US011370159B2

( 12 ) United States Patent ( 10) Patent No .: US 11,370,159 B2

Chapman et al. (45 ) Date of Patent : Jun . 28 , 2022
( 54 ) APPARATUS FOR FORMING A ( 56 ) References Cited
CONTOURED HAT STIFFENER
U.S. PATENT DOCUMENTS
( 71 ) Applicant: The Boeing Company , Chicago , IL
( US ) 1,433,879 A 10/1922 Fancher et al .
1,965,716 A 7/1934 Thoms et al .
( 72 ) Inventors: Michael Robert Chapman , Federal (Continued )
Way, WA (US ) ; Gordon Dale Davis , FOREIGN PATENT DOCUMENTS
Marysville, WA ( US )
( 73 ) Assignee: The Boeing Company , Chicago , IL CA 2487697 A1 5/2006
( US ) DE 742682 C 12/1943
(Continued )
( * ) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 OTHER PUBLICATIONS
U.S.C. 154 ( b ) by 128 days .
Engineering Essentials : Cylinders, Hydraulics & Pneumatics, Jan.
( 21 ) Appl . No.: 16 /531,338 1 , 2012 , https://www.hydraulicspneumatics.com/technologies/
cylinders- actuators /article / 21882647/ engineering - essentials
(22 ) Filed : Aug. 5 , 2019 cylinders. ( Year: 2012 ) . *
(65 ) Prior Publication Data ( Continued )
US 2020/0001516 A1 Jan. 2 , 2020 Primary Examiner Michael N Orlando
Related U.S. Application Data Assistant Examiner — Christopher W Raimund
( 62 ) Division of application No. 14 / 795,354 , filed on Jul . (74 ) Attorney, Agent, or Firm Yee & Associates, P.C.
9 , 2015 , now Pat. No. 10,369,740 .
( 57 ) ABSTRACT
(51 ) Int. Ci . A flexible punch and die are used to form a flat composite
B29C 51/08 ( 2006.01 ) laminate charge into a stiffener having a desired cross
B29C 70/46 ( 2006.01 )
( Continued ) sectional shape. A desired contour is formed in the stiffener
by bending the punch and die . Ply wrinkling is avoided
( 52 ) U.S. CI . during contouring by maintaining those portions of the
CPC B29C 51/085 (2013.01 ) ; B29C 51/12 stiffener subject to wrinkling in tension as the contouring is
(2013.01 ) ; B29C 51/421 ( 2013.01 ) ; being performed . Bridging of the plies during the contouring
(Continued ) process is avoided by first contouring those sections of the
( 58 ) Field of Classification Search stiffener that are subject to wrinkling, and then contouring
CPC B29C 51/085 ; B29C 51/12 ; B29C 51/421 ; the remaining sections of the stiffener.
B29C 70/462; B29C 70/56 ; B29C 53/84 ;
(Continued ) 20 Claims , 13 Drawing Sheets
4

447
42
36

52 34 42a 38b
48 48

38a
54
-38c 38c
50 58 38
38 50

40 46

56

40
 US 11,370,159 B2
Page 2

( 51 ) Int . Ci. 7,464,508 B2 12/2008 Fournie et al .

B29C 70/56 ( 2006.01 ) 7,527,759 B2 5/2009 Lee et al .
7,622,066 B2 11/2009 Brustad et al.
B29D 99/00 ( 2010.01 ) 7,655,168 B2 2/2010 Jones et al .
B29C 51/12 ( 2006.01 ) 7,708,546 B2 5/2010 Lee et al .
B29C 51/42 ( 2006.01 ) 7,713,603 B2 5/2010 Farran et al .
B29L 31/00 ( 2006.01 ) 7,959,753 B2 5/2011 Nunez Delgado et al.
8,465,613 B2 6/2013 Rotter et al .
B29K 105/08 ( 2006.01 ) 8,551,382 B2 10/2013 Anderson et al .
B29K 105/00 ( 2006.01 ) 8,557,165 B2 10/2013 Jones et al .
B29L 9/00 ( 2006.01 ) 8,601,694 B2 12/2013 Brennan et al .
2004/0043196 Al 3/2004 Willden et al .
(52) U.S. Cl. 2004/0265536 A1 * 12/2004 Sana B29C 70/541
CPC B29C 70/462 (2013.01 ) ; B29C 70/56 428/119
( 2013.01 ) ; B29D 99/0003 (2013.01 ) ; B29K 2005/0142239 Al 6/2005 Frank
2006/0231981 A1 * 10/2006 Lee B29C 33/307
2105/08 ( 2013.01 ) ; B29K 2105/256 ( 2013.01 ) ; 264/320
B29L 2009/00 (2013.01 ) ; B29L 2031/001 2007/0039284 Al 2/2007 Munoz Royo et al .
(2013.01 ) ; B29L 2031/003 (2013.01 ) ; YO2T 2009/0297358 A1 12/2009 Anderson et al .
50/40 ( 2013.01) 2009/0320292 Al
2010/0074979 Al
12/2009 Brennan et al .
3/2010 Cundiff et al .
( 58 ) Field of Classification Search 2010/0102482 A1 4/2010 Jones et al .
CPC ....... B29C 53/04 ; B29C 51/082 ; B29C 51/14 ; 2011/0195230 A1 8/2011 Hanson
B29C 51/265 ; B29C 51/30 ; B29D 2013/0049258 A1 2/2013 Rotter et al .
99/0003 ; YO2T 50/40 ; B29K 2105/08 ; 2013/0340928 A1 * 12/2013 Rotter B29C 70/46
B29K 2105/25 B29L 2009 B29L 156/214
2031/003 ; B29L 2031/001 ; B29L 2014/0203477 A1 7/2014 Chapman et al.
2017/0008217 A1 1/2017 Chapman et al.
2031/3085 ; B29L 2031/3076
See application file for complete search history . FOREIGN PATENT DOCUMENTS
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U.S. PATENT DOCUMENTS EP 0659541 A1 6/1995
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 US 11,370,159 B2
Page 3

