The Boeing Company

Ivan Gilberto Ramirez

Andrew Elmer Modin

Richard Alexander Prause

Allen James Halbritter

Richard E Heath

John R Nibe

Byron James Autry

Richard E Heath, Iii

An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.

Methods, devices, and systems for forming a composite structure using an expandable pallet

Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Methods and systems for forming composite stringer assemblies

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Charleston, SC, United States of America

Ivan Gilberto Ramirez