straight channel. Optionally, the channel width (CW) varies along the channel height (Z axis), e.g., Figure 2E In this example, the channel width (CW) is greatest at the opening 113. This type of channel 112 may be referred to as a tapered channel and allows for stacking of the post-molding apparatus 100.

[0053] When the post-molding tool 100 is used to support the pre-cured composite stringer 190, the channel 112 is used to accommodate the cap portion 191 of the pre-cured composite stringer 190. Figure 2B, the cap portion 191 protrudes into the channel 112, while the flange portion 196 rests on the support surface 114. It should be noted that the same post-molding tool 100 can be used to support different types of pre-cured composite stringers 190, which may have cap portions 191 of different shapes and sizes. Therefore, the channel width (CW) is greater than the width of the cap portion 191 of the pre-cured composite stringer 190, or more specifically, greater than the width of the widest cap portion 191 among all pre-cured composite stringers 190 processed on the post-molding tool 100. For the purposes of this disclosure, for example, when the cap portion 191 has a tapered or curved cross-section, the width of the cap portion 191 is defined as the maximum width. Furthermore, the channel height is greater than the height of the cap portion 191 among the pre-cured composite stringers 190, or more specifically, greater than the height of the tallest cap portion 191 among all pre-cured composite stringers 190 processed on the post-molding tool 100. Typically, the cross-sectional profile of the channel 112 is sufficient to accommodate any cap portion 191 of the stringer 190 that is processed using the post-forming tooling apparatus 100 .

[0054] although Figures 2A-2C A rectangular cross-sectional profile of the channel 112 is shown, but any cross-sectional profile capable of accommodating the cap portion 191 of the pre-cured composite stringer 190 is within the scope of the present disclosure, such as Figure 2E , a tapered profile, a semi-circular profile, etc. In some examples, the cross-sectional profile of the channel 112 corresponds to the cross-sectional profile of the cap portion 191 , eg, both are tapered.

[0055] Reference Figure 2A , the support structure 120 is at least partially within the channel 112 and extends along the length of the channel 112. In some examples, when the pre-cured composite stringer 190 is supported by and processed using the post-forming tool 100, the support structure 120 is configured to conform to each cap portion 191 and maintain the cross-sectional shape of the cap portion 191. It should be noted that the same support structure 120 is used for different types and profiles of cap portions 191. The support structure 120 is able to conform to these different types and profiles while providing adequate support.

[0056] In some examples, the support structure 120 is formed of an elastic material that is configured to change shape when conforming to different types of cap portions 191. Some examples of suitable elastic materials include, but are not limited to, latex, silicones (e.g., peroxide or platinum cured silicones), and other similar materials. Some considerations for material selection include weight, cleanability, solvent resistance, stiffness, tear strength, elongation at break, and hardness.

[0057] In some examples, such as Figure 1AAs schematically shown in FIG, support structure 120 is attached to base 110 at the sidewalls of channel 112. In these examples, support surface 114 remains exposed and available for interfacing with flange portion 196 of pre-cured composite stringer 190. In other words, when flange portion 196 is positioned on support surface 114, such as compressed between support surface 114 and shroud 130, support structure 120 does not interfere. These examples are shown in FIG. Figure 2A and 2B It is schematically shown in FIG.

[0058] In some examples, support structure 120 comprises a gripping material or a plastically deformable material. For the purposes of this disclosure, a gripping material is defined as a material capable of changing its shape under one condition and maintaining its shape under another condition. More specifically, support structure 120 is co-molded or coformed with one of pre-cured composite stringers 190, then supports that stringer while maintaining its shape. For example, the shape of support structure 120 initially differs from the shape of pre-cured composite stringer 190. It should be noted that at this stage, pre-cured composite stringer 190 has not yet been formed. Both support structure 120 and the composite layup are loaded into a forming apparatus, various examples of which are described below, and the shape of support structure 120 is adjusted while forming pre-cured composite stringer 190. Thus, support structure 120 is co-molded or coformed with pre-cured composite stringer 190.

[0059] When supporting that particular stringer, the shape is maintained by the support structure 120 during the various operations of the post-forming apparatus 100. In some examples, when processing multiple stringers of the same type (e.g., the cross-sectional shape of the cap portion is the same), the shape will be retained. When a different type of stringer is to be supported, the shape of the support structure 120 is changed, such as by co-molding or forming with the other stringer. These examples are Figure 3A and 3B Schematically shown in .

[0060] Reference Figure 3A In some examples, the support structure 120 includes a support flange 124 extending from the support surface 114 of the base 110 and outside the channel 112. Similar to the portion of the support structure 120 that extends into the channel 112 and supports the cap portion 191 of the stringer 190, the support flange 124 is specifically shaped to support the flange portion 196 of the stringer 190. In some examples, the shape of the support flange 124 is different from the shape of the support surface 114. Therefore, the same post-molding tooling apparatus 100 can be used to support stringers having flange portions of different shapes.

[0061] In some examples, support structure 120 can be moved from base 110. For example, support structure 120 can be moved from base 110 to change the shape of support structure 120, such as when support structure 120 is formed from a clamping material. In some examples, different types of support structures 120 are used with the same base 110.

