Method and apparatus for forming structural members

Background of the invention<u style="single">Field of invention</u> The present invention relates to the manufacture of structural members, and more specifically to devices and methods for molding curved structural members.

<u style="single">Description of related technology</u> Composite members are commonly used in applications such as aircraft and other transportation equipment, where light weight and high strength are desired or required. Composite members often have to be molded into curved configurations according to the particular application of the member. Complex curved composite members are constructed in the desired configuration while the composite member is typically in a "green" or uncured state, and then cured while being supported by the desired configuration. Will be done. One conventional method for molding such curved composites is by manually placing the composite on a mandrel or other tool that defines a male pattern corresponding to the desired configuration. For example, the composite material can be arranged as a pre-impregnated composite fiber ply (prepreg), for example an epoxy impregnated charcoal fiber laminate. The ply is placed by hand on the mandrel and is typically cured on the mandrel to form the member using heat and / or pressure. Alternatively, the composite is a dry fiber ply ("dry fabric" Arranged as fabric) "), the adhesive material can be added separately. In either case, the resulting structural member can be molded into a variety of desired shapes. However, such a manual layup process is time consuming. In addition, a separate mandrel must typically be provided to form each particular configuration of the composite member.

According to another conventional method known as drape molding for producing composite members, a laminated charge on a flat sheet or a blank of composite material is molded onto the mandrel. In particular, the charge is heated and pressed around the male mandrel using a vacuum bag. Drape molding has been successfully used to mold composite parts when the part being molded has only a few prepreg plies. However, it specifies thick laminates and, for example, C-shaped, I-shaped, or L-shaped beams and long flange lengths, contours along that length, variable thickness, joggles (or changes in direction), or offsets. For complex shapes such as composite members, vacuum bag drape molding can result in ply wrinkles.

Transferred to the assignee of the present application, 2004<u style="single">Published on November 9th</u>, U.S. Patent entitled "Forming Method for Composites"<u style="single">Patent No. 6,814,916</u>Describes a system and method of molding a composite to reduce the buckling of the fibers of the composite. In particular, the composite charge can be molded on the mandrel using a bladder and hot plate.<u style="single">Published October 10, 2006</u>The United States entitled "Composite Spar Drape Forming Machine"<u style="single">Patent No. 7,118,370</u>Has also been assigned to the assignee of the present application, which also describes the machines and methods for molding the composite material around the mandrel.

While the devices and methods described above are useful for molding composite members, there continues to be a need for improved devices and methods for molding composite members. The method is to produce composite members that define a variety of contours, including contours with different thicknesses, curves, angles, flanges, etc. Must be able to.

<p> Outline of the invention The present invention provides an apparatus and associated method for molding a structural member from a charge or blank. The charge is placed on the first die of the device and can be molded into the desired configuration defined by the recess or cavity of the die by inserting a second die or tool into the recess.</p><p> According to one embodiment of the invention, the device comprises a first die supported by a frame. The first die has first and second longitudinal incompressible portions that are traversely adjustable between the first and second positions and adjusts the recesses in minutes. The second die, which is also supported by the frame, defines the outer surface corresponding to the recess of the first die. At least one of the dies is adjustable with respect to the frame in the direction towards the opposite die so that the second die can be inserted into the first recess, thereby pulling the portion of the first die. Adjust outward in the transverse direction and mold the charge between the first and second dies into the structural member configuration. At least one motion control device is configured to control the transverse adjustment of the first die portion. The first die can also be adapted to regulate the transverse motion of the charge so that the opposing surfaces of the charge are subject to tensile stress during the molding process. The first die supports the die in the construction of the structural member without reconstructing the support frame and the second die, for example so that the die can support the molded charge during subsequent processing operations. It may be easily removable from the support frame along with the molded charge to be made. In some cases, one of both dies may be flexible and a locking device may be provided to hold the respective positions of the first die portion. Both dies can contain multiple segments connected in the longitudinal direction.</p><p> According to another aspect of the invention, a device comprising a support tray and first and second parts of a die supported by the tray is provided. Each portion extends longitudinally and is traversably adjustable to define recesses between the portions to at least partially receive the charge during the molding process. The position of each part can be held by one or more locks.</p><p> Furthermore, the present invention provides a device comprising a die defining an aperture corresponding to a predetermined configuration of a structural member and a tool configured to be inserted into the aperture. The positioning device is configured to insert the tool into the aperture at least partially, thereby shaping the charge into the configuration defined between the tool and the die. In addition, the molding apparatus is configured to adjust a portion of the charge outside the aperture of the die, thereby wrapping the charge at least partially around the tool. The molding device and / or the positioning device is configured to compress the charge against the tool, thereby molding the structural member into a predetermined configuration of the structural member. The tool can be a rigid member or an inflatable bladder, and the positioning device is configured to selectively engage and disengage the tool so that it is wrapped by a charge. be able to. The positioning device can also be configured to push the tool into the aperture in the first direction, and the forming device is configured to extend in the transverse direction of the die 2 to bend one or more edges of the charge against the tool. Can be done.</p><p> According to the method of the present invention, first and second dies are provided to mold the charge. The first die contains the first and second parts, the part being traversely adjustable between the first and second positions, with at least a recess that receives the second die. It is structured in a second position to collaborate and regulate. The charge is placed between the dies and the second die is at least partially inserted into the recess so that the portion of the first die is transversely outward. Adjusted and the charge is molded between the dies into a structural member configuration. Each portion of the first die can be urged inward in the transverse direction to control the transverse motion of the portion.</p><p> The charge is constrained to the first die, for example by exhausting the gas through multiple apertures defined by the portion of the first die so that the opposing surfaces of the charge are subjected to tensile stress during the molding process. Can be done. In some cases, the first die can be bent during the molding process and the position of the portion of the first die can be locked after the charge has been molded. The charge can thus be supported by the first die during the molding process and during subsequent processing operations performed after the die has been removed from the apparatus. In addition, the charge can be laid up on the first die as multiple compound plies.</p><p> According to another method of the invention, the charge is placed on a die having first and second longitudinal portions, eg, as multiple plies of composite material. The portions are adjusted in the transverse direction so that the portions work together to define the recess. The charge is molded on the portion. The charge is then trimmed to a predetermined configuration of the structural member while being supported on the die. The charge can be constrained to the die so that both opposing surfaces of the charge are subjected to tensile stress during the molding process. Each portion can be urged inward in the transverse direction during the molding process to control the adjustment of the portion. Further, the die portion can be locked in place after the molding process to prevent adjustment of the transverse direction of the portion being trimmed.</p><p> According to another embodiment of the invention, the charge is placed on the die that defines the aperture, and the tool is at least partially inserted into the aperture so that the charge is defined between the tool and the die. Molding. For example, the tool can be selectively engaged and disengaged from the positioning device so that the tool can be configured to be wrapped by a charge. The forming apparatus is adjusted outside the die aperture to wrap the charge at least partially around the tool. The charge is then compressed against the tool in order to mold the structural member into a predetermined configuration, such as a tubular configuration. For example, the tool can be inflated, or a positioning device or molding machine can be pushed against the tool to compress the charge.</p>