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Brittles, “ New Developments in Resin Transfer Moulding ,” Proc .
19th International Composites Congress , Nov. 1994 , pp . 11-26 .
Musch et al ., “ Tooling With Reinforced Elastomeric Materials,"
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The Longest Carbon Nanotubes You Have Ever Seen, http : //www .
spacemart.com/reports/The_Longest_Carbon_Nanotubes_You_Have
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Growing Carbon Nanotubes Aligned With Patterns, NASA Tech
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NPO30205.html, 2 pages.
Garcia et al . , “ Hybrid Carbon Nanotube - Composite Architectures,”
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Office Action , dated Jan. 10. 2018 , regarding U.S. Appl. No.
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Final Office Action , dated Jul. 12. 2018 , regarding U.S. Appl. No.
14/795,354, 20 pages .
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Notice of Allowance , dated Mar. 25 , 2019 , regarding U.S. Appl. No.
14/795,354 , 10 pages .
* cited by examiner
U.S. Patent Jun . 28 , 2022 Sheet 1 of 13 US 11,370,159 B2

32

24
20 .

1
.
FIG 26 22
FIG
2
.
20a
30 33

30a 31
26
24
22 33 22
31
26 28

28
22
26
U.S. Patent Jun . 28 , 2022 Sheet 2 of 13 US 11,370,159 B2

50

48
?? 1
38b

46
.
4

3
.
FIG
... 54 58
56
38C 38

42 42a
34
52 40

36 48
44
50
U.S. Patent Jun . 28 , 2022 Sheet 3 of 13 US 11,370,159 B2
38 40

56

.
54

4
.
FIG
56
09 60

56
44 42 34 38 36
U.S. Patent Jun . 28 , 2022 Sheet 4 of 13 US 11,370,159 B2

50
48

20
26
386 38

42
22
44 380 46
58
24
5
.
FIG
54
6
.
FIG 56
380
?
38a
34
26 38
40

48
36
50
U.S. Patent Jun . 28 , 2022 Sheet 5 of 13 US 11,370,159 B2

1
I 26 38a
1
.
1

42

22 .

.
38 20

34

La 42a

54
7

FIG . 6
U.S. Patent Jun . 28 , 2022 Sheet 6 of 13 US 11,370,159 B2

50

48

38
34
20
26

46
44
22 54
FIG
7
.

42 22 1
5838c 24
38a
26

40
38
38b
1 48
36
50
U.S. Patent Jun . 28 , 2022 Sheet 7 of 13 US 11,370,159 B2

50

48

38
26
34
45
22
20
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45
44
64 62 54
64a 64
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.
8

62
42
646
45
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38c 24

26
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36
50
U.S. Patent Jun . 28 , 2022 Sheet 8 of 13 US 11,370,159 B2

74
- -74
44 36 -76

70
68

89
83

68a 68a
9
.
FIG
68a 68a
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.
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9A
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65
U.S. Patent Jun . 28 , 2022 Sheet 9 of 13 US 11,370,159 B2

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1

89 76
36
1
83
1

9A
.
FIG
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Il

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L
U.S. Patent Jun . 28 , 2022 Sheet 10 of 13 US 11,370,159 B2

78 78

85 85
10
.
FIG
75 + 75
7
ITE 84 11
.
FIG

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36
77
77

76 76 76 76
U.S. Patent Jun . 28 , 2022 Sheet 11 of 13 US 11,370,159 B2

50
48

56 26 8

54
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46
22
24
12
.
FIG
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58
54
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38

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U.S. Patent Jun . 28 , 2022 Sheet 12 of 13 US 11,370,159 B2

PLACE FLAT COMPOSITE 88

CHARGE ON A DIE

79 PLACE FLAT COMPOSITE HEAT THE COMPOSITE

CHARGE TO AT LEAST ITS 89
CHARGE ON DIE
FORMING TEMPERATURE
80 HEAT THE COMPOSITE CHARGE
TO FORMING TEMPERATURE PUNCH FORM THE
COMPOSITE CHARGE
BETWEEN THE DIE AND
FORM STRINGER HAT SECTION PUNCH INTO A GENERALLY 90
81 ( USE PUNCH TO DRIVE THE STRAIGHT STIFFENER
CHARGE INTO THE DIE CAVITY) HAVING A HAT - SHAPED
CROSS - SECTION
PLACE A PORTION OF THE
82 COMPOSITE CHARGE IN FORMA CONTOUR IN THE
TENSION ( COMPRESS ONE OF STRAIGHT STIFFENER BY
THE FLANGES AND THE CAP) FIRST FORMING A PORTION
OF THE CONTOUR IN AN
FORM A CONTOUR IN THE INTERMEDIATE SECTION OF
COMPOSITE CHARGE WHILE THE THE STRAIGHT STIFFENER -91
86 PORTION OF THE COMPOSITE AND THEN FORMING OTHER
CHARGE IS HELD IN TENSION PORTIONS OF THE
CONTOUR ON OPPOSITE
SIDES OF THE
HOLD THE CONTOURED INTERMEDIATE SECTION
STIFFENER IN THE CONTOURED
87 PUNCH AND DIE UNTIL THE
STIFFENER COOLS BELOW THE HOLD THE CONTOURED
FORMING TEMPERATURE STIFFENER BETWEEN
CONTOURED PUNCH AND
DIE UNTIL THE STIFFENER 92
FIG . 13 COOLS BELOW THE
FORMING TEMPERATURE