[0062] The shroud 130 is configured to be attached to the base 110 such that a respective one of the pre-cured composite stringers 190 is positioned between the shroud 130 and the base 110 while being supported by the post-molding tooling 100. More specifically, the flange portion 196 of the pre-cured composite stringer 190 is positioned between the shroud 130 and the support surface 114 and, in some examples, is compressed between the shroud 130 and the support surface 114, as for example Figure 3C The cover 130 is configured to seal against the base 110. Specifically, the cover 130 includes a vacuum seal 132 that engages with the seal receiver 115.

[0063] In some examples, the base 110 includes a pass-through 116 in fluid communication with the channel 112 and configured to control the pressure within the channel 112 and beneath the support structure 120. For example, the pass-through 116 is used to maintain the pressure beneath the support structure 120 at the same level as the surrounding environment, such as when the cap portion 191 of the pre-cured composite stringer 190 is inserted into the channel 112 and engaged with the support structure 120, or more specifically, when the cap portion 191 pushes the support structure 120 deeper into the channel 112, thereby reducing the volume beneath the support structure 120.

[0064] In some examples, the post-molding processing apparatus 100 further includes a flexible insert 140, such as Figure 2D . The flexible insert 140 is positioned with the channel 112 and below the support structure 120 and is used to provide additional support to the cap portion 191. The flexible insert 140 allows the use of a support structure 120 that is very flexible and can conform to greater variations in the cap portion 191 than, for example, when the support structure 120 is used without the flexible insert 140. In some examples, the flexible insert 140 is made of a resilient rubber, such as Rubber, latex or similar materials.

[0065] Reference Figure 2F In some examples, the post-molding apparatus 100 includes a through-hole bladder seal 180 and a terminal bladder seal 182. It should be noted that in the following reference to Figure 5D -E further described capsule 520 is made of silicone, or other similar materials. In some examples, the material of bladder 520 is reinforced or layered. During processing, bladder 520 is vented to the autoclave atmosphere during the curing process and to the ambient atmosphere during any compaction / vacuum bagging. Therefore, in some examples, one end of bladder 520 includes a fitting with a vent hole. Figure 2F A through-hole bladder seal 180 shown in FIG connects the fitting, allowing bladder 520 to vent while inside post-molding tooling 100. In some examples, post-molding tooling 100 includes through-hole bladder seals on both ends.

[0066] Example of a method of manufacturing a composite stringer

[0067] Figure 4 is a method for manufacturing a composite stringer 198 (see FIG. Figure 1B ) is a process flow diagram of a method 400. The composite stringer 198 should be distinguished from the pre-cured composite stringer 190, which is an intermediate structure used to form the composite stringer 198. Therefore, in some examples, the pre-cured composite stringer 190 and the composite stringer 198 have the same size and shape. Figures 1C-1E 1 represents both the pre-cured composite stringer 190 and the composite stringer 198. In some examples, the composite stringer 198 comprises a fiber reinforced composite material, which may also be referred to as a reinforced composite material. This type of material includes one or more heterogeneous polymer-based components and one or more non-polymer-based components (e.g., carbon fiber). Figure 4 and Figure 5A -G describes method 400 in more detail.

[0068] The method 400 includes (block 410) forming the pre-cured composite stringer 190, such as using composite layups 502. This operation uses a forming apparatus 510 (such as Figure 5A and 5B The molding device 510 is different from the post-molding processing device 100 ( Figures 5C-5F As described above, the post-molding processing apparatus 100 increases the throughput of the molding apparatus 510 by using the post-molding processing apparatus 100 to perform various subsequent operations.

[0069] In some examples, the composite layup 502 includes uncured, pre-impregnated reinforcement tapes or fabrics, which may be referred to as prepregs. The tapes or fabrics include fibers, such as graphite fibers, embedded in a matrix material, such as a polymer, or more specifically, an epoxy or phenolic resin. In some examples, the tapes or fabrics are unidirectional or woven, depending on the design and degree of reinforcement desired for the resulting composite stringer 198.

[0070] During the forming operation (block 410), the composite layup 502 is positioned on a forming apparatus 510, such as Figure 5A In some examples, such as when the support structure 120 is co-molded with the pre-cured composite stringer 190, the support structure 120 is positioned between the composite layup 502 and the molding device 510. These examples are further described below with reference to block 412. The molding device 510 includes a molding base 511 with a molding cavity 512 that defines the shape of the cap portion 191 of the pre-cured composite stringer. Figure 5B The forming apparatus 510 further includes a forming die 513 that pushes a portion of the composite layup 502 into the forming cavity 512 and against a wall of the forming cavity 512 .

[0071] After this operation is completed, the composite layup 502 is formed into a pre-cured composite stringer 190. The pre-cured composite stringer 190 includes a cap portion 191 disposed between a forming die 513 and the walls of a forming cavity 512. The pre-cured composite stringer 190 also includes a flange portion 196 that extends outside of the forming cavity 512 and, for example, conforms to a forming surface 514 of a forming base 511. In some examples, the forming die 513 includes specially configured bladders that press against the flange portion 196. These bladders are pressurized and contact the flange portion 196 before forming the cap portion 191, in some examples to varying pressure levels, to allow the composite layup 502 to slide against the forming surface 514 as the cap portion 191 is formed.

