US 11,951,658 B2
Systems and methods for forming composite members
Scott Edward Krajca, Seattle, WA (US); Darrell Darwin Jones, Mill Creek, WA (US); Paul Chace Wilcoxson, Kent, WA (US); Kurtis S. Willden, Kent, WA (US); Long Hoang Ly, Renton, WA (US); Daniel R. Smith, Jr., Woodinville, WA (US); and Jeremy Justice, Seattle, WA (US)
Assigned to THE BOEING COMPANY, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Aug. 5, 2021, as Appl. No. 17/394,771.
Claims priority of provisional application 63/078,551, filed on Sep. 15, 2020.
Prior Publication US 2022/0080622 A1, Mar. 17, 2022
Int. Cl. B29C 31/08 (2006.01); B29C 70/20 (2006.01); B29C 70/22 (2006.01); B29C 70/38 (2006.01); B29C 70/54 (2006.01); B29L 9/00 (2006.01)
CPC B29C 31/085 (2013.01) [B29C 70/202 (2013.01); B29C 70/22 (2013.01); B29C 70/38 (2013.01); B29C 70/545 (2013.01); B29C 2793/0081 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a composite member constructed from a plurality of composite plies, the method comprising:
introducing first composite plies onto a conveyance member from a first supply station with the first supply station positioned at a first longitudinal end of the conveyance member and with a transfer station positioned at a second longitudinal end of the conveyance member positioned at a transfer station;
introducing second composite plies onto the conveyance member from one or more second supply stations that are positioned away from the first supply station along one or both lateral sides of the conveyance member extending between the first longitudinal end and the second longitudinal end;
orienting the first and second composite plies on the conveyance member;
transferring the first composite plies and the second composite plies from the conveyance member to the transfer station that is positioned at the second longitudinal end of the conveyance member;
individually transferring each of the first and second composite plies to a forming tool at the transfer station; and
forming the first and second composite plies on the forming tool;
the first composite plies comprising different design variables than the second composite plies, with the design variables comprising one or more of material, fiber orientation, and ply widths.