Detailed description of the invention The invention is described more fully herein with reference to the accompanying drawings, the drawings showing some, but not all, examples of the invention. The present invention can be embodied in various forms and should not be construed as limited to the examples described. Throughout the drawing, the same numbers refer to the same elements.

With reference to the drawings, in particular FIGS. 1, 5 and 12, the apparatus 10 for molding the structural member 12 according to one embodiment of the present invention forms the structural member 12 of various sizes and configurations. It can be used for processing. The configuration shown in FIG. 12 and described throughout this description is a hat stringer for making a complex with a reinforced hat portion. The stringers are shown as approximately straight lines, but may be curved or have complex curvatures, depending on the intended use. The structural member 12 is typically manufactured from blank or charge 14. The charge 14 can be, in particular, a laminated member made of a composite material, i.e. a fiber reinforced material arranged in a matrix material. Illustrative composites are fiberglass, metals, minerals, graphite or carbon, nylon, EI DuPont de Numur &amp; Company (EI) Reinforcing members such as individual fibers, strands, blades, woven or non-woven mats, made from materials such as aramids such as Kevlar®, a registered trademark of du Pont de Nemours and Company. including. The matrix material can be a thermoplastic or thermosetting polymeric resin. An exemplary thermosetting tree Fats include allyls, alkyd polyesters, bismaleimides (BMIs), epoxies, phenolic resins, polyesters, polyurethanes (PURs), polyurea-formaldehydes, cyanate esters and vinyl ester resins. Exemplary thermoplastic resins are liquid crystal polymer (LCP); polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), perfluoroalkoxy resin (PFA), polychlorotrifluoroethylene (PCTFE) and Fluoroplastics containing polyfluoromethyl vinylether (MFA); Victrex PLC Corporation, Thornton Cleveley Lancashire, Thornton Cleveley Lancashire, Lancashire, UK Polyetheretherketone (PEEK)®, a registered trademark of UK), ketone-based resins; polyamides such as nylon-6 / 6, 30% glass fiber; polyethersulfone (PES); polyamideimide ( Polyester thermoplastics containing PAIS), polyethylene (PE); polybutylene terephthalates (PBT), polyethylene terephthalates (PET), and poly (phenylene terephthalates); polysulfone (PSU); or poly (phenylene). Includes sulfide) (PPS). Alternatively, the charge may require heating during the molding process, including but not limited to non-composite or non-reinforced materials such as polymers such as thermoplastics and thermosetting resins. Can be made from materials.

In some cases, Charge 14 is made from a material with a low level of stickiness. That is, conventional composite laminates typically have sufficient adhesiveness to hold the layers of the laminate together during manual layup operations and subsequent solidification and molding processes, as used in the present invention. The stickiness level of the material to be obtained does not have to be substantially so sticky, and device 10 is sufficient to charge 14 throughout the various manufacturing operations so that the layers do not separate from each other despite the low level of stickiness. Can give a lot of support. For example, the material for Charge 14 is from the AccuTack® Adhesion Tester (under standard atmospheric conditions) from the Swing-Albert Instrument Company of Philadelphia, PA, Philadelphia, PA. It can have an adhesive level of about 0.1 lbs / in to 1 lb / in, measured by the force required to pull. One such low-adhesion material is Toray Industries Inc. of Tokyo, Japan. It may be made of Toray® 3900 series resin from of Tokyo, Japan), which can be used in combination with reinforcing materials such as carbon or fiberglass. In addition, the device 10 can improve the level of stickiness between the plies as the material is molded. This improved tackiness is sufficient to hold the layers together and maintain the molded shape.