[0072] In some examples, forming the pre-cured composite stringer 190 on the forming apparatus includes (block 412) forming the support structure 120 of the post-forming tooling apparatus 100. For example, the support structure 120 includes a clamping material, various examples and features of which are described above. In some examples, the support structure 120 is formed in a separate operation from the pre-cured composite stringer 190. Alternatively, the support structure 120 and the pre-cured composite stringer 190 are co-formed or co-molded in the same overall operation, such as the operation represented by block 412 being part of the operation represented by block 410. Figure 4 . In other words, the support structure 120 is placed into the forming apparatus 510 along with the composite layup 502. At this stage, the shape of the support structure 120 differs from the shape of the pre-cured composite stringer 190 that will be formed and defined by the forming apparatus 510. For example, the support structure 120 may have previously been used to support another pre-cured composite stringer 190 having a different shape. During the parallel operations represented by blocks 410 and 412, the pre-cured composite stringer 190 is formed while the support structure 120 is also co-formed or co-molded. This support structure forming operation (block 412) may also be referred to as a shape-changing operation.

[0073] In some examples, the method 400 also includes trimming the pre-cured composite stringer 190, such as cutting portions of the pre-cured composite stringer 190. For example, the cutting may be performed using an ultrasonic knife.

[0074] The method 400 continues (block 420) by transferring the pre-cured composite stringer 190 from the forming apparatus 510 to the post-forming processing apparatus 100. For example, Figures 5B-5C FIGURE 5 illustrates the transfer of a pre-cured composite stringer 190 from a forming apparatus 510 to a post-forming apparatus 100. Various examples of post-forming apparatus 100 have been described above. In some examples, the pre-cured composite stringer 190 is transferred unsupported. Alternatively, the pre-cured composite stringer 190 is transferred with a support structure 120.

[0075] In some examples, the transfer operation includes controlling the pressure inside the channel 112 of the base 110. For example, inserting the cap portion 191 of the pre-cured composite stringer 190 into the channel 112 may cause air to be displaced from the channel 112, such as through the through-holes 116.

[0076] In some examples, the transfer operation includes (block 422) stretching the support structure 120 of the post-forming tooling 100. In these examples, the support structure 120 is formed of an elastic material that conforms to the shape of the cap portions 191 of the pre-cured composite stringer 190 as the cap portions are inserted into the channels 112. More specifically, the elastic material is configured to change shape as it conforms to each of the cap portions 191. As described above, in some examples, the cap portions 191 have different cross-sectional shapes. Figures 2A-2B As shown, this tensile characteristic of the support structure 120 allows for supporting pre-cured composite stringers 190 having cap portions 191 of varying sizes.

[0077] In some examples, the transfer operation includes (block 424 ) adjusting the shape of the post-molding tooling apparatus 100 . Figure 6A and 6B The base 110 of the post-molding tool 100 is shown having a pivot point defined by a first axis 601. For simplicity, other parts of the post-molding tool 100, such as the support structure 120, are not shown. The pivot point allows the base 110 to have in-plane bending and accommodate straight pre-cured composite stringers (in Figure 6A configuration shown in ) and pre-cured composite stringers with in-plane bending (in Figure 6B ). Although Figure 6A and 6BOnly one pivot point is shown, but one skilled in the art will appreciate that any number of pivot points may exist. Furthermore, in some examples, the post-molding apparatus 100 includes out-of-plane bending capabilities. It should be noted that some degree of bending, particularly localized bending, in the pre-cured composite stringer can be accommodated by the sides of the channel 112 within the base 110 without causing the base 110 to bend.

[0078] In some examples, the method 400 includes (block 430) inspecting the pre-cured composite stringer 190. This inspection is performed while the pre-cured composite stringer 190 is positioned on the post-molding tooling apparatus 100. For example, the inspection may involve inspecting the surface of the pre-cured composite stringer 190 for wrinkles, bubbles, foreign object debris (FOD), loose fibers, wrinkles, and shape. It should be noted that the inspection operation is performed remotely from the molding apparatus 510 and the curing apparatus 540, thereby allowing other pre-cured composite stringer processing to proceed on these apparatuses and increasing overall process throughput.

[0079] The method 400 includes (block 440 ) installing a bladder 520 on the pre-cured composite stringer 190 , such as in Figure 5D The bladder 520 is schematically shown in FIG. The bladder 520 is installed when the pre-cured composite stringer 190 is positioned on the post-molding tooling apparatus 100. In some examples, the bladder 520 is encased in a bladder wrap and then cured as the stringer skin when the bladder 520 is removed. The bladder 520 is used to provide support within the pre-cured composite stringer 190 during the curing operation. In some examples, the bladder 520 is a solid object composed of silicone, polyurethane, or similar materials, including any combination thereof. In some examples, the bladder 520 is shaped to substantially correspond to the pre-cured composite stringer 190.

[0080] The method 400 includes (block 450) installing the noodle 530 at the interface between the bladder 520 and the pre-cured composite stringer 190 and within the plane of the support surface 114 of the base 110, as shown. Figure 5E This installation operation is performed when the pre-cured composite stringer 190 is positioned on the post-forming tooling 100. The strip 530 is also known as a radius filler.

[0081] In some examples, the method 400 includes (block 460) compacting the pre-cured composite stringer 190 while the pre-cured composite stringer 190 is positioned on the post-molding tool 100. For example, the compacting operation involves sealing the cover 130 of the post-molding tool 100 against the base 110 of the post-molding tool 100, as shown in FIG. Figure 5FIn some examples, the pressing operation further includes contacting at least the flange portion 196 of the pre-cured composite stringer 190 with the shroud 130 of the post-molding tool 100 .

