Corrugated Composite Stringer Forming Tool
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Solution Overview
Problem
Current methods for constructing fiber reinforced composite stringers in aerospace structures, such as fuselages, cannot form multiple stringers from a single unitary piece of composite material while meeting the necessary specifications for bridging between the stringer body and adjacent flange.
Innovation Solution
A tool with forming blocks, a compaction mechanism, and a block translating mechanism is used to form corrugated structures from pliable blanks, allowing for the creation of stiffened composite structures by translating valley forming blocks towards ridge forming blocks to define a corrugated form, which can be used to construct stringers that meet the required specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fiber reinforced composite stringers are formed individually and coupled to the skin in an outer mold line layup arrangement, then the stringers can be manufactured separately, but the manufacturing process becomes complex and time-consuming with multiple assembly steps
Solution Approach 1:
The patent combines multiple stringers into a single integrated composite structure that is formed as one unitary piece. This merging of multiple stringers into a single manufactured component eliminates the need for separate stringer manufacturing and assembly operations, directly reducing assembly process complexity while maintaining manufacturing flexibility through the modular corrugated design
Solution Approach 2:
The patent segments the stringer structure into distinct functional zones (body portions and flange portions) within a single integrated component. This segmentation allows different regions to be optimized for their specific functions while being manufactured as one piece, reducing assembly steps while maintaining design flexibility
2Device complexity
If multiple stringers are constructed from the same unitary piece of composite material, then assembly complexity is reduced, but meeting the requisite specifications for bridging between the body and adjacent flange becomes difficult
Solution Approach 1:
The patent employs a dynamic forming process where a mold is configured to receive and form the pliable composite blank into the desired corrugated stringer shape. The mold includes specific features (such as a first portion and a second portion that can be positioned relative to each other) that enable precise control over the bridging geometry, allowing the single unitary piece to meet the requisite bridging specifications between body and flange portions
Solution Approach 2:
The patent changes the physical state of the composite material from a pliable blank to a cured corrugated stringer structure through controlled forming and curing processes. This parameter change allows the material to be shaped into precise geometries meeting specification requirements while maintaining the benefits of single-piece construction
3Productivity
If a single unitary piece of composite material is used to construct multiple stringers, then production efficiency improves, but the structural requirements for bridging between body and flange become harder to meet
Solution Approach 1:
The patent incorporates preliminary forming actions within the mold design, where the pliable composite blank is pre-shaped into the corrugated stringer configuration before final curing. The mold includes predetermined geometries (first portion and second portion) that guide the material into the correct bridging configurations, ensuring specification compliance is achieved during the forming process itself rather than requiring post-processing
Solution Approach 2:
The patent uses the mold as an intermediary tool that translates the design specifications into the physical stringer geometry. The mold's specific features (first portion, second portion, and their relative positioning) act as mediators that ensure the single unitary piece meets the requisite bridging specifications while being manufactured efficiently as one component
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient formation of stiffened composite structures with corrugated stringers that meet the necessary strength and stiffness requirements, facilitating the construction of aerospace components like fuselages with improved structural integrity.
Implementation Method 1
a compaction mechanism configured to selectively conform the pliable blank to the corrugated form
Data Source
AI summary
Tools for forming a corrugated structure from a pliable blank include a plurality of forming blocks that laterally move relative to each other, a compaction mechanism configured to selectively conform the pliable blank to the forming blocks, and a block translating mechanism configured to reconfigure the tool from a pre-formed configuration to a post-formed configuration, in which the forming blocks are positioned closer together than when the tool is in the pre-formed configuration. Associated systems, methods, and apparatuses also are disclosed herein.