Net shape formation of composite stringers including out-of-plane features

Abstract

This disclosure relates to the net shape formation of a composite stringer including an out-of-plane feature. A tool is configured to form a composite blank into a stringer having a net shape and including at least one out-of-plane feature. The out-of-plane feature is formed by a shim removably attached to the tool. A series of shims can be used to form out-of-plane features with different properties.

Description

Technical Field

[0001] This disclosure generally relates to the production of composite parts, and more specifically, to methods and apparatus for manufacturing composite stringers that include out-of-plane features such as bends. Background Technology

[0002] Composite stringers are used in aircraft and other applications to reinforce the outer skin and transfer loads on it. In some cases, stringers must form a profile along their length and / or include out-of-plane features (such as bends). These features make the production of composite stringers more challenging due to stress concentrations that occur when forming them.

[0003] One technique for producing composite stringers with out-of-plane features (such as bends) involves using a punch to form a flat composite blank into a die. After the stringer is formed into the desired cross-sectional shape by the punch, it is transferred to a forming die in a mating tray, where out-of-plane features (such as bends) are formed in the stringer. Forming bends in this manner often results in stress concentrations, which can cause undesirable delamination and / or resin buildup, thus affecting stringer performance. Therefore, stringers containing these defects must be reworked and sometimes discarded.

[0004] Therefore, it is desirable to provide a stringer production method and apparatus that reduces stringer wrinkles and resin buildup by forming the stringers into a net shape. Summary of the Invention

[0005] This disclosure generally relates to the production of composite stringers, and more specifically, to a production process and equipment for manufacturing composite stringers having out-of-plane features.

[0006] According to one aspect, an apparatus is provided for manufacturing a composite stringer having at least one out-of-plane feature therein. The apparatus includes: a mold including a mold cavity; and a tool configured to form a composite preform into the mold cavity. The apparatus further includes a shim attached to the tool. The shim is configured to form an out-of-plane feature in the composite stringer as the tool forms the composite preform into the mold cavity.

[0007] According to another aspect, an apparatus for manufacturing composite stringers is provided. The apparatus includes: a punch; a die capable of forming a composite blank into the die via the punch; and a series of spacers. The spacers are each configured to form different features in the composite blank. Each spacer is releasably attached to the punch, thereby allowing a single punch to be configured to produce stringers with different features.

[0008] According to other features, a method is provided for manufacturing a composite stringer having out-of-plane features into a net shape. The method includes: mounting a shim on a tool; and using the tool to form a composite blank into a composite stringer. The forming step includes using the shim to form out-of-plane features in the composite blank while forming the composite blank through the tool.

[0009] One advantage of the disclosed embodiments is that composite stringers having one or more out-of-plane features (such as bends) can be formed into a net shape in a single forming operation. Another advantage is that the composite stringers can be formed into a net shape with reduced wrinkling and resin buildup. Another advantage is that the secondary forming operations previously required to produce out-of-plane features in the stringers can be eliminated. Other advantages include the ability to produce composite stringers with various out-of-plane features using a series of shims formed with a single forming tool. Another advantage is the reduction in the number of tools required to produce composite stringers with different features, thereby reducing process time and saving material and labor costs. Another advantage is the ability to produce stringers with out-of-plane features exhibiting higher quality and reducing the need for stringer rework.

[0010] The features, functions, and advantages discussed may be implemented independently in various examples of this disclosure, or may be combined in other examples, as further details of which may be understood with reference to the following description and figures. Attached Figure Description

[0011] The appended claims set forth novel features that are considered exemplary embodiments. However, the exemplary embodiments, preferred modes of use, other objects, and advantages thereof will be best understood by reading in conjunction with the accompanying drawings and by referring to the following detailed description of exemplary examples of the present disclosure, wherein:

[0012] Figure 1 It is a three-dimensional illustration of a composite cap-shaped truss with out-of-plane features.

[0013] Figure 2 It shows Figure 1 An illustration of the end view of the cross-sectional shape of the truss.

[0014] Figure 3 This is a top view illustration of the composite cap-shaped stringers attached to the skin.

[0015] Figure 4 It is along Figure 3 The diagram shows the cross-sectional view taken from line 4-4.