[0082] In some examples, the method 400 includes staging and transporting the pre-cured composite stringer 190. These operations are performed while the pre-cured composite stringer 190 is positioned on the post-forming tool 100. In addition, the post-forming tool 100 is used to store the pre-cured composite stringer 190 and provide support for the pre-cured composite stringer 190.

[0083] The method 400 continues (block 490) by transferring the pre-cured composite stringer 190 from the post-forming tooling 100 to the curing device 540. For example, Figures 5F-5G 5 shows the transfer of the pre-cured composite stringer 190 from the post-molding tool 100 to the curing device 540. In some examples, the pre-cured composite stringer 190 is transferred with the bladder 520 and / or the strip 530, which are installed on the pre-cured composite stringer 190 when the pre-cured composite stringer 190 is positioned on the post-molding tool 100.

[0084] The method 400 includes (block 492 ) curing the pre-cured composite stringer 190 on a curing device 540 to form a composite stringer 198 , such as Figure 5G and 5H For example, Figure 5G The pre-cured composite stringer 190 shown is subjected to heat and pressure to cross-link the resin within the pre-cured composite stringer 190. Unlike the pre-cured composite stringer 190, Figure 5H The illustrated composite stringer 198 does not require the level of support required of the pre-cured composite stringer 190. Therefore, the post-forming apparatus 100 is not used for the composite stringer 198.

[0085] In some examples, additional pre-cured composite stringers 199 (eg, Figure 1E , an example of which is shown in FIG. 4 , and the various operations of the method 400 are repeated (decision block 494 ). Specifically, the additional pre-cured composite stringer 199 has a different design than the pre-cured composite stringer 190 previously processed using the same post-forming tooling apparatus 100 . Figures 1C-1E Various designs of pre-cured composite stringers are shown. Other example designs of pre-cured composite stringers are possible.

[0086] Specifically, method 400 includes forming additional pre-cured composite stringers 199 on an additional forming apparatus 410. Unlike post-forming tooling apparatus 100, which can be used universally on various pre-cured composite stringers of varying designs, the forming apparatus is a dedicated tool. In some examples, during this operation of forming the additional pre-cured composite stringers 199, support structure 120 undergoes reshaping or reconfiguration. More specifically, support structure 120 may have a different shape when supporting additional pre-cured composite stringers 199 than when supporting pre-cured composite stringers 190.

[0087] The method 400 continues (block 420) by transferring the additional pre-cured composite stringer 199 from the forming apparatus to the post-forming tooling apparatus 100. As described above, the additional pre-cured composite stringer 199 has a different design than the pre-cured composite stringer 190, and more specifically, a different cross-sectional profile.

[0088] In some examples, the method 400 continues by installing additional bladders on the additional pre-cured composite stringers 199 while the additional pre-cured composite stringers 199 are positioned on the post-forming tool 100. Additionally, a noodle is installed on the additional pre-cured composite stringers 199 while the additional pre-cured composite stringers 199 are positioned on the post-forming tool 100. However, these operations are optional.

[0089] The method 400 continues by transferring the additional pre-cured composite stringer 199 along with the additional bladder and the additional noodle from the post-forming tooling apparatus 100 to an additional curing apparatus and curing the pre-cured composite stringer 190 using the additional curing apparatus to form the additional composite stringer.

[0090] Figure 7 is a process flow diagram of a method 700 for supporting a pre-cured composite stringer 190 using a post-forming tool 100 according to some examples of the present disclosure. The method 700 includes (block 720) transferring the pre-cured composite stringer 190 to the post-forming tool 100, for example, at Figure 5C Schematically illustrated in FIG. Various examples of pre-cured composite stringers 190 are described above. For example, pre-cured composite stringers 190 include cap portions 191 that are supported during transfer of pre-cured composite stringers 190 to post-molding tooling 100. Post-molding tooling 100 includes a base 110 that includes a channel 112. Post-molding tooling 100 also includes a support structure 120 that is at least partially within channel 112 and extends along the length of channel 112.

[0091] When the pre-cured composite stringer 190 is transferred to the post-molding processing device 100, the support structure 120 is in contact with the cap portion 191 of the pre-cured composite stringer 190 in the form of a mold. Figure 5C . More specifically, when the pre-cured composite stringer 190 is positioned in the post-molding tooling apparatus 100, the support structure 120 maintains the cross-sectional shape of the cap portion 191 of the pre-cured composite stringer 190. In some examples, the support structure 120 is made of a flexible material that provides this conformal support. In other examples, the support structure 120 is made of a clamping material that reshapes with each new pre-cured composite stringer.

[0092] In some examples, the transfer operation (block 720) includes (block 722) stretching the support structure 120 of the post-forming tooling apparatus 100, e.g. Figures 2A-2B 1. In these examples, the support structure 120 is formed of an elastic material that conforms to the shape of the cap portion 191 of the pre-cured composite stringer 190 when the cap portion is inserted into the channel 112. This stretching characteristic of the support structure 120 allows for supporting pre-cured composite stringers 190 having cap portions 191 of varying sizes.