The charge 14 is typically a substantially flat uncured member. Therefore, the charge 14 can be molded into a desired shape of the structural member 12 by pressure with or without heating the charge 14. The structural member 12 according to the present invention can define various contours and configurations including curves, angles, flanges, complex contours and the like. In particular, the structural member 12 can define a stringer or other long member having a uniform or non-uniform cross-sectional contour along the length of the member. According to one embodiment of the invention shown in FIG. 12, the structural member 12 is a hat-shaped member, i.e., a curved or angled portion 16 that defines a slot or channel 18 along the longitudinal direction. , A member including a transverse flange 20, a tab 22, or other mechanism extending outwardly outward from a curved or angled portion 16. Structural members 12 can be used in, but are not limited to, a variety of industries and applications related to the manufacture of aircraft and other aerospace structures and transportation equipment. In addition, structural members 12 can be used independently or in combination with other structures and devices. In particular, after the structural member 12 has been molded, the member 12 flies. It can be used in the fuselage part of the machine structure. For example, before or after each structural member 12 is cured, one or more of the members 12 can be given to the mandrel of the machine to make the fuselage part. The fiber reinforced plastic can be placed over the member 12, and then the fiber reinforced plastic can be cured (or co-cured with the structural member 12) to produce a finished assembly for the airframe.

With reference to the embodiment of FIG. 1 again, the molded apparatus 10 shown includes a frame 24 for supporting a first die 26 and a second die 28 for molding the charge 14. The first die 26 includes a first portion 30 and a second portion 32 supported by the tray 34. The second die 28 is configured to be adjusted towards the first die 26 to shape the charge 14 into the desired shape.

The tray 34 and the first die 26 can be inserted into and removed from the frame 24 of the device 10. In particular, as shown in FIGS. 2 to 3, the frame 24 can include a channel 36 for receiving the tray 34. The channel 36 can include a plurality of rollers 38 extending inward from the wall of the channel 36 to support the tray 34. That is, the trays 34 can be inserted between each pair of rollers 38, and the rollers 38 can be arranged in pairs so as to limit longitudinal movement of the tray 34 through the frame 24. The channel 36 can also include a tray 34, and thus a guide 40 that contacts the bottom of the tray 34 to keep the first die 26 in the desired configuration. The tray 34 can be inserted into the channel 36 and after the charge 14 on the first die 26 has been molded, the tray 34 has the first die 26 and the molded charge 14 placed on the tray 34. Can be removed with. For example, the tray 34 can be inserted into the channel 36 in a first direction parallel to the longitudinal direction of the tray 34 and then removed from the channel 36 in the same or opposite direction. Alternatively, in another embodiment of the invention, the tray 34 can be inserted / removed in other directions, such as in a transverse direction with respect to the longitudinal direction of the tray 34 and dies 26, 28.

Since the tray 34 is positioned on the channel 36, the first die 26 can be supported by the frame 24 and the charge 14 can be positioned between the first die 26 and the second die 28. In this regard, the charge 14 can be placed on the first die 26 before or after inserting the die into the frame 24 of the device 10. According to one embodiment of the invention, the charge 14 is placed on the first die, for example by individually arranging multiple layers or plies of the composite so that the charge 14 is laid up directly on the first die 26. 26 Can be molded on. Thus, the ply or other member of the charge 14 can be positioned relative to the first die 26 such that the charge 14 is indexed relative to the first die 26. For example, if some of the plies on charge 14 extend only partially along charge 14, then both ends of the ply or "ply drop (ply)" "Drop)" can be accurately positioned with respect to the first die 26. Further, if the charge 14 specifies the mechanisms to be molded or placed prior to the molding process, those mechanisms can be indexed to the first die 26. For example, edges, apertures, thickened or thinned parts, embedded fasteners, supports, or other mechanisms of the charge 14 are accurately positioned with respect to the first die 26. Can be done. The first die 26 can then be indexed during molding and / or other processes. Thus, the charge 14 can be indexed once for the die 26, and the die 26 can then be indexed for other devices for processing, so that the charge 14 is assigned to each process. Charge 14 is accurately positioned without the need for direct indexing.

As shown in FIGS. 4 and 5, the first longitudinal portion 30 and the second longitudinal portion 32 of the first die 26 define a slot or recess 42 between the portions 30, 32. Therefore, the structure is substantially parallel. Each of the portions 30 and 32 of the first die 26 is adjustable in the transverse direction so that the recess 42 can be opened and closed by moving the portions 30 and 32 inward or outward, respectively. When parts 30, 32 of the first die 26 are adjusted outward to the first or open position, the recess 42 is large enough to receive the second die 28, at least in part. Can be. If the portions 30, 32 of the first die 26 are adjusted inward to the second or closed position, the recess 42 may be smaller than the second die 28. In some cases, portions 30, 32 of the first die 26 can contact each other in the closed position.