FIG . 14
U.S. Patent Jun . 28 , 2022 Sheet 13 of 13 US 11,370,159 B2

98

102
1 SPECIFICATION AND DESIGN

104 MATERIAL PROCUREMENT

1
106 COMPONENT AND SUBASSEMBLY
MANUFACTURING

108 SYSTEM INTEGRATION

1
110 CERTIFICATION AND DELIVERY

112 l IN SERVICE

114 MAINTENANCE AND SERVICE

FIG . 15

100

AIRCRAFT
116 AIRFRAME INTERIOR 120

SYSTEMS
PROPULSION ELECTRICAL
126 128 118
122 124
HYDRAULIC ENVIRONMENTAL

FIG . 16
 US 11,370,159 B2
1 2
APPARATUS FOR FORMING A contoured along its length , beginning at the apex of the
CONTOURED HAT STIFFENER intended contour, in order to reduce or eliminate possible
bridging of the plies during contouring.
This application is a divisional of U.S. patent application According to one disclosed embodiment, a method is
Ser. No. 14 / 795,354 , filed Jul . 9 , 2015 , now U.S. Pat. No. 5 provided of forming a contoured hat- shaped composite
10,369,740 , the disclosure of which is incorporated by stiffener having a cap , a pair of flanges and a pair of webs
reference herein in its entirety. connecting the cap with the flanges. The method includes
placing a generally flat composite laminate charge on a die
BACKGROUND INFORMATION having a die cavity in which the cap and the webs may be
10
1. Field
formed . The method also includes forming the cap and the
webs using a punch to drive the charge into the die cavity .
The present disclosure generally relates the fabrication
A portion of the charge is placed in tension by compressing
of composite stiffeners, and deals more particularly with a either the flanges or the cap . A contour is formed into a
method and apparatus for reducing wrinkling of contoured 15 composite charge while the portion of the charge is being
held in tension . Maintaining tension on a portion of the
hat -type stiffeners formed from a single composite charge. charge during contouring substantially reduces or eliminates
2. Background ply wrinkling.
According to another disclosed embodiment, a method is
Composite stiffeners such as spars and stringers are used 20 provided of forming a hat-shaped composite stiffener con
in a wide range of aerospace, marine and other applications. toured along its length . The method includes placing a flat
In some cases , stiffeners must be contoured along their composite charge on a die , and punch forming the composite
length to conform the geometry of a structure, such as an charge between the die and a nch into a generally straight
aircraft wing or fuselage skin . stiffener having a hat - shaped cross - section . The method also
One technique for fabricating contoured composite stiff- 25 includes forming a contour in the straight stiffener by first
eners involves punch forming a composite laminate charge forming a portion of the contour in an intermediate section
into a straight stiffener, and contouring the straight stiffener of the straight stiffener and then forming the other sections
by placing a contourable vacuum fixture inside the stiffener. of the contour. The forming operation may be performed in
Vacuum is applied to the vacuum fixture and the stiffener is a sequential manner in which contouring of the stiffener is
then transferred to a female cure tool having a desired 30 first performed at the apex of the contour, followed by
stiffener contour. This approach is labor intensive and adds contouring of the remainder of the stiffener.
to tooling costs . According to still another disclosed embodiment, an
More recently, it has been proposed to fabricate contoured apparatus is provided for forming a hat stiffener contoured
composite stiffeners, such as stringers, using punch forming along its length , wherein the hat stiffener includes a pair of
in which aa flat composite laminate charge is punched formed 35 webs connecting a cap with a pair of flanges . The apparatus
into aa die to achieve the desired cross - sectional shape . Both includes a die adapted to have a composite charge placed
the punch and the die are articulated along their lengths, thereon . The die includes first and second spaced apart die
allowing them to bend . Once the charge has been punch members defining a die cavity therebetween . The apparatus
formed to the desired cross - sectional shape , the punch and also includes a punch adapted to be driven into the die cavity
the die are forced to bend, thereby forming the stiffener to 40 for forming a portion of the composite charge into the cap
the desired contour. Problems arise, however, where the and the webs . The apparatus also includes a former device
composite stiffener is highly contoured . As the formed for forming the contour into the hat stiffener after the hat
charge is bent to the desired contour, portions of the charge, stiffener has been punch formed . The apparatus further
such as the webs in aa hat stiffener, are placed in compression, includes a device for reducing wrinkling of the webs as the
resulting in undesired wrinkling of some of the plies of the 45 former is bending the contour into the hat stiffener. The
charge. Hand rework of the stiffeners is required to eliminate device includes at least one pressure plate adapted to com
the wrinkling, adding to labor costs and reducing production press a portion of the composite charge.
rate . The features, functions, and advantages can be achieved
Accordingly, there is a need for a method and apparatus independently in various embodiments of the present dis
that allow punch forming of highly contoured composite 50 closure or may be combined in yet other embodiments in
stiffeners, such as hat stringers, which substantially reduce which further details can be seen with reference to the
or eliminate ply wrinkling caused by material compression following description and drawings.
as the stiffener is formed to the desired contour.
BRIEF DESCRIPTION OF THE DRAWINGS
SUMMARY 55
The novel features believed characteristic of the illustra
The disclosed embodiments provide aa method and appa- tive embodiments are set forth in the appended claims . The
ratus for fabricating substantially wrinkle - free , highly con- illustrative embodiments, however, as well as a preferred
toured composite laminate stiffeners. The stiffeners are mode of use , further objectives and advantages thereof, will
punch formed from a single composite charge and then 60 best be understood by reference to the following detailed
contoured along their lengths. A portion of the shaped description of an illustrative embodiment of the present
stiffener is pinched and thereby compressed , as the shaped disclosure when read in conjunction with the accompanying
composite charge is being contoured . The compression of a drawings, wherein :
portion of the charge causes the remainder of the stiffener to FIG . 1 is an illustration of a perspective view of a
be placed in tension which prevents plies of the stiffener 65 composite hat stiffener having a concave contour.
from wrinkling as the stiffener is being contoured . In one FIG . 2 is an illustration similar to FIG . 1 but showing one
variation of the method, the stiffener may be sequentially end of a composite hat stiffener having a convex contour.
 US 11,370,159 B2
3 4
FIG . 3 is an illustration of a traverse , cross - sectional view
anywhere along its length . For example, the hat stiffener 20
of an apparatus for punch forming the contoured composite may be contoured only in an intermediate section , or con
hat stiffener shown in FIG . 1 , illustrating setup of the die in toured only at its outer ends.
preparation for performing a punch forming operation . As will be discussed below in more detail , the hat stiffener
FIG . 4 is an illustration of a cross - sectional view taken 5 20 may be formed from a single composite laminate charge
along the line 4-4 in FIG . 3 . of fiber reinforced plies , such as , without limitation, carbon
FIG . 5 is an illustration similar to FIG . 3 but showing the fiber reinforced plastic . FIG . 2 illustrates an alternate form
punch having partially formed the charge into the die . of a hat stiffener 20a that may be produced according to the
FIG . 6 is an illustration of the area designated as “ FIG . 6 " disclosed embodiments, that possesses a contour 30a
in FIG . 5 . 10 wherein the flanges 26 are on the inside radius of the contour
FIG . 7 is an illustration similar to FIG . 5 but showing the 30a . The hat stiffeners 20 , 20a described above are merely
hat stiffener having been fully formed to the desired cross- illustrative of a wide range of contoured , composite laminate
sectional shape. stiffeners that may be fabricated using the disclosed method
FIG . 8 is an illustration similar to FIG . 7 but showing a and apparatus.
pressure plate compressing the cap against the punch to shift 15 Attention is now directed to FIGS . 3 and 4 which illustrate
the neutral axis of the shaped stiffener and thereby place the an apparatus for fabricating composite laminate stiffeners,
webs and flanges in tension . such as the contoured composite laminate stiffeners 20 , 20a ,
FIG . 9 is an illustration of a side view of a contour respectively shown in FIGS . 1 and 2. The apparatus broadly
forming device used to contour the punch formed hat comprises a punch 42 attached to an upper flexible plate 44 ,
stiffener, only one of the pressure plate cylinders shown for 20 and aa die 36 mounted on a lower flexible plate 40. The plates
clarity . 40 , 44 are forced together, driving the punch 42 into the die
2

