Forming Tool And Methods For Forming A Curvature Into A Composite Stiffener

{
  "publication_number": "US2021179292A1",
  "country": "US",
  "kind": "A1",
  "title": "Forming Tool And Methods For Forming A Curvature Into A Composite Stiffener",
  "abstract": "Methods of forming a curvature into a composite stiffener and a forming tool are presented. The composite stiffener is positioned in a forming region created by a base assembly and an upper assembly. A first airflow is applied through the material of the base assembly. A second airflow is applied through the material of the upper assembly. A plurality of brackets of the upper assembly is moved relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener.",
  "claims": [
    "1. A forming tool comprising: a base assembly formed by a plurality of segments and a material for distributing a first airflow to a forming region created by the base assembly and an upper assembly, the first airflow providing an air bearing or a holding force; the upper assembly comprising a plurality of brackets and material for distributing a second airflow to the forming region in an opposite direction to the first airflow; and actuators connected to the plurality of brackets and the plurality of segments, the actuators configured to move each of the plurality of segments relative to each other to change a curvature of the forming region along a length of the forming region. 2. The forming tool of claim 1, wherein the plurality of brackets comprises pairs of brackets, each pair individually moveable relative to a longitudinal axis of the forming region. 3. The forming tool of claim 2, wherein the actuators comprise a number of actuators connected to the plurality of brackets such that the number of actuators move each pair of the plurality of brackets independently relative to the remaining brackets of the plurality of brackets. 4. The forming tool of claim 3, wherein the actuators are connected to the plurality of brackets and the plurality of segments such that the actuators change the curvature of the forming region while maintaining a cross-section of the forming region. 5. The forming tool of claim 4 further comprising: a controller configured to send commands to at least one of the actuators to change the curvature of the forming region according to NC programming, air pressure sources to control at least one of the first airflow or the second airflow, actuated locks configured to selectively restrain the plurality of segments relative to compliant connectors, or actuated locks configured to selectively restrain the plurality of brackets relative to compliant connectors. 6. The forming tool of claim 1, wherein the material for distributing the second airflow is formed of a porous material to provide the second airflow to the forming region. 7. The forming tool of claim 1, wherein the material for distributing the second airflow includes at least one of perforations or channels to provide the second airflow to the forming region. 8. The forming tool of claim 1, wherein the material for distributing the first airflow is formed of a porous material to provide the first airflow to the forming region. 9. The forming tool of claim 1, wherein the material for distributing the first airflow of the base assembly includes at least one of perforations or channels to provide the first airflow to the forming region. 10. The forming tool of claim 1 further comprising: compliant connectors extending through and connecting the plurality of segments; and actuated locks configured to selectively restrain the plurality of segments relative to the compliant connectors. 11. The forming tool of claim 1 further comprising: compliant connectors extending through and connecting the plurality of brackets; and actuated locks configured to selectively restrain the plurality of brackets relative to the compliant connectors. 12. The forming tool of claim 1 further comprising: air pressure sources pneumatically connected to at least one of the material or the plurality of segments of the base assembly to provide the first airflow through the material; and air pressure sources pneumatically connected to at least one of the material or the plurality of brackets of the upper assembly to provide the second airflow through the material. 13. (canceled) 14. A method of forming a curvature into a composite stiffener, the method comprising: positioning the composite stiffener over a segment of a base assembly; placing a pair of brackets of an upper assembly over the composite stiffener to form a forming region having a cross-section; and moving the segment and the pair of brackets within a manufacturing environment while maintaining the cross-section of the forming region to form the curvature into the composite stiffener. 15. The method of claim 14, wherein moving the segment and the pair of brackets is part of synchronized movement of a plurality of brackets of the upper assembly and a plurality of segments of the base assembly to form the curvature into the composite stiffener. 16. The method of claim 14 further comprising: sending a first airflow through material of the base assembly in a first direction relative to the forming region, wherein the first direction is one of positive airflow or negative airflow; and sending a second airflow through material of the upper assembly in a second direction relative to the forming region, wherein the second direction is opposite the first direction. 17. The method of claim 14 further comprising: sending a second airflow through material of the upper assembly to the forming region, wherein sending the second airflow through the material of the upper assembly comprises sending a negative airflow through the material associated with at least one bracket of a plurality of brackets of the upper assembly to the forming region and sending a positive airflow through the material associated with at least one bracket of the plurality of brackets to the forming region. 18. The method of claim 14 further comprising: sending a first airflow through material of the base assembly to the forming region, wherein sending the first airflow through the material comprises sending a negative airflow through a portion of the material associated with at least one segment of a plurality of segments of the base assembly to the forming region and sending a positive airflow through a portion of the material associated with at least one segment of the plurality of segments to the forming region. 19. (canceled) 20. A method of forming a curvature into a composite stiffener, the method comprising: positioning the composite stiffener in a forming region created by a base assembly and an upper assembly; applying a first airflow through a material of the base assembly; applying a second airflow through a material of the upper assembly; and moving a plurality of brackets of the upper assembly relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener. 21. The method of claim 20, wherein the second airflow through the material of the upper assembly has an opposite direction to the first airflow through the material of the base assembly of an associated segment of the base assembly. 22. The method of claim 20, wherein moving the plurality of brackets relative to each other comprises moving the plurality of brackets as pairs perpendicular relative to a longitudinal axis of the composite stiffener. 23. The method of claim 22, wherein moving the plurality of brackets relative to each other comprises rotating a pair of the plurality of brackets around the longitudinal axis of the composite stiffener to introduce a roll into the composite stiffener. 24. The method of claim 22, wherein moving the plurality of brackets relative to each other comprises moving a pair of the plurality of brackets in a first direction relative to the longitudinal axis of the composite stiffener to introduce a pitch into the composite stiffener. 25. The method of claim 22, wherein moving the plurality of brackets relative to each other comprises moving a pair of the plurality of brackets in a second direction relative to the longitudinal axis of the composite stiffener to introduce a yaw into the composite stiffener. 26. The method of claim 20 further comprising: moving a plurality of segments of the base assembly relative to each other as the plurality of brackets is moved relative to each other to maintain a cross-section of the forming region, wherein moving the plurality of segments relative to each other comprises moving the plurality of segments perpendicular relative to a longitudinal axis of the forming region. 27. The method of claim 20 further comprising: curing the composite stiffener after forming the curvature into the composite stiffener. 28. The method of claim 27 further comprising: removing the plurality of brackets from the composite stiffener; and lifting the composite stiffener with the curvature from the base assembly, wherein the curing is performed after lifting the composite stiffener. 29. The method of claim 27 further comprising: removing the plurality of brackets from the composite stiffener; and positioning a number of caul plates on the composite stiffener. 30. (canceled)"
  ],
  "cpc": [
    "B29D 99/0003",
    "B29C 2043/3222",
    "B29C 2043/3618",
    "B29C 33/302",
    "B29C 33/308",
    "B29C 33/3814",
    "B29C 43/10",
    "B29C 70/44",
    "B29C 70/462",
    "B29L 2031/3085",
    "B64F 5/10"
  ],
  "assignees": [
    "BOEING CO"
  ],
  "filing_date": "2019-12-13",
  "publication_date": "2021-06-17",
  "priority_date": "2019-12-13",
  "application_number": "US-201916713902-A",
  "family_id": "73834259",
  "citations": [
    "US2016375631A1"
  ]
}