[0016] Figure 5 It is used for stamping. Figure 1 A cross-sectional view of the tool assembly of the composite stringers is shown.

[0017] Figure 6 yes Figure 5 The illustration shows a partial side view of the stamping forming part of the tool set shown in the figure.

[0018] Figure 7 It is along Figure 5 The diagram shows the cross-section taken from line 7-7.

[0019] Figure 8 It is similar to Figure 6 The illustration shows a gasket with openings that reduce stringer wrinkling during stringer profile forming.

[0020] Figure 9 It is similar to Figure 8 The illustration shows that the punch and shim have been shaped into the desired profile.

[0021] Figure 10 yes Figure 9 The illustration shows the area designated as "10", but also a portion of the stringers.

[0022] Figure 11 yes Figure 9 The illustration shows the area designated as "11", but also a portion of the stringers.

[0023] Figure 12 This is a cross-sectional view of the punch and top plate, showing an example of magnetic attachment of the gasket.

[0024] Figure 13 It is similar to Figure 12 The illustration shows an example of magnetic attachment of a gasket.

[0025] Figure 14 It is similar to Figure 12 The illustration shows another example of magnetic attachment of the gasket.

[0026] Figure 15 This is a schematic partial side view illustration of a series of gaskets.

[0027] Figure 16 This is a schematic side view illustration of another series of gaskets.

[0028] Figure 17 This is a schematic side view illustration of yet another series of gaskets.

[0029] Figure 18 This is a flowchart illustrating a method for manufacturing composite stringers with out-of-plane characteristics.

[0030] Figure 19 This is an illustration showing an exploded perspective view of the compactor and gasket.

[0031] Figure 20 It is similar to Figure 19 The illustration shows that the gasket has been installed on the compactor.

[0032] Figure 21 This is a flowchart illustrating a method for manufacturing composite stringers with out-of-plane features.

[0033] Figure 22 This is an illustration showing a cross-sectional view of a compactor that will be placed on a mold and formed / compacted as a composite stringer.

[0034] Figure 23 This is a flowchart illustrating a method for manufacturing composite stringers containing local out-of-plane features using a compactor to transport and shape / compact the composite stringers.

[0035] Figure 24 It is a flowchart illustrating the methods of aircraft manufacturing and maintenance.

[0036] Figure 25 It is a block diagram of an airplane. Detailed Implementation

[0037] First refer to Figure 1 and Figure 2 The composite stringer 30 comprises a composite laminate consisting of fiber-reinforced layers of polymers (such as thermosetting or thermoplastic polymers). In the illustrated example, the composite stringer 30 is a cap-shaped stringer comprising a cap-shaped portion 36 and a pair of outwardly extending flanges 44. The cap-shaped portion 36 includes a top cover 40, which is connected to the flanges 44 via a pair of inclined sides 42 (sometimes referred to as webs). Although the disclosed embodiments are described in conjunction with cap-shaped stringers, composite stringers having any of a wide variety of cross-sectional shapes can be produced using the principles of the disclosed embodiments.

[0038] specifically refer to Figure 1 , Figure 3 and Figure 4The composite stringer 30 includes one or more out-of-plane features 34 along its length. In the illustrated example, the out-of-plane feature 34 is a bend 35, which includes an upslope / downslope 46 along its length that is shaped like the cross-section of the composite stringer 30. However, the bend 35 is merely an example of a wide range of possible out-of-plane features 34 that may be required in a particular application within the composite stringer 30. In the illustrated example, the composite stringer 30 is attached to the skin 32 by any suitable technique, such as co-curing, bonding, or fasteners. The skin 32 includes a liner 48 made of composite layer 50, which may be needed to locally reinforce an area of ​​the skin 32 or for other reasons. The bend 35 bridges over the liner 48 and has a length and profile that closely matches the cross-sectional shape of the liner 48. Although the composite stringer 30 is shown as having only one bend 35, it may have any number of bends 35 with the same or different profiles, depending on the application, in order to accommodate various features or other conditions present on the skin 32.