[0093] In some examples, the transfer operation (block 720 ) includes (block 724 ) adjusting the shape of the post-molding tooling apparatus 100 . Figure 6A and 6B The base 110 of the post-molding tool 100 is illustrated having a pivot point defined by a first axis 601. For simplicity, other parts of the post-molding tool 100, such as the support structure 120, are not shown. The pivot point allows the base 110 to have in-plane curvature and accommodate straight pre-cured composite stringers (in Figure 6A configuration shown in ) and pre-cured composite stringers with in-plane bending (in Figure 6B ). Although Figure 6A and 6B Only one pivot point is shown, but one skilled in the art will appreciate that any number of pivot points may exist. Furthermore, in some examples, the post-molding apparatus 100 includes out-of-plane bending capabilities. It should be noted that some degree of bending, particularly localized bending, in the pre-cured composite stringer can be accommodated by the sides of the channel 112 within the base 110 without causing the base 110 to bend.

[0094] In some examples, the transfer operation (block 720 ) includes (block 726 ) positioning the cover 130 of the post-molding tooling apparatus 100 against the base 110 of the post-molding tooling apparatus 100 , e.g. Figure 5FIn some examples, the cover 130 seals against the base 110. Additionally, in some examples, the cover positioning operation (block 726) compacts at least the flange portion 196 of the pre-cured composite stringer 190.

[0095] In some examples, the transfer operation (frame 720) includes (block 728) controlling the pressure inside the channel 112 of the base 110. For example, inserting the cap portion 191 of the pre-cured composite stringer 190 into the channel 112 may cause air to be displaced from the channel 112, such as through the through-holes 116.

[0096] In some examples, the method 700 includes (block 730 ) storing the pre-cured composite stringer 190 . More specifically, (block 740 ) the pre-cured composite stringer 190 is stored in the post-forming tool 100 before being removed from the post-forming tool 100 .

[0097] The method 700 continues (block 740) by removing the pre-cured composite stringer 190 from the post-molding tooling 100. For example, the pre-cured composite stringer 190 is transferred to the curing device 540, e.g. Figure 5G Optionally, the pre-cured composite stringer 190 is transferred to other equipment, such as for inspection.

[0098] The method 700 proceeds, or more specifically repeats (decision block 794 ), wherein (block 720 ) the additional pre-cured composite stringer 199 is transferred to the post-molding tooling apparatus 100 , e.g. Figure 5I The additional pre-cured composite stringer 199 includes an additional cap portion 193 such that the cross-sectional shape of the additional cap portion 193 of the additional pre-cured composite stringer 199 is different from the cross-sectional shape of the cap portion 191 of the pre-cured composite stringer 190, as shown in FIG. Figure 5C However, despite this difference in cross-sectional shape, the support structure 120 of the post-molding tool 100 still conforms to the additional cap portion 193 of the additional pre-cured composite stringer 199. Furthermore, the support structure 120 retains the cross-sectional shape of the additional cap portion 193 of the additional pre-cured composite stringer 199.

[0099] Aircraft Example

[0100] In some examples, the methods and systems described above are used on aircraft and more generally in the aerospace industry. Specifically, these methods and systems can be used during aircraft manufacturing and during aircraft repair and maintenance.

[0101] Therefore, the above-mentioned apparatus and method are suitable for Figure 8 Aircraft manufacturing and service method 900 is shown and Figure 9 Aircraft 902 is shown. During pre-production, method 900 includes specification and design 904 of aircraft 902 and material procurement 906. During production, parts and subassembly manufacturing 908 and system integration 910 of aircraft 902 occur. Thereafter, aircraft 902 undergoes certification and delivery 912 for entry into service 914. During customer service, aircraft 902 is scheduled for routine maintenance and service 916, which also includes modification, reconfiguration, refurbishment, etc.

[0102] In some examples, each process of method 900 is performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this description, a system integrator includes, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party includes, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may include, for example, an airline, a leasing company, a military entity, a service organization, or the like.

[0103] like Figure 9 As shown, aircraft 902 produced by method 900 includes airframe 918 and interior 922 having a plurality of systems 920. Examples of systems 920 include one or more of propulsion system 924, electrical system 926, hydraulic system 928, and environmental system 930. Any number of other systems may be included. Although an aviation example is shown, the principles of the examples described herein are applicable to other industries, such as the automotive industry.

[0104] The apparatus and methods described herein may be employed during any one or more stages of method 900. For example, parts or subassemblies corresponding to manufacturing 908 may be manufactured or fabricated in a manner similar to parts or subassemblies produced while aircraft 902 is in service. Furthermore, one or more apparatus examples, method examples, or a combination thereof may be utilized during manufacturing 908 and system integration 910, for example, by substantially expediting assembly of aircraft 902 or reducing the cost of aircraft 902. Similarly, one or more apparatus examples, method examples, or a combination thereof may be utilized while aircraft 902 is in service, such as, but not limited to, during maintenance and service 916.

[0105] Further embodiments

[0106] Further, the description includes embodiments according to the following clauses:

[0107] Clause 1. A post-forming apparatus for supporting pre-cured composite stringers, the pre-cured composite stringers including cap portions having different cross-sections between the pre-cured composite stringers, the post-forming apparatus comprising:

[0108] A base comprising a channel having a channel width and a channel height, wherein:

[0109] The channel width is greater than the width of the cap portion of the pre-cured composite stringer, and

[0110] the channel height being greater than the height of the cap portion of the pre-cured composite stringer;

[0111] a support structure extending at least partially within the channel and along the length of the channel and configured to conform to and maintain the cross-sectional shape of each of the cap portions when a corresponding one of the precured composite stringers is supported by the post-forming tooling; and

[0112] A shroud is configured to be attached to the base such that a corresponding one of the pre-cured composite stringers is positioned between the shroud and the base while supported by the post-molding tooling.