The second die 28 is configured to push the charge 14 towards the first die 26 so that it can be molded between the dies 26 and 28. For example, as shown in FIG. 6, the second die 28 can be connected to a shaft 44 that is extended or retracted by a plurality of actuator devices 46 such as hydraulic actuators, barometric actuators, or electric actuators. The second die 28 typically defines a contour that at least partially corresponds to the contour of the first die 26. For example, the second die 28 defines a tapered or wedged portion 48 that corresponds to the tapered or angled surface 50 defined by each of the portions 30, 32 of the first die 26. Can be done. Further, the second die 28 can define flanges or stops 52 that are outwardly located on both sides of the tapered portion 48.

In some cases, the second die 28 can define contours such as ridges or slots 29 (FIGS. 13A to 13C) that contour the charge 14 during molding. For example, slot 29 can extend longitudinally along the length of the second die 28, and charge 14 provides a channel-shaped or slot-shaped mechanism corresponding to slot 29 of the second die 28. It can be molded to define the contours it contains. For example, a pinch actuator 96 can be used to urge the material of charge 14 into slot 29. In this way, various contours or mechanisms can be molded in the charge 14. In some cases, the contour or mechanism may remain on the structural member 12 molded from the charge 14. However, as an alternative, such contours or mechanisms given to the charge 14 can be removed before the structural member 12 is fully molded, for example during the curing of the charge 14. In this regard, the temporary formation of such contours or mechanisms on the charge 14 will typically occur, for example, when the carbon fiber composite is cured from the untreated (green) state. The stress of the charge 14 during the molding process is increased by providing additional material throughout the charge 14 so that it may be necessary if the material "debulks" or otherwise shrinks during curing. It can be reduced and the dimensional accuracy of the completed structural member 12 can be improved. In either case, the second die 28 can be easily replaced, for example by removing the pin 45a connecting the T-nut or bobbin 45b of the die 28 to the shaft 44, resulting in different configurations. The die can be used with the device 10.

The device 10 can further include a motion control device 54 configured to control the transverse position of each portion 30, 32 of the first die 26 along the length of the device 10. As shown in FIG. 6, each of the motion control devices 54 can be extended to the first die 26 so that the opening of the first die 26 is controlled by the device 54. Therefore, the device 54 responds to the outward movement of the first die 26, and for that purpose, to the second die 28 extending into the recess 42 between the portions 30, 32 of the first die 26. Can face each other. In other words, as shown in FIG. 7, the extension of the second die 28 to the recess 42 tends to adjust the portions 30, 32 of the first die 26 outward. However, outward motion can be controlled by the run control device 54, thereby exerting a pressure on the charge 14 between the two dies, the speed of the molding process, the degree of motion of the dies 26, 28, and / Or molding Other aspects of the machining operation can be increased. Each drive control device 54 can be either various types of actuators or other motion controllers. For example, each operation control device 54 can be an active device such as a solenoid, a stepper motor, other electrical actuators, a hydraulically or barometrically controlled cylinder. Alternatively, each operation control device 54 may be a general passive device such as a mechanical spring, passive hydraulic or barometric cylinder. In any case, each operation control device 54 slows the movement of parts 30, 32 of the first die 26, for example, to maintain a predetermined minimum pressure between the dies 26, 28 during molding. You can do it or you can stop it. In some cases, the force exerted on the charge 14 between the dies 26, 28 is a load cell 33 (shown in FIGS. 13A to 13C), which is an electronic transducer that typically gives an electronic signal representing the forming force. It can be monitored by a monitoring device such as.

Further, each of the operation control devices 54 can be independently adjusted so that the positions of the portions 30 and 32 of the first die 26 are independently and selectively determined along the length of the device 10. In this regard, one or both of the dies 26, 28 can be made from a material that is generally uncompressible and hard but allows some flexibility. For example, each of the dies 26, 28 can be made from a polymer such as high density polyethylene (HDPE). This flexibility allows the dies 26, 28 to be pushed into a slightly non-linear configuration to match the non-uniformity along the length of the charge 14. For example, if the charge 14 specifies different thicknesses along its length, parts 30, 32 of the first die 26 are pushed more outward where the charge 14 is thickest, and parts 30, 32. Can be pushed less outward where the charge 14 is not very thick. Parts 30, 32 of the first die 26 may also be adjusted by non-uniform amounts to accommodate other features, such as non-uniformity or non-linearity of the second die 28.

The second die 28 is stretched by a plurality of actuators 46 towards the first die until the charge 14 is molded into a predetermined configuration, whereby parts 30, 32 of the first die 26 are stretched. Encourage outward. As shown in FIG. 8, the tapered portion 48 of the second die 28 can be completely inserted into the recess 42 between the portions 30, 32 of the first die 26, the second die 28. The flange 52 defined by can be pushed towards the first die 26, preventing the second die from being further inserted into the recess 42, and the second die 28 allows the first die 26 to be pushed forward. Furthermore, it prevents being urged outward. That is, the flange 52 of the second die 28 can act as a stop to prevent further molding of the charge 14. In some cases, the second die 28 can be made from at least a slightly flexible material and the actuator is in a non-linear configuration compared to the first configuration of the second die 28. Can be extended to slightly different positions so that is placed against charge 14. In this way, the second die 28 can be bent to match the deformation in the charge 14, the first die 26, and so on.