[0039] Figures 5 to 7 A tool set 52 is illustrated, which is used to form a composite blank 72 into a composite stringer 30 having a bend 35. The tool set 52 includes a tool 54 and a die 59. In this example, the tool 54 is a punch 56, and the die 59 includes a pair of die portions 60 spaced apart to form a die cavity 64. The punch 56 may be formed from a flexible material such as an elastomer, nylon, or PTFE (polytetrafluoroethylene) (to name just a few), allowing it to bend as needed. In the illustrated example, the punch 56 is mounted on the bottom of a top plate 58, which is flexible and may include, for example, but not limited to, an aluminum sheet. However, in other examples, the top plate 58 may also be an elastomer or other polymer integrally formed with the punch 56. The cross-sectional shape of the punch 56 corresponds to the cap-shaped portion 36 of the composite stringer 30. Figure 2 The IML (inner mold line) of the model is basically matched.

[0040] The mold section 60 is mounted to facilitate lateral movement 66 on the base plate 62. In one example, the mold section 60 includes a series of interconnected mold blocks that allow the mold section 60 to bend out of plane. A pair of side plates 70 are fixed to the base plate 62 on the outside of the mold section 60. Inflatable side air bladders 68 are located between the mold section 60 and the side plates 70, respectively. The side air bladders 68 can be inflated by a fluid such as air and are used to control the outward lateral movement of the mold section 60 during the forming process. A tool assembly 52 can be mounted in a press (not shown) that moves the top plate 58 and the base plate 62 relative to each other, thereby causing the punch 56 to move into the mold cavity 64 with a desired force and at a desired rate.

[0041] In the illustrated example, the punch 56 is substantially straight along its length. However, in other examples discussed below, the punch 56 may have one or more bends along its length. To form bends 35 or other out-of-plane features 34 in the composite stringer 30, a shim 74 is mounted above the punch 56, the shim 74 having a surface profile that substantially matches the bend 35. The shim 74 can be releasably attached to the punch 56 and / or the top plate 58 by any suitable means such as double-sided tape, a mechanical latch (not shown), or a magnetic latch discussed later. Thus, shims 74 of different shapes can be interchangeably mounted on the same punch 56 to form different out-of-plane features. Depending on the application, it may be necessary to also mount a shim 76 on top of the die section 60.

[0042] The gasket 74 includes a top cover 80, sides 82, and flange 84 that form a profile substantially matching the IML of the bend 35. The thickness T of the gasket 74, and other dimensions or features, will depend on the application and the geometry / size of the bend 35. The gasket 74 includes an up-slope / down-slope 78 at its outer end, forming a smooth transition between the gasket 74 and the body of the punch 56. The gasket 74 can be formed from any suitable material by any of a variety of manufacturing processes. For example, the gasket 74 may comprise laser-sintered nylon produced by 3D printing or photocured epoxy. Although only a single gasket 74 is illustrated in the figures, any number of gaskets 74 can be installed at any location along the length of the punch 56 to form corresponding out-of-plane features in the composite stringer 30.

[0043] The stringer forming operation begins as follows Figure 5 The tool assembly 52 is arranged as shown, with the punch 56 in an elevated position. A composite blank 72 (flat in this example) is placed on top of the die section 60, spanning the die cavity 64. To shape the composite blank 72 into the desired cross-sectional shape of the composite stringer 30, the top plate 58 moves downward, causing the punch 56 to form the composite blank 72 into the die cavity 64. As the punch 56 shapes the composite blank 72 into the cross-sectional shape of the composite stringer 30, a shim 74 also forms a bend 35 or other out-of-plane feature in the composite stringer 30. Thus, while the stringer 30 is being shaped into the desired cross-sectional shape, an out-of-plane feature 34 is formed in the stringer 30. The simultaneous forming of the stringer 30 and the out-of-plane feature 34 reduces strain in the stringer 30 that could cause wrinkling and resin aggregation during the forming process.