FIG . 9A is an illustration of the area designated as “ FIG . 36 , by a machine such as a press (not shown) in which the
9A ” in FIG . 9 . plates 40 , 44 are interposed between two later discussed
FIG . 10 is an illustration of aa side view of the segmented press platens 70 ( FIG . 9 ) . As best seen in FIG . 4 , both the die
die before a contour forming operation is commenced . 25 36 and the punch 42 are segmented along their respective
FIG . 11 is an illustration similar to FIG . 10 , but showing lengths. The segments of the die 36 and punch 42 are
initial contouring of an intermediate section of the seg- connected with each other by couplings 60 , allowing each of
mented die at the apex of the contour. the die 36 and punch 42 to flex and bend along their lengths.
FIG . 12 is an illustration similar to FIG . 8 , but showing an The die 36 comprises a pair of spaced apart die members 38
alternate embodiment of apparatus for reducing ply wrin- 30 defining a die cavity 46 therebetween within which the webs
kling during forming of the convex shaped composite hat 22 and cap 24 of the stiffeners 20 , 20a may be formed in a
stiffener shown in FIG . 2 . punch forming operation described below . Each of the die
FIG . 13 is an illustration of aa flow diagram of a method members 38 includes an outside radius edge 38a for forming
of forming a hat -shaped composite stiffener contoured along the radius corners 33 of the stiffener 20 , 20a , and the punch
its length . 35 42 includes outside radius edges 42a for forming the radius
FIG . 14 is an illustration of a flow diagram of another corners 31 of the stiffener 20 , 20a.
method of forming a hat shaped composite stiffener con- Inflatable bladders, which may comprise inflatable hoses
toured along its length . 48 , are captured between the die members 38 and outside
FIG . 15 is an illustration of a flow diagram of aircraft angle members 50 that are secured to the lower plate 40 .
production and service methodology. 40 Pressurization of the hoses 48 causes lateral pressure to be
FIG . 16 is an illustration of a block diagram of an aircraft. applied to the die members 38 which biases the die members
38 to move toward each other. A substantially flat, flexible
DETAILED DESCRIPTION pressure plate 54 is attached to the upper end of the output
rods 58 of a plurality of pneumatic or hydraulic pressure
Referring first to FIG . 1 , the disclosed embodiments 45 plate cylinders 56 , or similar motorized force applicators.
described below may be employed to fabricate aa stiffener 20 The cylinders 56 are distributed along the length of the
having a hat - shaped cross - section and aa curved longitudinal apparatus, as best seen in FIG . 4 in order to apply a
axis 32. Stiffener 20 is referred to using various terms substantially uniform pressure to the pressure plate 54 along
throughout this description . Stiffener 20 is referred to herein its length . The output rods 58 extend through the lower plate
as , but not limited to , hat stiffener, contoured composite 50 40 into the die cavity 46. The pressure plate 54 extends
laminate stiffener, straight stiffener, composite stiffener, substantially parallel to the bottom of the punch 42 and is
composite laminate stiffener, straight composite laminate vertically displaceable within the die cavity 46 by the
stiffener, concave shaped stiffener, straight hat stiffener, cylinders 56 .
convex shaped stiffener, contoured hat - shaped composite FIG . 3 shows the apparatus setup in preparation for a
stiffener, contoured stiffener, and generally straight stiffener. 55 forming operation in which the cross - sectional shape of the
These various terms all refer to stiffener 20. Different stiffener 20 is punch formed . A generally flat composite
adjectives are associated with the various terms to describe charge 34 is placed on the die 36 , overlying the upper
stiffener 20 at various stages as stiffener 20 is shaped . surfaces 38b of the die members 38. Intermediate portions of
Stiffener 20 includes aa hat section 28 comprising a pair of the composite charge 34 are supported on the pressure plate
webs 22 that connect a cap 24 with a pair of flanges 26. The 60 54 which is displaced upwardly to a position where it is
cap 24 is connected with the webs along radius corners 31 , substantially parallel with upper surfaces 38b of the die
while the flanges 26 are connected with the webs 22 along members 38. A heating blanket 52 may be placed over the
radius corners 33. The hat stiffener 20 is contoured 30 in the composite charge 34 in order to heat the composite charge
YZ plane throughout its length . In this example, the stiffener 34 to its forming temperature prior to commencement of a
20 has a concave contour 30 , wherein cap 24 is located on 65 forming operation. Other forms of heating devices, such as
the inside radius of the stiffener 20. In other examples, the infrared lamps or heated gas blowers ( both not shown) may
hat stiffener 20 may be contoured at one or more locations be used in lieu of the heating blanket 52 to heat the
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composite charge to its forming temperature. After heating In one embodiment, the length of the piston rods 83 is
the composite charge 34 to its forming temperature, the adjusted to match the desired contour to be formed, and the
heating blanket 52 is removed , and a punch forming opera- platens 70 are moved toward each other in order to apply the
tion is commenced . force needed to bend the die 36 and the punch 42 , and thus
FIGS . 5 and 6 show the punch 42 partially displaced 5 the composite stiffener 20 , to the desired contour. In other
downwardly to begin driving and forming the composite embodiments, the platens 70 may be initially adjusted to a
charge 34 into the die cavity 46. The downward force desired spacing , and the pneumatic cylinders 68 may be
applied by the punch 42 overcomes the upward force applied employed to apply the force necessary to bend the die 36 and
by the pressure plate 54 allowing the composite charge 34 to punch 42 to the desired contour. As the die 36 is bending to
be formed between the punch 42 and the die members 38. 10 the desired contour in the XY plane, the cap 24 remains
The downward displacement of the punch 42 applies lateral compressed by the pressure plates to maintain the webs 22
forces on the die members 38 which overcomes the biasing and flanges 26 in tension , thereby preventing ply wrinkling
forces applied by the hoses 48 , causing the die members 38 that may be caused by the bending forces that are applied to
to move away from each other. As best seen in FIG . 6 , the the webs 22 and flanges 26. Following the contouring
punch 42 draws the composite charge 34 between the radius 15 operation , the stiffener 20 is allowed to cool to a temperature
edges 38a , 42a of the die members 38 and punch 42 below the forming temperature, preferably to room tempera