According to one embodiment of the invention, the separation of parts 30, 32 of the first die 26 during molding applies tension to the charge 14. More specifically, both the first surface 60, which is directed towards the first die 26, and the second surface 62, which is directed toward the second die 28, are in the forming process. Instead of the compressive stress that would have occurred on the first surface 60 of the charge 14 if parts 30, 32 of the die 26 of 1 remained stationary in an open configuration throughout the molding operation, the tension Can be exposed. Although the present invention is intended not to be limited to any particular theory of motion, maintaining the charge 14 in a tensioned state during the forming operation can reduce or eliminate the occurrence of wrinkles in the charge 14. it is conceivable that.

In some cases, the charge 14 can be held by and / or against the first die 26 during the molding process. For example, FIG. 9 shows a tray according to one embodiment of the present invention. 34 and parts 30, 32 of the first die 26 are shown. The first portion 30 of the first die 26 is shown in an assembled configuration with a perforated cover sheet 64, and the second portion 32 of the first die 26 is for the purpose of being clearly illustrated. Shown without a perforated cover sheet 64. The portions 30 and 32 define a plurality of apertures 66 for exhausting gas from the surfaces of the respective portions 30 and 32 where the charge 14 is arranged during the molding process, respectively. Therefore, the charge 14 can be regulated by a partial vacuum formed between the charge 14 and the respective portions 30, 32. Aperture 66 can be connected to one or more internal chambers 68 (FIG. 9A) extending longitudinally along each portion 30, 32, and each chamber 68 is configured to exhaust gas from chamber 68. It is maintained at low pressure by the gas exhaust device 70. Each perforated cover sheet 64 can define a plurality of relatively small apertures 72 such that outside air is drawn through the entire cover sheet 64, thereby charging the charge 14 to the first cover sheet 64, and therefore the first. Constrain to parts 30 and 32 of die 26. The cover sheet 64 can be formed, for example, from a porous Vyon® sheet, which is a registered trademark of Porvair of Norfolk, England.

The device 10 can also be configured to secure the first die 26 portions 30, 32 in a particular position. For example, if parts 30, 32 are pushed outward by non-uniform distances at various points along device 10, eg, to define the configuration of non-linear parts 30, 32, then parts 30, 32 are in that position. Can be locked to. When the first die 26 is locked to the desired configuration of the charge 14, the first die 26 is framed 24 so that the first die 26 supports the charge 14 in the desired configuration during subsequent processing. Can be removed from. For example, as shown in FIGS. 8 and 10, each portion 30, 32 of the first die 26 can be connected to the tray 34 by a plurality of locking devices 74. In the embodiments shown, each locking device 74 includes a bolt 76 extending through tray 34. Each bolt 76 extends through slot 78 of portions 30, 32 (FIG. 10A), so that portions 30, 32 are provided by the head 80 of each bolt 76 located opposite tray 78 to slot 78. It is fixed and each part 30, 32 is slidably adjustable with respect to the bolt 76. That is, the bolt 76 remains stationary in the hole defined through the tray 34, and each portion 30, 32 can be adjusted outward and inward to open and close the recess 42 between the portions 30, 32. A spring 82 is provided to each bolt 76 between the tray 34 and the nut 84 on the bolt 76. For example, a spring 82, which is a disc or bellville spring, urges the nut 84 away from the tray 34, so that the head 80 of the bolt 76 urges parts 30, 32, respectively, against the tray 34. Lock parts 30 and 32 to tray 34 by friction. Each part 30, 32 can be independently fixed to a desired configuration, which may include a configuration such that each portion 30, 32 is bent along a length and / or is in a non-linear configuration. The locking device 74 can be placed in multiple positions along the length of each portion 30, 32. In operation, each locking device 74 It can be released by urging the nut 84 against the tray 34 to overcome the spring force and release the frictional force between the respective portions 30, 32 and the tray 34. In fact, as shown in FIG. 8, the device 10 can include an actuator 88 configured to extend and push against the locking device 74 to unlock each device 74 during molding. .. The actuator 88 can retract and unlock the locking device 74 once the charge 14 has been molded into the desired configuration, so that even if the tray 34 is removed from the frame 24, the first die 26 Parts 30 and 32 are locked in place.

In this way, the structural member 12 can be removed from the device 10 together with the tray 34 and the first die 26 after the molding process. The tray 34 can then be sent to a subsequent processing station for further processing of structural member 12. Further, since the structural member 12 is indexed to the tray 34 and the first die 26, the tray 34 or the first die 26 is It can be used to index the structural member 12 for subsequent movements. For example, the charge 14 is further compressed and / or cured to the desired configuration while being supported by the first die 26. Further, as shown in FIG. 11, the structural member 12 can be trimmed with a knife blade 90 or the like that reciprocates with ultrasonic waves, controlled by a multi-axis adjustable automated trimming head 92. The tray 34 is relative to the work table 94 or other structures associated with the trimming head 92 so that the trimming head 92 can accurately trim the structural member 12 to the desired configuration without the need for the structural member 12 to be indexed directly again. Can be indexed.