[0044] In some examples, the composite stringer 30 can be formed along its length into a desired profile in a secondary forming operation, in which the punch 56 and the die 59 are formed by a suitable profile-changing mechanism (not shown). To enable the spacer 74 to bend while the punch 56 is forming the profile, the spacer 74 is provided with a set of first openings 86 in the form of slots, extending completely across the top cover 80 and the sides 82 of the spacer 74. Optionally, the spacer 74 may also include a set of second openings 88, which may also be in the form of slots, extending completely across the top cover 80 but only partially through the sides 82 of the spacer 74. The second openings 88 reduce wrinkling or buckling of the composite stringer 30 as it is forming the profile.

[0045] Also refer to Figure 10 and Figure 11 As the composite stringer 30 is forming its profile, the first opening 86 can be partially or completely closed 92, thereby allowing the gasket 74 to bend together with the punch 56. However, during the profile formation, the second opening 88 remains open, causing the composite blank 72 to strain into the second opening 88, where it forms relatively small folds 90, thus having no substantial impact on stringer performance.

[0046] As previously mentioned, the shim 74 is releasably attached to the tool 54. The shim 74 can be releasably attached to the tool 54 using a magnet 96, thereby enabling easy installation and removal of the shim 74 to provide a variety of bend locations and conditions. The use of the magnet 96 also facilitates the interchangeability of multiple shims 74 in different configurations with a single tool. Figure 12 An example of a gasket attachment technique is illustrated, which includes one or more magnetic latches 100, each magnetic latch including a magnet 96 embedded in a flange 84 of a gasket 74. In this example, a top plate 58 is formed of a magnetic material or a flexible adhesive material containing a magnetic material. The top plate 58 is attracted to the magnet 96, thereby releasably locking the gasket 74 to a tool 54.

[0047] Figure 13 Another example of a magnetic latch 100 is illustrated, in which a magnetic material insert 94 is built into a top plate 58 and aligned with a magnet 96 built into a flange 84 of a gasket 74.

[0048] Figure 14 Another example of the magnetic latch 100 is illustrated, wherein a magnetic material insert 94 is built into the flange 84 of the gasket 74. An electromagnet 98 mounted on or built into the top plate 58 is energized to attract the magnetic material insert 94, thereby releasably holding the gasket 74 onto the tool 54. Other combinations of magnets and magnetic materials can be used to magnetically attach the gasket 74 to the tool 54.

[0049] The focus now is on Figures 15 to 17 , Figures 15 to 17 Examples of series 102a, 102b, 102c of shims 74 are shown, which can be used to form any of the various out-of-plane features such as bends in composite stringers 30. By providing one or more series 102a, 102b, 102c of shims 74 with different properties commonly used to form out-of-plane features, custom manufacturing of shims to meet the requirements of specific applications can be avoided. Shims 74 can be designed to achieve various bend conditions used in multiple stringers 30. For example, stringers 30 having bends 35 with a slope or height within a specified range can all use the same shims 74. Therefore, it may be desirable to provide a series of shims 74 (each shim having unique properties), thereby allowing the selection of a specific shim from this series of shims 74 for forming bends 35 in any of the multiple stringers 30.

[0050] Any desired characteristics of gasket 74 can be designed to vary within series 102a, 102b, and 102c. For example, Figure 15 Example 102a of gasket 74 is given, wherein the ramp angle RA can be linearly or non-linearly from RA1 to RA2. n Internal changes. Figure 16 Series 102b of gasket 74 is illustrated, wherein the length of gasket 74 may be linear or non-linear from L1 to L n Internal changes. Figure 17 Series 102c of gasket 74 is illustrated, wherein the height of gasket 74 may be linearly or non-linearly varying from H1 to H. n Internal variations. Although not shown in the figure, a series 102 of gaskets 74 may also be provided, including variations in multiple gasket characteristics, such as ramp angle, length and / or height (to name a few).

[0051] Figure 18 The steps of a method for manufacturing a composite stringer 30 having one or more out-of-plane features 34 are generally illustrated. Starting at step 104, a shim 74 is mounted on a tool 54. In step 106, the composite blank 72 is shaped into the composite stringer 30 using the tool 54, which includes forming the out-of-plane features 34 in the composite blank 72 using the shim 74 while forming the composite blank 72 through the tool 54. The use of the shim 74 allows for the formation of the out-of-plane features 34 in the stringer 30 simultaneously with, rather than subsequently in, a secondary forming operation. The simultaneous formation of the out-of-plane features 34 and the shape of the stringer 30 reduces strain in areas of the stringer 30, particularly the top cap 40 and the sides 42, that could cause delamination and / or resin buildup.