respectively. As the punch 42 descends into the die cavity ture, while it remains held under pressure between the
46 , the upper plate 44 compresses the outer edges of the contoured punch 42 and die 36. By cooling the stiffener 20
composite charge 34 against the upper surfaces 38b of the while it remains in the contoured punch 42 and die 36 , the
die members 38 , thereby forming the flanges 26. FIG . 7 20 desired shape of the stiffener 20 is maintained and does not
shows the punch 42 having fully descended into the die distort due to material creep caused by resin which would
cavity 46 to complete forming of the cross - sectional shape otherwise remain slightly soft.
of the stiffener 20 . Depending upon the degree of contour desired , the
Referring now to FIG . 8 , with the cross - sectional shape of uncured plies of the composites laminate stiffener 20 may be
the straight stiffener 20 having been formed , the cylinders 56 25 subject to undesired bridging during the contouring process .
apply force to the pressure plate 54 , causing the pressure In order to reduce or eliminate possible bridging , the con
plate 54 to apply pressure to the cap 24 , thereby pinching the touring process may be carried out in a sequential manner,
cap 24 between the pressure plate 54 and the punch 42. The such that those sections of the stiffener 20 that are most
compression 43 of the cap 24 by the pressure plate 54 shifts likely to buckle are contoured first, before other sections are
62 the neutral axis 64 of the stiffener 20 , 20a from the 30 contoured . For example, referring now to FIGS . 10 and 11 ,
position shown at 64a to the position shown at 64b . The stiffener 20 has a midpoint 85 corresponding to an apex 84
neutral axis 64 is the location on the cross section of the of the final contour 30 (FIG . 1 ) of the stiffener 20. The
stiffener 20 , 20a at which the composite charge 34 is neither midpoint 85 or apex 84 lies within an intermediate section
in tension or compression. Thus, shifting of the neutral axis 75 of the straight stiffener 20. The remaining sections 77 , 78
64 toward the cap 24 causes the webs 22 and flanges 26 to 35 are located on opposite sides of the intermediate section 75 .
be placed in tension 45. As will be discussed below in more Referring particularly to FIG . 11 , according to the disclosed
detail, tensioning of the webs 22 and the flanges 26 in this method , potential ply bridging is reduced or eliminated by
manner during the subsequent contour forming operation initially contouring only the intermediate section 75 which
reduces or eliminates ply wrinkling in the formed charge 34 . contains the apex 84 of the final stiffener contour 30. Then,
FIGS . 9 and 9A illustrate a device which may comprise, 40 having contoured the intermediate section 75 , the remaining,
without limitation, a press 65 or similar device for forming outer sections 77 , 78 may be contoured using the former
a contour in the straight stiffener 20 that has been punch shown in FIG . 9. In some embodiments , after the interme
formed to the desired cross sectional shape, as described diate section 75 is contoured , remaining outer sections 77 ,
above in connection with FIGS . 3-8 . In this example, the 78 of the stiffener 20 may be sequentially contoured in a
stiffener 20 is formed with a concave contour 30 in the YZ 45 manner similar to that described immediately above .
plane ( FIG . 1 ) . The press 65 may also be employed for From the discussion above in connection with FIGS . 3-11 ,
forming a stiffener 20a with a convex contour 30a . The die it may be appreciated that ply wrinkling during contouring
36 , which is sandwiched between the lower and upper plates of a straight composite laminate stiffener 20 may be reduced
40 , 44 ( the punch 42 not shown) of the press 65 , is or eliminated by placing those portions of the stiffener 20
positioned between two opposing sets of force applicators , 50 subject to wrinkling in tension , achieved by placing another
such as pneumatic cylinders 68 or motor members that are portion of the stiffener 20 in compression. In the case of the
mounted on platens 70 of the press 65 or similar platforms concave shaped stiffener 20 shown in FIG . 1 , the cap 24 is
that are adapted to move 74 toward and away from each compressed to maintain the webs 22 and flanges 26 in
other. tension during the contouring process . A similar method
The pneumatic cylinders 68 , or similar force generators, 55 may be employed to avoid ply wrinkling when contouring a
are arranged in opposing pairs and have displaceable piston straight stiffener into the convex shape shown in FIG . 2. For
rods 83 that are connected to the upper and lower plates 40 , example , referring now to FIG . 12 , a die 36 and punch 42
44. The pressure plate cylinders 56 are distributed along the arrangement similar to that previously described, are
length of the die 36 as previously discussed in connection employed to form a substantially flat composite laminate
with FIG . 4 , although only one is shown in FIGS . 9 and 9A 60 charge 34 into a straight hat stiffener that is subsequently
for clarity of illustration . The pressure plate cylinders 56 are contoured into the convex shaped stiffener 20a shown in
mounted on two support structures 76 which may be flexible FIG . 2. A pair of pressure plates 54 recessed into the bottom
or segmented, and are respectively attached to the upper of the upper plates 44 are connected to piston rods 58 of a
flexible plates 40 , 44. As previously mentioned , the piston series of pneumatic cylinders 56 distributed along the length
rods 58 (FIG . 9A) extend through the plates 40 , 44 into the 65 of the plate 44. After the composite charge 34 is formed into
die cavity 46 (FIG . 8 ) and are respectively connected to the the desired cross sectional shape , the flanges 26 are com
pressure plates 54 . pressed by the pressure plates 54. Compression of the
 US 11,370,159 B2
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flanges 26 in turn places the webs 22 and cap 24 in tension . number of vendors, subcontractors, and suppliers; and an
With the webs 22 and cap 24 held in tension , the straight operator may be an airline , leasing company, military entity,
stiffener 20a may be contoured into a desired convex shape service organization, and so on .
using the contour former shown in FIG . 9 . As shown in FIG . 16 , the aircraft 100 produced by
FIG . 13 broadly illustrates the overall steps of one method 5 exemplary method 98 may include an airframe 116 with a
for forming a contoured , hat - shaped composite stiffener 20 . plurality of systems 118 and an interior 120. Examples of
Beginning at 79 , a flat composite laminate charge 34 is high- level systems 118 include one or more of a propulsion
placed on the die 36 , and at 80 , the charge 34 is heated to at system 122 , an electrical system 124 , a hydraulic system