Further, as shown in FIG. 8, the device 10 can include a pinch actuator 96 configured to selectively extend and retract through the holes 98 of the tray 34. In the stretched position, each pinch actuator 96 can contact the charge 14, thereby urging the charge 14 against the second die 28 and until the charge 14 is molded. Maintains the position of charge 14 against. An intermediary member such as a longitudinal wedge can be provided between the pinch actuator 96 and the charge 14 so that the charge 14 is held against the second die 28 along the entire length of the charge 14.

FIG. 13 shows another embodiment of the present invention, defining a regulatory unit 100 for the device 10 to regulate the movement of the charge 14 with respect to each of the portions 30 and 32 of the first die 26. The regulator 100 may be a bracket-like member extending along the lengths of portions 30, 32 of the first die 26, at least partially regulating the transverse edges 102, 104 of the charge 14. For example, regulator 100 may define a slot 106 for receiving the transverse edges 102, 104 of the charge 14, so that the edges 102, 104 are in portions 30, 32 of the first die 26. Retained against. The regulator 100 may be a fixed device or adjustable, i.e., pushing the charge 14 against the portions 30 and 32 of the first die 26 to further constrain the charge 14. The indicated regulator 100 or other configuration regulators may be used in combination with or in place of the exhaust device 70.

The charge 14 can optionally be fixed or regulated during the molding process using a variety of other devices or methods. In some cases, the regulator can be connected to the second die 28. For example, FIGS. 13A-13C show another exemplary embodiment of the invention, wherein the second die 28 of device 10 includes an adjustable regulator 100a. Each regulator 100a includes a weight member 160 that is adjustablely connected to one of the flanges 52 of the second die 28. For example, the weight member 160 can define a slot 162 that receives a protrusion or pin 164 extending from each flange 52, so that the weight member 160 can be adjusted with respect to the second die 28. Yes, that is, it is adjusted up and down with respect to the flange 52 as shown in FIGS. 13A-13C. Each weight member 160 can be urged towards the first die 26 by the weight of the member 160 and / or by a urging member such as a spring, as shown in FIG. 13A. Thus, the second die 28 is adjusted towards the first die 26 and the weight member 160 can come into contact with the charge 14 before the charge is significantly molded between the dies 26, 28. The heavy member 160 can be sufficiently urged against the first die 26 so that the member 160 regulates the charge 14 during the molding process. In another embodiment of the invention, the regulator 100a can be actively adjusted. For example, a motor or other actuator can be provided to adjust the position of the regulator 100a. In addition, the regulator can be made from a flexible material such as rubber or polymer. In fact, in some cases, each regulatory unit 100a can include an inflatable bladder that can be filled with gas, which allows it to expand towards charge 14 on the first die 26, forming a process. Hold charge 14 in place.

The first die 26 of the device 10 shown in FIGS. 1-13 is used for the subsequent processing of the structural member 12. It can be used for molding processing in the same way as it is. Therefore, the charge 14 can be placed on the first die 26, the charge 14 can be processed by the device 10, and the first die 26 is removed from the device 10 to another processing station or device. Can be further processed with. The structural member 12 can then be removed from the first die 26 and the first die 26 can be reused for molding of another structural member 12. Of course, a plurality of first dies 26 may be operated on the device 10 so that the device 10 can be operated even when one of the dies 26 is used to support the charge 14 or the structural member 12 outside the device 10. It can be used. In some cases, the plurality of dies 26 can specify different lengths, cross sections, etc. for molding structural members 12 having different configurations.

The first die 26 and / or the second die 28 may be adjustable to define a non-linear configuration for shaping the charge 14 into a configuration that curves, for example, with respect to one or more axes. In this regard, FIGS. 13D to 13E show that the frame 24 of device 10 may include an adjustable support such as a pogo 25, each of which typically selectively extends or retracts the actuating rod 25b. It is shown that the actuator 25a that can be used is included. The actuating rod 25b of the Pogo 25 is rotatably adjustable by a rotatable connection 25c so that the charge 14 can be supported in a curved, twisted, or other three-dimensional contoured configuration. possible. Each rod 25b is die via a channel portion 36a containing a pair of rollers 38 arranged to define a nip for receiving the tray 34, for example as described above in connection with FIGS. 2 and 3. Can support 26 and 28. Thus, the pogo 25 can be adjusted to support the tray 34 and the first die 26 in the desired configuration, so that the charge 14 is molded to the desired configuration, cured, or otherwise. Can be processed with. The pogo 25 can mold the frame 24 of the apparatus 10, which is used to support the tray 34 and the first die 26 while the charge 14 is being molded with the second die 28. .. Alternatively, the pogo 25 has a tray 34, a first die 26, a charge 14, during a separate molding operation performed before or after the molding of the charge 14 with the second die 28. And can be used to support the second die 28. Therefore, the charge 14 is molded into a nearly non-linear configuration defined by the configuration of the pogo 25, either individually or in connection with the molding of the charge 14 between the first die 26 and the second die 28. Can be done.

