Systems, tools, and methods for forming corrugated structures and apparatuses including corrugated structures

• US 9,023,265 B1
• Filed: 01/28/2013
• Issued: 05/05/2015
• Est. Priority Date: 01/28/2013
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Rotter, Daniel M., Robins, Brian G., Willden, Kurtis S., Metschan, Stephen Lee, Coxon, Brad Andrew, Kirchmeier, Stephen Keith, Anderson, Joseph D.
• Primary Examiner(s): DANIELS, MATTHEW J
• Application Number:
  US13/752,139
• Time in Patent Office: 827 Days
• US Class Current: 264/258
• CPC Class Codes: B29C 53/24 of plates or sheets
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29C 70/541 Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29L 2031/3082 Fuselages

Abstract

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.

Claims

1. A tool for forming a corrugated structure from a pliable blank, the tool comprising:

a plurality of forming blocks laterally and movably supported relative to each other;

wherein the tool defines a pre-formed configuration and a post-formed configuration;

wherein when the tool is in the pre-formed configuration, the forming blocks are spaced laterally further away from each other than when the tool is in the post-formed configuration;

wherein when the tool is in the post-formed configuration, the plurality of forming blocks collectively defines a corrugated form; and

wherein the plurality of forming blocks includes;

at least one ridge forming block having an upper surface configured to at least partially define a respective ridge of the corrugated structure; and

at least two valley forming blocks separate from the at least one ridge forming block positioned on opposite lateral sides of the at least one ridge forming block, wherein each valley forming block has an upper surface that is lower than the upper surface of the at least one ridge forming block and that is configured to at least partially define a respective valley of the corrugated structure;

a compaction mechanism configured to selectively conform the pliable blank to the corrugated form; and

block translating mechanisms positioned between each of the at least two valley forming blocks and the at least one ridge forming block configured to reconfigure the tool from the pre-formed configuration to the post-formed configuration by selectively translating the at least two valley forming blocks laterally relative to and toward the at least one ridge forming block while the compaction mechanism operatively conforms the pliable blank to the corrugated form.

2. The tool of claim 1, wherein the plurality of forming blocks includes a plurality of ridge forming blocks and a plurality of valley forming blocks laterally supported in an alternating arrangement.

3. The tool of claim 1, wherein the compaction mechanism includes:

a gas-impermeable flexible sheet configured to be positioned operatively atop the pliable blank when the pliable blank is positioned operatively atop the plurality of forming blocks, wherein the gas-impermeable flexible sheet is configured to be sealed around a perimeter of the pliable blank when the pliable blank is positioned operatively atop the plurality of forming blocks; and

a vacuum system configured to selectively evacuate air from between the gas-impermeable flexible sheet and the plurality of forming blocks when the pliable blank is positioned operatively atop of the plurality of forming blocks to conform the pliable blank to the corrugated form.

4. The tool of claim 1, wherein the block translating mechanisms include bladders positioned between each adjacent pair of forming blocks of the plurality of forming blocks, and wherein the bladders are configured to selectively deflate to cause the forming blocks to translate toward each other when the tool is reconfigured from the pre-formed configuration to the post-formed configuration.

5. The tool of claim 1, further comprising:

wherein the block translating mechanisms include mechanical linkages configured to operatively translate the forming blocks when the tool is reconfigured from the pre-formed configuration to the post-formed configuration.

6. The tool of claim 1, wherein the block translating mechanisms include a spring interconnecting each adjacent pair of forming blocks of the plurality of forming blocks, and wherein the springs are configured to selectively compress to permit the forming blocks to translate toward each other when the tool is reconfigured from the pre-formed configuration to the post-formed configuration.

7. The tool of claim 1, wherein the tool includes a control system connected to the block translating mechanisms configured to sequentially translate select forming blocks of the plurality of forming blocks in a predetermined order to reconfigure the tool from the pre-formed configuration to the post-formed configuration.

