Composite Stiffener Layup Using Segmented Charges on Curved Tools

Solution Overview

Problem

The challenge in manufacturing composite stiffeners lies in efficiently placing composite material strips in non-zero orientations, such as ±45° and 90°, which requires repeated laying and cutting, making the process slow and costly.

Innovation Solution

The system employs a support surface, sheet-locating device, separation device, layup tool, compaction device, and tool-positioning device to facilitate the formation of composite stiffeners by extending composite sheet portions beyond the support surface, separating them to form charges, and compacting them on a curved layup surface with a compaction force normal to the surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If composite material strips are placed in non-zero orientations (±45° and 90°) by repeated laying and cutting, then the desired stiffener geometry is achieved, but the manufacturing process becomes slow and costly

Engineering Contradiction:

Improvestiffener geometryVSAvoidmanufacturing speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The composite sheet is divided into multiple charges by the separation device, allowing each charge to be positioned and compacted independently. This segmentation enables efficient creation of complex geometries including non-zero orientations without repeated laying and cutting operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The layup tool is positioned at various angles relative to the compaction device, introducing angular dimensionality to the layup process. This allows composite charges to be placed in non-zero orientations (±45° and 90°) directly, eliminating the need for repeated cutting and re-laying operations

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Shape

If composite material strips are placed in non-zero orientations (±45° and 90°) by repeated laying and cutting, then the desired stiffener geometry is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improvestiffener geometryVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The composite sheet is divided into multiple charges by the separation device, allowing each charge to be positioned and compacted independently. This segmentation enables efficient creation of complex geometries including non-zero orientations without repeated laying and cutting operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The layup tool is positioned at various angles relative to the compaction device, introducing angular dimensionality to the layup process. This allows composite charges to be placed in non-zero orientations (±45° and 90°) directly, eliminating the need for repeated cutting and re-laying operations

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If the compaction force is applied normal to the curved layup surface, then proper compaction of composite charges is achieved, but the tool positioning complexity increases

Engineering Contradiction:

Improvecompaction qualityVSAvoidtool positioning system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The tool-positioning device dynamically adjusts the layup tool's angular position relative to the compaction device, allowing the compaction force to remain normal to the curved layup surface throughout the compaction process. This dynamic positioning ensures proper compaction quality while accommodating the curvature of the layup surface

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The tool-positioning device acts as an intermediary between the layup tool and compaction device, coordinating their relative positions and movements to ensure the compaction force is applied normal to the curved layup surface, thereby simplifying the control of complex positioning requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12515420B2Method for forming a composite stiffener

Publication Date: 2026.01.06 THE BOEING CO

AI summary

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