least its forming temperature . At 81 , a straight stiffener 20 126 , and an environmental system 128. Any number of other
having a hat shaped section is formed using a punch 42 to 10 systems may be included . Although an aerospace example is
drive the charge 34 into a cavity 46 in the die 36. At 82 , a shown, the principles of the disclosure may be applied to
portion of the composite charge 34 is placed in tension by other industries, such as the marine and automotive indus
compressing another portion of the charge 34 , such as the tries.
flanges 26 or the cap 24. At 86 , a contour is formed in the Systems and methods embodied herein may be employed
composite charge 34 while the portion of the composite 15 during any one or more of the stages of the production and
charge 34 is held in tension throughout the contouring service method 98. For example , components or subassem
process . At 87 , the contoured stiffener 20 is held in the blies corresponding to production process 98 may be fabri
contoured die 36 and punch 42 until the stiffener 20 cools to cated or manufactured in a manner similar to components or
a temperature that is below the forming temperature, and subassemblies produced while the aircraft 100 is in service .
preferably room temperature to avoid creep of the stiffener 20 Also , one or more apparatus embodiments, method embodi
shape when it is removed from the punch 42 and die 36 . ments, or a combination thereof may be utilized during the
Attention is now directed to FIG . 14 which broadly production stages 106 and 108 , for example, by substantially
illustrates the overall steps of an alternate method of forming expediting assembly of or reducing the cost of an aircraft
the contoured, hat - shaped composite stiffener 20. Beginning 100. Similarly , one or more of apparatus embodiments,
at 88 , a flat composite charge 34 is placed on the die 36 , and 25 method embodiments, or a combination thereof may be
at 89 , the charge 36 is heated to at least its forming utilized while the aircraft 100 is in service , for example and
temperature using a heating blanket 52 or other suitable without limitation, to maintenance and service 114 .
heating devices. At 90 , the composite charge 34 is punch As used herein , the phrase " at least one of ” , when used
formed between the die 36 and the punch 42 into a generally with a list of items , means different combinations of one or
straight stiffener 20 having a hat - shaped cross - section . At 30 more of the listed items may be used and only one of each
91 , a contour is formed in the straight stiffener 20 by first item in the list may be needed . For example, " at least one of
forming a portion of the contour in an intermediate section item A , item B , and item C ” may include, without limitation ,
of the stiffener, and then forming other portions of the item A , item A and item B , or item B. This example also may
contour on opposite sides of the intermediate section . At 92 , include item A , item B , and item C or item B and item C. The
following contouring, the charge 34 is held in the contoured 35 item may be a particular object, thing, or a category. In other
die 36 and punch 42 until the stiffener cools to below its words, at least one of means any combination items and
forming temperature, and preferably to room temperature to number of items may be used from the list but not all of the
avoid possible creep of the stiffener shape when it is items in the list are required .
removed from the punch 42 and die 36 . The description of the different illustrative embodiments
Embodiments of the disclosure may find use in a variety 40 has been presented for purposes of illustration and descrip
of potential applications , particularly in the transportation tion , and is not intended to be exhaustive or limited to the
industry, including for example, aerospace, marine, automo- embodiments in the form disclosed . Many modifications and
tive applications and other application where contoured variations will be apparent to those of ordinary skill in the
elongate composite laminate stiffeners, such as stringers and art. Further, different illustrative embodiments may provide
spars , may be used . Thus, referring now to FIGS . 15 and 16 , 45 different advantages as compared to other illustrative
embodiments of the disclosure may be used in the context of embodiments . The embodiment or embodiments selected
an aircraft manufacturing and service method 98 as shown are chosen and described in order to best explain the
in FIG . 15 and an aircraft 100 as shown in FIG . 16. Aircraft principles of the embodiments, the practical application, and
applications of the disclosed embodiments may include , for to enable others of ordinary skill in the art to understand the
example , without limitation , contoured stringers, spars and 50 disclosure for various embodiments with various modifica
similar structural members. During pre -production , exem- tions as are suited to the particular use contemplated.
plary method 98 may include specification and design 102 of What is claimed is :
the aircraft 100 and material procurement 104. During 1. An apparatus configured to form a hat stiffener that
production , component and subassembly manufacturing comprises a pair of webs that connect a cap with a pair of
106 , and system integration 108 of the aircraft 100 takes 55 flanges and aa contour along a length of the hat stiffener such
place . Thereafter, the aircraft 100 may go through certifica- that the apparatus comprises:
tion and delivery 110 in order to be placed in service 112 . an upper platen and a lower platen, wherein :
While in service by a customer, the aircraft 100 is scheduled the lower platen comprises lower pneumatic cylinders
for routine maintenance and service 114 , which may also configured to drive lower piston rods against a lower
include modification , reconfiguration, refurbishment, and so 60 support structure that supports a lower plate that
on . holds aa die that comprises a first die member and a
Each of the processes of method 98 may be performed or second die member configured to space apart from
carried out by a system integrator, a third party, and / or an each other and form a cavity therebetween , wherein
operator ( e.g. , a customer ). For the purposes of this descrip the lower support structure comprises lower pressure
tion , a system integrator may include without limitation any 65 plate cylinders that comprise lower output rods con
number of aircraft manufacturers and major -system subcon figured to :
tractors; a third party may include without limitation any extend through the lower plate ;
 US 11,370,159 B2
9 10
connect to a pressure plate that rests within the cavity a heating blanket configured to lay above the composite
and on the lower plate ; and charge held by the die ; and