[0052] The focus now is on Figure 19 and Figure 20 , Figure 19 and Figure 20 An example of a tool 56 in the form of a compactor 108 is illustrated, which can be used to form, transport, and / or compact a composite stringer 30, in this example, the composite stringer 30 being a cap-shaped stringer. The compactor 108 includes a one-piece cap-shaped body 110 and an integral flange 112 formed of a flexible material such as an elastomer. The cap-shaped body 110 includes an inner cavity 120 and a series of openings 114, which may include slots arranged along the length of the compactor 108. In some examples, the openings 114 may be configured to redirect stresses formed in the composite blank 72 during the contouring of the composite stringer 30, thereby reducing stringer wrinkling. The compactor 108 includes an end wall 116 provided with a fitting 118 adapted to connect the inner cavity 120 to a vacuum source (not shown). A vacuum applied to the inner cavity 120 causes air to be drawn in through the openings 114, thereby creating a suction effect.

[0053] When the compactor 108 is placed within the correspondingly shaped composite stringer 30 and a vacuum is drawn into the compactor 108, the composite stringer 30 is drawn into the compactor 108, thereby enabling the compactor 108 to pick up the composite stringer and transport it to a desired location, such as to a forming station or a mating pallet (neither shown). One or more gaskets 74 may be attached at any location along the length of the compactor 108 to form and / or compact one or more out-of-plane features 34 in the composite stringer 30, functioning similarly to the gaskets 74 attached to the previously described punch 56. The gaskets 74 include openings 86 such as slots that allow air to pass through the gaskets 74 and be drawn into the cavity 120 of the compactor 108.

[0054] Figure 21 A general example of using Figure 19 The steps of the method for forming and transporting the composite stringer 30 using the compactor 108 are as follows: Starting at step 122, one or more shims 74 are attached to the compactor 108. In step 124, the compactor 108 is used as a forming tool to form the composite blank 72 into the composite stringer 30. In step 126, using the shims 74 attached to the compactor 108, local out-of-plane features are formed in the composite blank 72 while it is being formed. Optionally, in step 128, after the composite blank 72 has been formed into the composite stringer 30, the shims 74 can be removed from the compactor 108. In step 130, the compactor 108 can be used to pick up the composite stringer 30 and transport it to a desired location, such as to a mating pallet, compactor, or storage location.

[0055] Figure 22 It is shown that the compactor 108 has been used through the opening 114 ( Figure 19The suction force of the pump picks up the composite stringer 30 and immediately lowers it 138 into the mold cavity 132 in the forming mold 134. The forming mold 134 includes a mold surface 136 that forms a profile along its length. After the composite stringer 30 is placed in the mold cavity 132, forming pressure is applied to the compactor 108, causing the composite stringer 30 to be formed into the profile of the mold cavity 132. In addition, a gasket 74 forms an out-of-plane feature in the composite stringer 30 during this profile forming process. Additional pressure applied to the compactor 108 by any suitable device such as a vacuum bag (not shown) causes the composite stringer to be compacted onto the forming mold 134.

[0056] Figure 23 The steps of a method for compacting a composite stringer 30 and / or shaping it into a desired profile including one or more out-of-plane features 34 are generally illustrated. Beginning at step 140, a composite blank 72 is stamped into a composite stringer 30 having the desired cross-sectional shape. Next, in step 142, one or more shims 74 are mounted on a compactor 108. In step 144, the composite stringer 30 is picked up using the compactor 108 and conveyed to a forming die 134 or a mating pallet. In step 146, the composite stringer 30 is shaped and / or compacted using the compactor 108 with the shims 74 mounted thereon. In step 148, local out-of-plane features are formed in the composite stringer 30 using the shims 74 during the forming / compacting process.