[0113] Clause 2. The post-molding apparatus of clause 1, wherein the support structure is formed of an elastic material configured to change shape when conformed to each of the cap portions.

[0114] Clause 3. The post-forming apparatus of clause 2, wherein the support structure is attached to the base at the sidewalls of the channel.

[0115] Clause 4. The post-forming apparatus of any one of Clauses 1-3, wherein the support structure comprises a clamping material or a plastically deformable material.

[0116] Clause 5. The post-forming apparatus of clause 4, wherein the support structure is co-formed with a corresponding one of the pre-cured composite stringers.

[0117] Clause 6. The post-molding apparatus of Clause 4, wherein the support structure comprises a support flange on a support surface of the base and extending outside of the channel.

[0118] Clause 7. The post-forming apparatus of clause 4, wherein the support structure is removable from the base.

[0119] Clause 8. The post-molding processing apparatus of any one of Clauses 1-7, wherein the base includes a through-hole fluidly connected to the channel and configured to control the pressure inside the channel.

[0120] Clause 9. The post-forming apparatus of any one of Clauses 1-8, further comprising a flexible insert positioned with the channel and beneath the support structure.

[0121] Clause 10. The post-molding processing apparatus of any one of Clauses 1-9, wherein the cover is configured to seal against the base.

[0122] Clause 11. A method of manufacturing a composite stringer, the method comprising:

[0123] forming a pre-cured composite stringer on a forming device, the pre-cured composite stringer including a cap portion;

[0124] The pre-cured composite stringer is transferred from the forming device to a post-forming device, wherein the post-forming device comprises:

[0125] a base including a channel, and

[0126] a support structure extending at least partially within and along the length of the channel and configured to conform to and maintain the cross-sectional shape of the cap portion; and

[0127] installing a bladder on the pre-cured composite stringer while the pre-cured composite stringer is positioned on the post-forming tool;

[0128] installing a noodle at the interface between the bladder and the pre-cured composite stringer and in the plane of the support surface of the base while the pre-cured composite stringer is positioned on the post-forming tool;

[0129] transferring the pre-cured composite stringer along with the bladder and the noodle from the post-forming unit to a curing unit; and

[0130] The pre-cured composite stringer is cured on the curing device, thereby forming the composite stringer.

[0131] Clause 12. The method of Clause 11, further comprising inspecting the pre-cured composite stringer while the pre-cured composite stringer is positioned on the post-forming tool.

[0132] Clause 13. The method of any of Clauses 11-12, further comprising compacting the pre-cured composite stringer while positioning the pre-cured composite stringer on the post-forming tool.

[0133] Clause 14. The method of Clause 13, wherein compacting the pre-cured composite stringer includes sealing a cover of the post-forming tool against the base of the post-forming tool.

[0134] Clause 15. The method of Clause 14, wherein compacting the pre-cured composite stringer comprises contacting at least a flange portion of the pre-cured composite stringer with a shroud of the post-forming tool.

[0135] Clause 16. The method of any of Clauses 11-15, wherein forming the pre-cured composite stringer on the forming device includes forming a support structure of the post-forming tool.

[0136] Clause 17. The method of any of Clauses 11-16, wherein transferring the pre-cured composite stringer from the forming device to the post-forming tooling device includes controlling a pressure within a channel of the base.

[0137] Clause 18. The method of any of Clauses 11-17, wherein transferring the pre-cured composite stringer from the forming device to the post-forming device comprises stretching a support structure of the post-forming device.

[0138] Clause 19. The method according to any one of clauses 11-18, further comprising:

[0139] forming another pre-cured composite stringer on another forming device;

[0140] transferring the additional pre-cured composite stringer from the forming device to the post-forming device, wherein the additional pre-cured composite stringer has a different cross-sectional profile than the pre-cured composite stringer;

[0141] installing an additional bladder on the additional pre-cured composite stringer while the additional pre-cured composite stringer is positioned on the post-forming tool;

[0142] installing an additional strip on the additional pre-cured composite stringer while the additional pre-cured composite stringer is positioned on the post-forming tool;

[0143] transferring the additional pre-cured composite stringer along with the additional bladder and the additional noodle from the post-forming device to an additional curing device; and

[0144] The pre-cured composite stringer is cured using the additional curing device, thereby forming an additional composite stringer.

[0145] Clause 20. The method of Clause 19, wherein the support structure has a different shape when supporting the additional pre-cured composite stringer than when supporting the pre-cured composite stringer.

[0146] Clause 21. A method comprising:

[0147] The pre-cured composite stringer including the cap portion is transferred to a post-forming tool comprising:

[0148] a base including a channel, and

[0149] a support structure extending at least partially within and along the length of the channel and conforming to and maintaining the cross-sectional shape of the cap portion of the precured composite stringer; and

[0150] removing the pre-cured composite stringer from the post-forming tool; and

[0151] The additional pre-cured composite stringer including the additional cap portion is transferred to the post-forming tool, wherein a support structure of the post-forming tool conforms to the additional cap portion of the additional pre-cured composite stringer and maintains a cross-sectional shape of the additional cap portion of the additional pre-cured composite stringer, the cross-sectional shape of the additional cap portion of the additional pre-cured composite stringer being different from the cross-sectional shape of the cap portion of the pre-cured composite stringer.