8. The tool of claim 7,

wherein the plurality of forming blocks includes a plurality of ridge forming blocks and a plurality of valley forming blocks laterally supported in an alternating arrangement;

and

wherein the plurality of forming blocks also includes a central forming block, and wherein the control system is configured to sequentially translate pairs of forming blocks toward the central forming block beginning with a pair of forming blocks closest to the central forming block and ending with a pair of forming blocks furthest from the central forming block to reconfigure the tool from the pre-formed configuration to the post-formed configuration.

9. The tool of claim 1, wherein the corrugated form includes contours in three dimensions.

10. The tool of claim 1, wherein the at least one ridge forming block includes a base block and a filler structure removably engaged to an upper side of the base block, wherein the filler structure is configured to be selectively disengaged from the upper side of the base block and to remain with the corrugated structure after the tool has operatively loaded the corrugated structure onto a layup mandrel.

11. The tool of claim 10, wherein the filler structure is configured to be captured between the corrugated structure and a skin segment while the corrugated structure is operatively loaded on the layup mandrel.

12. A system for assembling a stiffened composite structure including a corrugated structure, the system comprising:

a tool for forming a corrugated structure from a pliable blank, the tool comprising;

a plurality of forming blocks laterally and movably supported relative to each other;

wherein the tool defines a pre-formed configuration and a post-formed configuration;

wherein when the tool is in the pre-formed configuration, the forming blocks are spaced laterally further away from each other than when the tool is in the post-formed configuration;

wherein when the tool is in the post-formed configuration, the plurality of forming blocks collectively defines a corrugated form; and

wherein the plurality of forming blocks includes;

at least one ridge forming block having an upper surface configured to at least partially define a respective ridge of the corrugated structure; and

at least two valley forming blocks separate from the at least one ridge forming block positioned on opposite lateral sides of the at least one ridge forming block, wherein each valley forming block has an upper surface that is lower than the upper surface of the at least one ridge forming block and that is configured to at least partially define a respective valley of the corrugated structure;

a compaction mechanism configured to selectively conform the pliable blank to the corrugated form; and

block translating mechanisms positioned between each of the at least two valley forming blocks and the at least one ridge forming block configured to reconfigure the tool from the pre-formed configuration to the post-formed configuration by selectively translating the at least two valley forming blocks laterally relative to and toward the at least one ridge forming block while the compaction mechanism operatively conforms the pliable blank to the corrugated form;

a supply of pliable blanks for forming a plurality of corrugated structures with the tool;

a layup mandrel for receiving a corrugated structure of the plurality of corrugated structures; and

a supply of skin segments for loading onto the layup mandrel over one or more loaded corrugated structures.

13. The system of claim 12, further comprising:

a supply of filler structures;

wherein the at least one ridge forming block includes a base block and a filler structure from the supply of filler structures removably engaged to an upper side of the base block, wherein the filler structure is configured to be selectively disengaged from the upper side of the base block and to remain with the corrugated structure after the tool has operatively loaded the corrugated structure onto the layup mandrel.

14. The system of claim 12, wherein the pliable blanks and the skin segments are constructed of pre-preg composite plies.

15. A method of forming a corrugated structure, the method comprising:

providing a tool comprising;

a plurality of forming blocks laterally and movably supported relative to each other;

wherein the tool defines a pre-formed configuration and a post-formed configuration;

wherein when the tool is in the pre-formed configuration, the forming blocks are spaced laterally further away from each other than when the tool is in the post-formed configuration;

wherein when the tool is in the post-formed configuration, the plurality of forming blocks collectively defines a corrugated form; and

wherein the plurality of forming blocks includes;

at least one ridge forming block having an upper surface configured to at least partially define a respective ridge of the corrugated structure; and

at least two valley forming blocks separate from the at least one ridge forming block positioned on opposite lateral sides of the at least one ridge forming block, wherein each valley forming block has an upper surface that is lower than the upper surface of the at least one ridge forming block and that is configured to at least partially define a respective valley of the corrugated structure;