[0057] Examples of this disclosure can be found in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace, marine, automotive applications, and other applications in which composite reinforcements (such as composite stringers in aircraft) can be used. Therefore, reference is now made to… Figure 24 and Figure 25 , can be as Figure 24 The aircraft manufacturing and maintenance methods 150 shown and such Figure 25 Examples of this disclosure are used in the context of the aircraft 152 shown. Aircraft applications of the disclosed examples may include various composite stringers, such as those in an aircraft, having profiles, bends, varying thicknesses, and / or one or more out-of-plane features along their length. In the early stages of production, exemplary method 150 may include the specification and design 154 of the aircraft 152 and material procurement 156. During production, the manufacturing of components and sub-assemblies of the aircraft 152 and system integration 160 are performed. Thereafter, the aircraft 152 may be inspected and delivered 162 for entry into service 164. During customer entry into service, the aircraft 152 is scheduled for routine maintenance and overhauls 166, which may also include modifications, refits, refurbishments, etc.

[0058] Each process of method 150 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0059] like Figure 25 As shown, an aircraft 152 produced using the exemplary method 150 may include a fuselage 168 having multiple advanced systems 170 and an interior 172. Examples of advanced systems 170 include one or more of a propulsion system 174, an electrical system 176, a hydraulic system 178, and an environmental system 180. Any number of other systems may be included. Although an aerospace example is shown, the principles of this disclosure can be applied to other industries such as the marine and automotive industries.

[0060] The systems and methods implemented herein may be employed during any one or more stages of the aircraft manufacturing and maintenance method 150. For example, components or sub-assemblies corresponding to production process 158 may be made or manufactured in a manner similar to the production of components or sub-assemblies of aircraft 152 in service. Additionally, one or more equipment examples, method examples, or combinations thereof may be utilized during production processes 158 and 160, for example, by significantly accelerating the assembly of aircraft 152 or reducing the cost of aircraft 152. Similarly, one or more equipment examples, method examples, or combinations thereof may be utilized when aircraft 152 is in service (e.g., but not limited to maintenance and overhaul 166).

[0061] This disclosure includes exemplary implementations in accordance with the following terms.

[0062] Clause 1. An apparatus for manufacturing a composite stringer (30) having at least one out-of-plane feature (34), said apparatus comprising:

[0063] Mold (59), which includes a mold cavity (64);

[0064] Tool (54), configured to form composite blank (72) into the mold cavity (64); and

[0065] A gasket (74) is attached to the tool (54) and configured to form an out-of-plane feature (34) in the composite stringer (30) as the tool (54) shapes the composite blank (72) into the mold cavity (64).

[0066] Clause 2. The device according to Clause 1, wherein the tool (54) is a punch (56) having a cross-sectional profile that matches the cross-sectional profile of the composite stringer (30).

[0067] Clause 3. The device according to Clause 1, wherein the tool (54) is a compactor (108) configured to compact the composite stringer (30).

[0068] Clause 4. The equipment according to any one of Clauses 1 to 3, wherein:

[0069] The tool (54) has a length; and

[0070] The gasket (74) extends laterally across the tool (54) and is configured to modify the outer contour of the tool (54) along a portion of the length of the tool (54).

[0071] Clause 5. The device according to any one of Clauses 1 to 4, wherein the out-of-plane feature (34) is a bend (35) in the composite stringer (30).

[0072] Clause 6. The device according to any one of Clauses 1 to 5, wherein the composite stringer (30) is a cap stringer, and the gasket (74) includes a pair of flanges (84) and cap portions (80, 82) covering a portion of the length of the tool (54) of the tool (54).

[0073] Clause 7. The device according to any one of Clauses 1 to 6, wherein the gasket (74) comprises:

[0074] A set of first openings (86) that allow the gasket (74) to bend; and

[0075] A second set of openings (88) are provided, into which the composite blank (72) can be strained when the tool (54) forms the composite blank (72).

[0076] Clause 8. The device according to any one of Clauses 1 to 7, the device further comprising a magnetic latch (100) configured to releasably attach the pad (74) to the tool (54).

[0077] Clause 9. The device according to Clause 8, wherein the magnetic latch (100) comprises:

[0078] At least one magnet (96) is mounted on one of the tool (54) and the pad (74); and

[0079] An element (94) made of magnetic material is mounted on the other of the tool (54) and the pad (74) and is configured to be magnetically attracted to the magnet (96).