press the pressure plate against a surface of a punch the punch configured to drive the composite charge and
connected to an upper plate such that a uniform the pressure plate into the cavity and form the cap and
pressure is applied along an entire length of the 5 the pair of webs into a portion of the composite charge
pressure plate against an entire bottom of the to form the hat stiffener.
punch, wherein the entire bottom of the punch is 6. The apparatus of claim 5 , wherein each output rod in
substantially parallel to the pressure plate ; and the piston rods, respectively, directly connects to the lower
the upper platen comprises upper pneumatic cylinders 10
pressure plate cylinder connected to the lower support
that comprise upper piston rods connected to and structure through an opening in the lower plate and is
configured to drive against an upper support struc- configured to compress the cap and shift aa neutral axis in the
ture that comprises upper pressure plate cylinders composite charge.
that comprise upper output rods connected to the 7. The apparatus of claim 5 , wherein the pressure plate is
upper plate distributed along an upper length of the 15 configured to compress the cap between the pressure plate
die , wherein the upper plate is configured to com- and the punch , wherein a first surface of the cap contacts the
press a composite charge against an upper surface of pressure plate , and a second surface of the cap contacts the
the die and comprises the punch configured to drive punch .
the composite charge into the cavity and against the 8. The apparatus of claim 5 , wherein the upper platen and
pressure plate . 20 the lower platen are configured to bend the die and the punch
2. The apparatus of claim 1 , wherein the pressure plate is to bend the hat stiffener into a contoured shape that com
connected to the lower support structure through an opening prises an inside radius defined by the cap .
in the lower plate and configured to compress the cap and 9. The apparatus of claim 5 , wherein the upper platen and
shift a neutral axis in the composite charge. the lower platen are configured to bend the die and the punch
3. The apparatus of claim 1 , further comprising the upper 25 to :
pressure plate configured to compress one of the pair of initially form a first portion of the contour in an interme
flanges against one of the die members. diate section of the hat stiffener; and
4. The apparatus of claim 1 , wherein the the upper form other portions of the contour in remaining sections
pneumatic cylinders are distributed along the entire length of of the hat stiffener after the first portion of the contour
the die and the punch and are configured to apply a force that 30 has been formed in the intermediate section .
sequentially bends the die and the punch. 10. The apparatus of claim 5 , wherein the upper pneu
5. An apparatus configured to form a hat stiffener that matic cylinders are distributed along the entire length of the
comprises a contour along a length of the hat stiffener, such die and the punch and are configured to sequentially apply
that the hat stiffener comprises: a cap , a pair of flanges , and a force that sequentially bends the die and the punch.
a pair of webs that connect the pair of flanges to the cap , and 35 11. The apparatus of claim 5 , wherein the upper pneu
the apparatus comprises : matic cylinders are configured to apply a first force that
an upper platen and a lower platen, wherein : opposes a second force applied by the lower pneumatic
the lower platen comprises lower pneumatic cylinders cylinders.
configured to drive lower piston rods against a lower 12. The apparatus of claim 5 , further comprising the
support structure that supports a lower plate that 40 heating blanket configured to heat the composite charge to
holds a die that comprises a first die member and a a temperature that allows the composite charge to be formed .
second die member configured to space apart from 13. An apparatus configured to form a hat stiffener that
each other and form a cavity therebetween , wherein comprises a contour along a length of the hat stiffener, such
the lower support structure comprises lower pressure that the hat stiffener comprises: a cap , a pair of flanges, and
plate cylinders that comprise lower output rods con- 45 a pair of webs that connect the pair of flanges to the cap , such
figured to : that the apparatus comprises:
extend through the lower plate ; an upper platen and a lower platen, wherein :
connect to a pressure plate that rests within the cavity the lower platen comprises lower pneumatic cylinders
and on the lower plate ; and configured to drive lower piston rods against a lower
press the pressure plate against a surface of a punch 50 support structure that supports a lower plate that
that comprises segments coupled together and holds a die that comprises a first die member and a
attached to an upper plate connected to an upper second die member configured to space apart from
support structure such that a uniform pressure is each other and form a cavity therebetween , wherein
applied along an entire length of the pressure plate the lower support structure comprises lower pressure
against an entire bottom of the punch, wherein the 55 plate cylinders that comprise lower output rods con
entire bottom of the punch is substantially parallel figured to :
to the pressure plate; extend through the lower plate ;
the upper platen comprises upper pneumatic cylinders connect to a pressure plate that rests within the cavity
that comprise upper piston rods connected to and and on the lower plate ; and
configured to drive against the upper support struc- 60 press the pressure plate against a surface of a punch
ture , wherein the upper support structure comprises segmented together and attached to an upper plate
upper pressure plate cylinders that comprise upper connected to an upper support structure such that
output rods connected to the upper plate distributed a uniform pressure is applied along an entire
along an upper length of the die , wherein the upper length of the pressure plate against an entire
plate is configured to compress a composite charge 65 bottom of the punch, wherein the entire bottom of
against an upper surface of the die and comprises a the punch is substantially parallel to the pressure
punch ; plate;
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the upper platen comprises upper pneumatic cylinders 16. The apparatus of claim 13 , wherein the upper platen
that comprise upper piston rods connected to and and the lower platen are configured to bend the die and the
configured to drive against the upper support struc- punch to bend the hat stiffener into aa contoured shape having
ture , wherein the upper support structure comprises an inside radius defined by the pair of flanges.
upper pressure plate cylinders that comprise upper 5 17. The apparatus of claim 13 , wherein the upper platen
2