Further, as shown in FIG. 11, for example, each portion 30, 32 of the first die 26 can include a plurality of segments 30a, 32a arranged in the longitudinal direction. Each segment 30a, 32a can be a modular device with a connection mechanism for connecting to the other segments 30a, 32a of the respective portions 30, 32. Therefore, the first die 26 can be constructed with any number of module segments such that the first die 26 has a length corresponding to the length of the structural member 12 to be molded. The length of the die 26 can be adjusted so that the same module segments 30a, 32a form members 12 of different lengths. In particular, each module segment 30a, 32a can define an alignment rod 112 extending from the segment for engaging the corresponding alignment aperture 114 defined by the adjacent segments 30a, 32a. Further, if the first die 26 is configured to provide exhaust through the surface to constrain the charge 14, the internal chamber 68 of each module segment 30a, 32a will have a corresponding vacuum at the end of the segments 30a, 32a. It can be connected to adjacent segments 30a and 32a via the connection portion 116. The vacuum connections 116 at the exposed ends of the module segments 30a, 32a positioned at both ends of the assembled die 26 can be sealed with caps or plates, or those vacuum connections 116 provide the exhaust device 70. It can be used to connect. Although not shown in FIG. 11, an exhaust device is used to evacuate chambers 68 of parts 30, 32 of the first die 26 during operations following molding in device 10, such as during trimming by the trimming head 92. 70 keeps working Can be

While the structural member 12 molded according to the above description defines a slot or channel 18 along its length, the device 10 of the present invention is a partially or completely closed structural member 12a (FIG. 26). Can also be used for molding. For example, FIGS. 14 and 15 show another embodiment of device 10, which can be used to wrap a composite around an internal tool 120 to form a tubular structural member 12a. The device 10 includes a frame 24 for supporting a die 122 that defines a channel, slot, cavity or other recess 124 for receiving the charge 14. As shown, the die 122 defines a fixed configuration, but in other embodiments, the die 122 is the size of the recess 124 and / or as described, for example, in relation to portions 30, 32. It can include multiple parts that can be adjusted to change the configuration. In either case, the die 122 can support the frame 24 in a predetermined configuration. Thus, as shown in FIG. 16, the charge 14 is applied onto the die 122, which allows it to be indexed into a predetermined configuration for the device 10.

The second die or tool of device 10 is the internal tool 120. The device 10 can automatically position the internal tool 120 for molding, and in some cases the internal tool 120 can be separated from the remaining device 10. For example, device 10 may include a positioning device 126 for moving the internal tool 120 during molding. The positioning device 126 can selectively engage the internal tool 120 using, for example, a vacuum rail 128 that exhausts air from a plurality of vacuum mounting devices 130 positioned along the length of the rail 128. Therefore, the positioning device 126 engages the internal tool 120 to position the tool 120 and then allows the charge 14 to be wrapped around the tool 120 without being disturbed by the positioning device 126. To disengage or disengage. For example, as shown in FIG. 16, the internal tool 120 can be positioned remotely from the recess 124 so that the charge 14 can be placed above the recess 124. The first set of actuators 132 of the positioning device 126 is then used to extend the vacuum rail 128 to the internal tool 120 so that the vacuum mounting device 130 can engage the internal tool 120. The positioning device 126 can then push the internal tool 120 into the recess 124 to form the charge 14 at least partially. For example, the actuator 132 of the positioning device 126 can lift the internal tool 120 (FIG. 18), and the second set of actuators 134 of the positioning device 126 adapts the internal tool 120 to a position aligned with the recess 124. Can be done (Fig. 19). Also, the first set of actuators 132 extends the internal tool 120 relative to the charge 14 into the recess 124 so that the charge 14 is molded into the recess 124 between the die 122 and the internal tool 120. Can be done (Fig. 20). The positioning device 126 then releases the internal tool 120 in the recess 124, at least partially from the internal tool 120.

In particular, the first forming bar 136 can slide inward on the die 122 to a position where the internal tool 120 is located between the die 122 and the forming bar 136. In this way, the forming bar 136 can bend one of the transverse edges 102, 104 of the charge 14 with respect to the internal tool 120 (FIG. 22). The first forming bar 136 can be retracted, and the second forming bar 138 then extends to bend the other one of the transverse edges 102, 104 of the charge 14 with respect to the internal tool 120. Can be present (Fig. 23). Each forming bar 136, 138 can be stretched or retracted by one or more actuators 140, 142, such as an electrical, atmospheric, or hydraulic actuator. The device 10 may further include a heater 144 for heating the charge 14 to facilitate the molding process of the charge 14. For example, one or both molding bars 136, 13 8 can include a heater 144, such as an internal electrical resistance heating device, that heats the charge 14 to a desired temperature, thereby softening the charge 14. The internal tool 120 can also be heated by the heater 144, for example by placing the tool 120 on the forming bar 136, as shown in FIGS. 15 and 16. Other types of heaters can also be used to heat the charge 14 during the molding process, such as conduction or convection heaters, resistive heaters located on or in a second die, heating blankets, etc. Alternatively, it is another material that conducts heat to the charge 14 or the device 10 by being placed in contact with the charge 14 or the device 10.

