Alliant Techsystems Inc.

Northrop Grumman Innovation Systems, Inc.

Orbital Atk, Inc.

Mark Roman

Vernon M Benson

Todd A Rosevear

Jason K Slack

James L Harvey

Timothy S Olschewski

Todd Rosevear

Jason Slack

A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.

Composite structures including an elongated member exhibiting a curved shape

Apparatuses for forming a composite structure are configured to provide a tension at least partially along at least one ply of material as the at least one ply of material is supplied from a material feed assembly to a tool.

Composite structures, forming apparatuses and related systems and methods

Apparatus and methods for forming composite stiffeners and reinforcing structures

A composite structure is provided. In one embodiment, the structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation and the curved elongated member has a defined length. The curved elongated member further has a cross-sectional geometry that varies along the length.

Methods of forming an elongated composite structural member are provided. One method includes, providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. Laying up a first ply of preimpregnated fiber reinforced material over the mandrel. Applying a force to the first ply to establish a desired amount of tension within the first ply and then pressing the first ply onto the mandrel in a conformal manner. This includes passing at least one roller over the mandrel and the first ply while maintaining the desired amount of tension within the first ply. The at least one roller is at least partially complementary in shape with the mandrel.

Method of forming a curved composite structure are provided. In one embodiment, the method includes contacting at least one ply of preimpregnated material on a first surface of a curved mandrel. The first surface of the mandrel has a first radius of curvature. The mandrel further has at least one second surface that has a second radius of curvature. A tension gradient is introduced on the ply adjacent to the first radius of curvature and the ply is then pressed over the curved mandrel to form the curved composite structure.

A method and apparatus are provided for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. An apparatus may include a base with a substantially elongated mandrel mounted thereon. One or more rollers configured to at least partially complementarily engage the mandrel are configured to roll over and press one or more plies of composite material onto the mandrel. The mandrel may be disposed on a rotary table and configured to exhibit a curved elongated geometry to form at least partially curved or arcuate elongated members. The present invention enables the formation of elongated structural members from resin impregnated materials while maintaining the materials in a substantially uncured state. The formed members may then be cocured with a skin or other composite structure.

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Salt Lake City, UT, United States of America

Mark Roman