[0152] Clause 22. The method of Clause 21, wherein transferring the pre-cured composite stringer comprises positioning a cover of the post-forming tool against a base of the post-forming tool.

[0153] Clause 23. The method of any of Clauses 21-22, wherein transferring the pre-cured composite stringer to the post-forming tool comprises controlling a pressure within a channel of the base.

[0154] Clause 24. The method of any of Clauses 21-23, wherein transferring the pre-cured composite stringer to the post-forming tool comprises stretching a support structure of the post-forming tool.

[0155] Clause 25. The method of any of Clauses 21-24, wherein the post-forming tool is configured to store the pre-cured composite stringer prior to removing the pre-cured composite stringer from the post-forming tool.

[0156] in conclusion

[0157] Although the foregoing concepts have been described in detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be made within the scope of the appended claims. It should be noted that there are many alternative ways of implementing the methods, systems, and devices. Therefore, the present examples are to be considered as illustrative rather than restrictive.

Claims

1. A post-forming apparatus (100) for supporting pre-cured composite stringers (190), the pre-cured composite stringers (190) including cap portions (191) having different cross-sectional shapes between the pre-cured composite stringers, the post-forming apparatus (100) comprising: A base (110) comprising a channel (112) having a channel width and a channel height, wherein: The channel width is greater than the width of the cap portion (191) of the pre-cured composite stringer (190), and The channel height is greater than the height of the cap portion (191) of the pre-cured composite stringer (190); a support structure (120) extending at least partially within and along the length of the channel (112) and configured to conform to each of the cap portions (191) and to reshape to the respective different cross-sectional shapes of each of the cap portions (191) when a corresponding one of the pre-cured composite stringers (190) is supported by the post-forming apparatus (100); and A cover (130) is configured to be attached to the base (110) such that a corresponding one of the pre-cured composite stringers (190) is positioned between the cover (130) and the base (110) while being supported by the post-molding apparatus (100).

2. The post-molding processing device (100) according to claim 1, wherein the support structure (120) is formed of an elastic material, and the support structure (120) is configured to change shape when fitting each of the cap parts (191) to fit at least the side portion and the bottom portion of each of the different cross-sections of the cap part.

3. The post-molding apparatus (100) of claim 2, wherein the support structure (120) is attached to the base (110) at a sidewall of the channel (112).

4. The post-forming apparatus (100) of claim 1, wherein the support structure (120) comprises a clamping material or a plastically deformable material.

5. The post-molding apparatus (100) of claim 4, wherein the support structure (120) is co-molded with a corresponding one of the pre-cured composite longerons (190).

6. The post-molding apparatus (100) of claim 4, wherein the support structure (120) includes a support flange (124) on the support surface (114) of the base (110) and extending outside the channel (112).

7. The post-molding processing apparatus (100) according to claim 4, wherein the support structure (120) is removable from the base (110).

8. The post-molding processing device (100) according to any one of claims 1 to 7, wherein the base (110) includes a through hole (116) which is fluidly connected to the channel (112) and is configured to control the pressure inside the channel (112).

9. The post-molding apparatus (100) according to any one of claims 1 to 7, further comprising a flexible insert (140) positioned with the channel (112) and below the support structure (120).

10. The post-molding apparatus (100) according to any one of claims 1 to 7, wherein the cover (130) is configured to seal against the base (110).

11. The post-molding tooling apparatus (100) of claim 1, wherein the support structure (120) is configured to conform to at least a side portion and a bottom portion of each of the cap portions (191) when a corresponding one of the pre-cured composite longerons (190) is supported by the post-molding tooling apparatus (100).

12. The post-molding processing device (100) according to claim 1, wherein the different cross-sectional shapes of the cap portion (191) include a trapezoidal cross-sectional shape and a semicircular cross-sectional shape.

13. The post-molding tooling apparatus (100) of claim 1, wherein the support structure (120) is attached at an upper portion of the channel sidewall and extends to a lower portion of the channel (112).

14. The post-molding tooling apparatus (100) of claim 1, wherein the support structure (120) is configured to maintain each of the different cross-sectional shapes of each of the cap portions (191) when a corresponding one of the pre-cured composite stringers (190) is supported by the post-molding tooling apparatus (100).

15. The post-molding processing device (100) according to claim 1, wherein the channel width is greater than the maximum width of the cap portion (191).

16. The post-molding processing device (100) according to claim 1, wherein the channel height is greater than the maximum height of the cap portion (191).

17. The post-molding processing apparatus (100) of claim 1, wherein the support structure (120) comprises a latex or silicone material.

18. The post-forming tooling apparatus (100) of claim 1, wherein the different cross-sectional shapes include a tapered profile and a circular profile.

19. The post-molding apparatus (100) of claim 1, wherein the support structure (120) is configured to conform to each of the cap portions (191) protruding into the channel (112).

20. The post-molding apparatus (100) of claim 1, wherein the support structure (120) is configured to change shape with each cap portion (191) having a differently shaped profile.