[0080] Clause 10. An apparatus for manufacturing composite stringers, said apparatus comprising:

[0081] Punch head (56);

[0082] The mold (59) is capable of forming the composite blank (72) into the mold (59) by means of the punch (56); and

[0083] A series of gaskets (102) are configured to form different features (34) in the composite blank (72).

[0084] Each gasket (74) is configured to be releasably attached to the punch (56).

[0085] Clause 11. The device as described in Clause 10, wherein:

[0086] Each pad (74) includes a length (L), a height (H), and a ramp (78) with a ramp angle (RA), and

[0087] The gaskets (74) differ from each other in at least one of the following aspects: length (L), height (H), and slope angle (RA).

[0088] Clause 12. The apparatus according to Clause 10 or 11, wherein at least one of the gaskets (74) comprises:

[0089] A set of first openings (86) that allow the gasket (74) to bend; and

[0090] A second opening (88) is provided, into which the composite blank (72) can be strained when the punch (56) forms the composite blank (72).

[0091] Clause 13. The device according to any one of Clauses 10 to 12, wherein at least one of the different features (34) is a bend (35) in the composite stringer (30).

[0092] Clause 14. The device according to any one of Clauses 10 to 13, wherein the composite stringer (30) has a cap-shaped cross section (36) and the gasket (74) has a cross-sectional shape (80, 82, 84) matching the cap-shaped cross section (36).

[0093] Clause 15. A method for manufacturing a composite stringer (30) having an out-of-plane feature (34) into a net shape, said method comprising:

[0094] Install the gasket (74) onto the tool (54); and

[0095] The composite blank (72) is formed into the composite stringer (30) using the tool (54), which includes using the shim (74) to form out-of-plane features (34) in the composite blank (72) when forming the composite blank (72) by the tool (54).

[0096] Clause 16. The method according to Clause 15, wherein installing the gasket (74) comprises: magnetically attaching the gasket (74) to the tool (54).

[0097] Clause 17. The method according to Clause 15 or 16, wherein forming the composite blank (72) into the composite stringer (30) comprises: stamping the composite blank (72) into a die cavity (64).

[0098] Clause 18. The method according to any one of Clauses 15 to 17, said method further comprising:

[0099] A plurality of openings (86) are formed in the gasket (74), thereby allowing the gasket (74) to bend (92); and

[0100] To form the profile of the composite stringer (30), this includes bending the gasket (74).

[0101] Clause 19. The method according to any one of Clauses 15 to 18, said method further comprising:

[0102] The composite stringer (30) is picked up and transported using the tool (54).

[0103] Clause 20. The method described in Clause 19, further comprising:

[0104] After transport, the composite stringers (30) are compacted using the tool (54).

[0105] As used herein, the phrase “at least one” when used with a list of items means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, “at least one of item A, item B, and item C” may include, but is not limited to, item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. The item may be a specific thing, thing, or category. In other words, “at least one” means that any combination of items and multiple items may be applicable to the list, and not all items in the list are required.

[0106] Various illustrative examples have been shown for purposes of illustration and description, but this description is not intended to be exclusive or limited to the examples of the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different illustrative examples may offer different advantages compared to other illustrative examples. One or more examples have been selected and described in order to best illustrate the principles and practical applications of the examples, and to enable those skilled in the art to understand that this disclosure contains various examples with various modifications suitable for the particular intended use.

Claims

1. An apparatus for manufacturing a composite stringer (30) having at least one out-of-plane feature (34), the apparatus comprising: Mold (59), which includes mold cavity (64); Tool (54), which is configured to form the composite blank (72) into the mold cavity (64); as well as A gasket (74), attached to the tool (54) and configured to form an out-of-plane feature (34) in the composite stringer (30) as the tool (54) shapes the composite blank (72) into the mold cavity (64), wherein the gasket (74) comprises: A set of first openings (86) that allow the gasket (74) to bend; and A second set of openings (88) allows the composite blank (72) to be strained into the second openings (88) when the composite blank (72) is formed by the tool (54). The first set of openings (86) are in the form of slots, extending completely across the top cover (80) and side (82) of the gasket (74), and The set of second openings (88) are in the form of slots, extending completely across the top cover (80) but only partially through the side (82) of the gasket (74).