a compaction mechanism configured to selectively conform a pliable blank to the corrugated form; and

block translating mechanisms positioned between each of the at least two valley forming blocks and the at least one ridge forming block configured to reconfigure the tool from the pre-formed configuration to the post-formed configuration by selectively translating the at least two valley forming blocks laterally relative to and toward the at least one ridge forming block while the compaction mechanism operatively conforms the pliable blank to the corrugated form;

positioning the pliable blank operatively atop the plurality of forming blocks in the pre-formed configuration;

following the positioning, selectively translating the at least two valley forming blocks toward the at least one ridge forming block using the block translating mechanisms to reconfigure the tool to the post-formed configuration; and

concurrently with the translating, selectively conforming the pliable blank to the corrugated form using the compaction mechanism to form the corrugated structure.

16. The method of claim 15, wherein the plurality of forming blocks includes a central ridge forming block, and wherein the translating includes sequentially translating pairs of valley forming blocks beginning with a pair of valley forming blocks closest to the central ridge forming block and ending with a pair of forming blocks furthest from the central ridge forming block to reconfigure the tool from the pre-formed configuration to the post-formed configuration.

17. A tool for forming a corrugated structure from a pliable blank, the tool comprising:

a plurality of forming blocks laterally movably supported relative to each other and including a central forming block;

wherein the tool defines a pre-formed configuration and a post-formed configuration;

wherein when the tool is in the pre-formed configuration, the forming blocks are spaced laterally further away from each other than when the tool is in the post-formed configuration;

wherein when the tool is in the post-formed configuration, the plurality of forming blocks collectively defines a corrugated form; and

wherein the plurality of forming blocks includes;

a plurality of ridge forming blocks, each having an upper surface configured to at least partially define a respective ridge of the corrugated structure; and

a plurality of valley forming blocks separate from the plurality of ridge forming blocks laterally supported in an alternating arrangement with the plurality of ridge forming blocks, each valley forming block having an upper surface that is lower than the upper surfaces of the ridge forming blocks and that is configured to at least partially define a respective valley of the corrugated structure;

a vacuum compaction mechanism configured to selectively conform a pliable blank to the corrugated form, wherein the vacuum compaction mechanism includes;

a gas-impermeable flexible sheet configured to be positioned atop the pliable blank when the pliable blank is positioned atop the plurality of forming blocks, wherein the gas-impermeable flexible sheet is configured to be sealed around a perimeter of the pliable blank when the pliable blank is positioned atop the plurality of forming blocks; and

a vacuum system configured to selectively evacuate air from between the gas-impermeable flexible sheet and the plurality of forming blocks when the pliable blank is positioned atop of the plurality of forming blocks to conform the pliable blank to the corrugated form; and

block translating mechanisms positioned between each of the plurality of forming blocks configured to reconfigure the tool from the pre-formed configuration to the post-formed configuration by selectively translating the plurality of forming blocks laterally toward each other while the vacuum compaction mechanism operatively conforms the pliable blank to the corrugated form, wherein the block translating mechanisms include;

bladders positioned between each adjacent pair of forming blocks of the plurality of forming blocks, and wherein the bladders are selectively configured to deflate to cause the forming blocks to translate toward each other when the tool is reconfigured from the pre-formed configuration to the post-formed configuration; and

a control system connected to the block translating mechanisms configured to sequentially translate pairs of forming blocks toward the central forming block beginning with a pair of forming blocks closest to the central forming block and ending with a pair of forming blocks furthest from the central forming block to reconfigure the tool from the pre-formed configuration to the post-formed configuration.

18. The tool of claim 17, wherein each ridge forming block includes a base block and a filler structure removably engaged to an upper side of the base block, wherein the filler structure is configured to be selectively disengaged from the upper side of the base block and to remain with the corrugated structure after the tool has operatively loaded the corrugated structure onto a layup mandrel.