21. A method (400) of manufacturing a plurality of composite stringers, the method (400) comprising: forming a plurality of pre-cured composite stringers (190) on a forming device (510), wherein the pre-cured composite stringers (190) include different cap portions (191) having different cross-sectional shapes; Each of the pre-cured composite stringers (190) is transferred from the forming device (510) to a post-forming processing device (100), the post-forming processing device (100) comprising: a base (110) including a channel (112), and a support structure (120) extending at least partially within and along the length of the channel (112) and conforming to each cap portion (191) and reshaped for each different cross-sectional shape of each cap portion (191), wherein the support structure is attached to the base at the sidewalls of the channel; and installing a bladder (520) on a first pre-cured composite stringer (190) of the plurality of pre-cured composite stringers (190) while the first pre-cured composite stringer (190) is positioned on the post-molding tool (100); When the first pre-cured composite stringer (190) is positioned on the post-molding tooling (100), a noodle (530) is installed at the interface between the bladder (520) and the first pre-cured composite stringer (190) and within the plane of the support surface (114) of the base (110); transferring the first pre-cured composite stringer (190) along with the bladder (520) and the noodle (530) from the post-forming apparatus (100) to a curing apparatus (540); and The first pre-cured composite stringer (190) is cured on the curing device (540).

22. The method (400) of claim 21, further comprising inspecting each pre-cured composite stringer (190) while positioned on the post-forming tooling apparatus (100).

23. The method (400) of claim 21, further comprising compacting each pre-cured composite stringer (190) while positioning each pre-cured composite stringer (190) on the post-forming tool (100).

24. The method (400) of claim 23, wherein compacting each pre-cured composite stringer (190) includes sealing a cover (130) of the post-forming tool (100) against the base (110) of the post-forming tool (100).

25. The method (400) of claim 24, wherein compacting each pre-cured composite stringer (190) further comprises contacting at least a flange portion (196) of the pre-cured composite stringer (190) with a shroud (130) of the post-molding tool (100).

26. The method (400) of claim 21, wherein forming the pre-cured composite stringer (190) on the forming apparatus comprises forming a support structure (120) of the post-forming tooling apparatus (100).

27. The method (400) of claim 21, wherein transferring each pre-cured composite stringer (190) from the forming apparatus to the post-forming tooling apparatus (100) includes controlling pressure within a channel (112) of the base (110).

28. The method (400) of claim 21, wherein transferring each pre-cured composite stringer (190) from the forming apparatus to the post-forming apparatus (100) comprises stretching a support structure (120) of the post-forming apparatus (100).

29. The method (400) of claim 21, further comprising: forming another pre-cured composite stringer (199) on another forming device; transferring the additional pre-cured composite stringer (199) from the forming apparatus to the post-forming apparatus (100), wherein the additional pre-cured composite stringer (199) has a different cross-sectional profile than the pre-cured composite stringer (190); installing an additional bladder on the additional pre-cured composite stringer (199) while the additional pre-cured composite stringer (199) is positioned on the post-forming tooling apparatus (100); installing an additional strip on the additional pre-cured composite stringer (199) while the additional pre-cured composite stringer (199) is positioned on the post-forming tooling apparatus (100); transferring the additional pre-cured composite stringer (199) along with the additional bladder and the additional strip from the post-forming apparatus (100) to an additional curing apparatus; and The pre-cured composite stringer is cured using the additional curing device, thereby forming an additional composite stringer.

30. The method (400) of claim 29, wherein the support structure (120) has a different shape when supporting the additional pre-cured composite stringer (199) than when supporting the pre-cured composite stringer (190).

31. A method (700) of manufacturing a composite stringer, comprising: (720) Transferring the pre-cured composite stringer (190) including the cap portion (191) to a post-forming processing apparatus (100), the post-forming processing apparatus (100) comprising: a base (110) including a channel (112), and a support structure (120) extending at least partially within and along the length of the channel (112) and conforming to and maintaining the cross-sectional shape of the cap portion (191) of the pre-cured composite stringer (190); and (740) removing the pre-cured composite stringer (190) from the post-forming tooling apparatus (100); and (720) transferring the additional pre-cured composite stringer (199) including the additional cap portion (193) to the post-forming tooling apparatus (100), wherein: The support structure (120) of the post-molding processing device (100) is fitted to the additional cap portion (193) of the additional pre-cured composite longitudinal beam (199) and reshaped to a cross-sectional shape of the additional cap portion (193) of the additional pre-cured composite longitudinal beam (199), the cross-sectional shape of the additional cap portion (193) of the additional pre-cured composite longitudinal beam (199) being different from the cross-sectional shape of the cap portion (191) of the pre-cured composite longitudinal beam (190).

32. The method (700) of claim 31, wherein (720) transferring the pre-cured composite stringer (190) includes (726) positioning a hood (130) of the post-molding tool (100) against a base (110) of the post-molding tool (100).

33. The method (700) of claim 31, wherein (720) transferring the pre-cured composite stringer (190) to the post-molding tooling (100) includes controlling pressure within a channel (112) of the base (110).

34. The method (700) of claim 31, wherein (720) transferring the pre-cured composite stringer (190) to the post-forming tool (100) includes (722) stretching a support structure (120) of the post-forming tool (100).

35. The method (700) of claim 31, wherein the post-forming tooling (100) is configured to (730) store the pre-cured composite stringer (190) prior to (740) removing the pre-cured composite stringer (190) from the post-forming tooling (100).

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