2. The device according to claim 1, wherein, The tool (54) is a punch (56) having a cross-sectional profile that matches the cross-sectional profile of the composite stringer (30).

3. The device according to claim 1, wherein, The tool (54) is a compactor (108) configured to compact the composite stringer (30).

4. The device according to any one of claims 1 to 3, wherein: The tool (54) has a length; and The gasket (74) extends laterally across the tool (54) and is configured to modify the outer contour of the tool (54) along a portion of the length of the tool (54).

5. The device according to any one of claims 1 to 3, wherein, The out-of-plane feature (34) is the bend (35) in the composite stringer (30).

6. The device according to any one of claims 1 to 3, wherein, The composite stringer (30) is a cap-shaped stringer, and the gasket (74) includes a portion along the length of the tool (54) covering a pair of flanges (84) and a cap-shaped portion of the tool (54).

7. The device according to any one of claims 1 to 3, the device further comprising a magnetic latch (100) configured to releasably attach the pad (74) to the tool (54).

8. The device according to claim 7, wherein, The magnetic latch (100) includes: At least one magnet (96) is mounted on one of the tool (54) and the pad (74); and An element (94) formed of magnetic material is mounted on the other of the tool (54) and the pad (74) and is configured to be magnetically attracted to the magnet (96).

9. An apparatus for manufacturing composite stringers, the apparatus comprising: Punch (56); The mold (59) can form the composite blank (72) into the mold (59) through the punch (56); as well as A series of gaskets, each configured to form different features (34) in the composite blank (72). Each gasket (74) is configured to be releasably attached to the punch (56), wherein at least one of the gaskets (74) includes: A set of first openings (86) that allow the gasket (74) to bend; and A second opening (88) is provided, into which the composite blank (72) can be strained during the forming of the composite blank (72) by the punch (56). The first set of openings (86) are in the form of slots, extending completely across the top cover (80) and side (82) of the gasket (74), and The set of second openings (88) are in the form of slots, extending completely across the top cover (80) but only partially through the side (82) of the gasket (74).

10. The device according to claim 9, wherein: Each pad (74) includes a length (L), a height (H), and a ramp (78) with a ramp angle (RA), and The gaskets (74) differ from each other in at least one of the length (L), the height (H), and the slope angle (RA).

11. The device according to claim 9 or 10, wherein, At least one of the different features (34) is a bend (35) in the composite stringer (30).

12. The device according to claim 9 or 10, wherein, The composite stringer (30) has a cap-shaped cross section (36), and the gasket (74) has a cross section shape that matches the cap-shaped cross section (36).

13. A method for manufacturing a composite stringer (30) having out-of-plane features (34) into a net shape, the method comprising: Install the gasket (74) onto the tool (54); and The composite blank (72) is shaped into the composite stringer (30) using the tool (54), which includes using the shim (74) to form out-of-plane features (34) in the composite blank (72) while shaping the composite blank (72) by the tool (54). The gasket (74) includes: A set of first openings (86) that allow the gasket (74) to bend; and A second set of openings (88) allows the composite blank (72) to be strained into the second openings (88) when the composite blank (72) is formed by the tool (54). The first set of openings (86) are in the form of slots, extending completely across the top cover (80) and side (82) of the gasket (74), and The set of second openings (88) are in the form of slots, extending completely across the top cover (80) but only partially through the side (82) of the gasket (74).

14. The method according to claim 13, wherein, Installing the gasket (74) includes: magnetically attaching the gasket (74) to the tool (54).

15. The method according to claim 13 or 14, wherein, Forming the composite blank (72) into a composite stringer (30) includes: stamping the composite blank (72) into a mold cavity (64).

16. The method according to claim 13 or 14, further comprising: To form the profile of the composite stringer (30), this includes bending the gasket (74).

17. The method according to claim 13 or 14, further comprising: The composite stringer (30) is picked up and transported using the tool (54).

18. The method according to claim 17, further comprising: After transport, the composite stringers (30) are compacted using the tool (54).

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