output rods connected to the upper plate distributed and the lower platen are configured to bend the die and the
along an upper length of the die , wherein the upper punch to :
plate is configured to compress a composite charge initially form a first portion of the contour in an interme
against an upper surface of the die and comprises a diate section of the hat stiffener; and
punch; 10 form other portions of the contour in remaining sections
a heating device configured to heat the composite charge of the hat stiffener after the first portion of the contour
to a forming temperature; and has been formed in the intermediate section .
the punch configured to drive the composite charge and 18. The apparatus of claim 13 , wherein the the upper
the pressure plate into the cavity and form the cap and pneumatic cylinders are distributed along the entire length of
the pair of webs into a portion of the composite charge 15 the die and the punch and are configured to apply a force that
sequentially bends the die and the punch .
that forms the hat stiffener.
14. The apparatus of claim 13 , wherein each output rod , matic19. The apparatus of claim 13 , wherein the upper pneu
respectively, connects to the lower support structure through opposes cylinders are configured to apply a first force that
an opening in the lower plate and is configured to compress 20 cylinders.a second force applied by the lower pneumatic
the cap and shift a neutral axis in the composite charge. 20. The apparatus of claim 13 , further comprising the
15. The apparatus of claim 13 , further comprising upper
pressure plates configured to compress a portion of the pair heating device comprising a heating blanket.
of flanges between the pressure plate and the die members . * *