The charge 14 can then be compressed to the desired configuration. For example, if the edges 102, 104 of the charge 14 are folded against the internal tool 120 and the second forming bar 138 is located opposite the edges 102, 104 of the internal member 120, The positioning device 126 also extends here to exert a force on the second forming bar 138, thereby compressing the edges 102, 104 of the charge 14 between the internal tool 120 and the second forming bar 138. In some cases, the internal tool 120 may be a rigid member such that the edges 102, 104 of the charge 14 are compressed between the second forming bar 138 and the internal tool 120. Further, such a rigid internal tool can include an aperture on the surface through which the outside air can be exhausted, for example by an exhaust device fluidly connected to the tool's internal chamber. Therefore, the exhaust device can draw the charge 14 to the outer surface of the tool. Alternatively, as shown in FIG. 24, the internal tool 120 is configured to receive fluid from a pressurized fluid source 150 and thereby inflate relative to the die 122 and the forming bar 138. Can be a fluid. In this regard, the bladder can expand while being positioned in the recess 124, thereby providing sufficient rigidity to counter the compressive force for compressing the charge 14. After molding and compressing the charge 14 into the desired configuration of structural member 12, the positioning device 126 and forming bar 138 retract, resulting in the structural member 12 being exposed again and internal tools (if applicable). The pressurized fluid given to is released. In this way, the structural member 12 can be removed from the die 122, and the internal tool 120 can be removed from the structural member 12. In some cases, the structural member 12 is supported by the die 122, for example, trimming the structural member 12 to a desired configuration, otherwise giving the structural member 12 a mechanism, further hardening the structural member 12, and the like. Can be processed. In this regard, it is fine on the die 122 The die 122 may be easily removable from the support frame 24 so that the structural member 12 can be transported to another station or device for processing the building member 12. That is, the die 122 is a method other than cutting, bending, removing screws, removing bolts, or releasing easily removable connections such as the locking device 74, without significant reconstruction of the support frame 24 or die 22. Can be adapted to be removed without separating the die 122 from the support frame 24.

In each embodiment, the device 10 of the present invention is described to include movable male molded members 28, 120 that are adjusted with respect to recesses 42, 124 defined by female molded members 26, 122. To. However, in some cases, the male molded member is a stationary device in which the female molded member is adjusted towards the male member. In either case, the charge 14 can be molded into the desired shape of the structural member 12. In addition, the structural member 12 can be removed from both molded members, or the structural member 12 can be supported by one or both molded members during subsequent processing operations.

Many modifications and other embodiments of the present invention will be envisioned by those skilled in the art of the art in which the present invention benefits from the teachings set forth in the earlier description and associated drawings. Therefore, the present invention should not be limited to the specific examples and modifications disclosed, and is intended to include other examples within the scope of the appended claims. Specific terms are used, but they are used only in a general, descriptive sense, not for limited purposes.

<figref num="1">It is a perspective view which illustrates the apparatus for molding a structural member by one Example of this invention.</figref><figref num="2">It is a perspective view which illustrates the support frame of the apparatus of FIG.</figref><figref num="3">It is a perspective view which illustrates the part of the apparatus of FIG.</figref><figref num="4">It is a perspective view which illustrates the part of the apparatus of FIG.</figref><figref num="5">It is an elevation view which illustrates the apparatus of FIG.</figref><figref num="6">It is an elevational view illustrating the apparatus of FIG. 1, shown with a second die in a continuously stretched position.</figref><figref num="7">It is an elevational view illustrating the apparatus of FIG. 1, shown with a second die in a continuously stretched position.</figref><figref num="8">It is an elevational view illustrating the apparatus of FIG. 1, shown with a second die in a continuously stretched position.</figref><figref num="9">It is a perspective view which illustrates the support tray and the 1st die of the apparatus of FIG.</figref><figref num="9A">It is sectional drawing which illustrates the part of the 1st die along the line 9A-9A of FIG.</figref><figref num="10">FIG. 1 is a partial perspective view illustrating a support tray and a first die of the device.</figref><figref num="10A">It is sectional drawing which illustrates the part of the 1st die seen from the direction parallel to the longitudinal direction of the 1st die.</figref><figref num="11">It is a perspective view which illustrates the structural member in the trimming operation.</figref><figref num="12">It is a perspective view which illustrates the structural member molded by the apparatus of FIG.</figref><figref num="13">It is an elevation view which illustrates the apparatus for molding the structural member by another Example of this invention.</figref><figref num="13A">FIG. 5 is an elevational view showing an apparatus for molding a structural member according to another embodiment of the present invention with a charge that is not molded.</figref><figref num="13B">FIG. 6 is an elevational view illustrating the apparatus of FIG. 13A, with a partially molded charge.</figref><figref num="13C">It is an elevational view illustrating the apparatus of FIG. 13A with a fully molded charge.</figref><figref num="13D">FIG. 6 is a perspective view illustrating an apparatus according to an embodiment of the present invention, including a pogo for supporting a die.</figref><figref num="13E">It is a partial perspective view which illustrates the part of FIG. 13D.</figref><figref num="14">It is a perspective view which illustrates the apparatus for molding the structural member according to still another Example of this invention.</figref><figref num="15">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="16">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="17">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="18">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="19">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="20">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="21">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="22">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="23">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="24">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="25">FIG. 5 is a perspective view illustrating the apparatus of FIG. 14 at various stages during a molding operation according to an embodiment of the present invention.</figref><figref num="26">FIG. 5 is a perspective view illustrating a composite in which a hat portion molded by the apparatus of FIG. 15 is cured.</figref>