US 12,083,766 B2
Composite structures, forming apparatuses and related systems and methods
Christopher J. Madsen, Layton, UT (US); John B. Healey, South Weber, UT (US); Travis S. Olsen, Tremonton, UT (US); Ethan J. Hoffman, Ogden, UT (US); Jason H. Stulp, Kaysville, UT (US); Michael T. Tueller, Roy, UT (US); Wayne M. Roeber, Roy, UT (US); and Vernon M. Benson, Morgan, UT (US)
Assigned to Northrop Grumman Systems Corporation, Falls Church, VA (US)
Filed by Northrop Grumman Systems Corporation, Falls Church, VA (US)
Filed on May 17, 2021, as Appl. No. 17/322,440.
Application 17/322,440 is a division of application No. 15/807,453, filed on Nov. 8, 2017, granted, now 11,040,512.
Prior Publication US 2021/0268762 A1, Sep. 2, 2021
Int. Cl. B32B 1/08 (2006.01); B29C 70/32 (2006.01); B29C 70/38 (2006.01); B29C 70/56 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 15/02 (2006.01); B60R 19/03 (2006.01); D03D 1/00 (2006.01); D03D 13/00 (2006.01)
CPC B32B 1/08 (2013.01) [B29C 70/32 (2013.01); B29C 70/386 (2013.01); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/26 (2013.01); B32B 15/02 (2013.01); B60R 19/03 (2013.01); D03D 1/00 (2013.01); D03D 13/004 (2013.01); B29C 70/56 (2013.01); B32B 2262/101 (2013.01); B32B 2262/103 (2013.01); B32B 2262/105 (2013.01); B32B 2307/54 (2013.01); B32B 2605/18 (2013.01); D10B 2505/02 (2013.01)] 18 Claims
OG exemplary drawing
 
1. An apparatus for forming a composite structure, comprising: a forming tool having a forming surface configured to receive at least two plies of material to form the composite structure, the forming surface defining a tapered structure having minimal surface variations extending between axial ends of the forming tool, the forming surface including one or more axial and circumferential discontinuities in the tapered s structure comprising one or more of a bump out, a bump in, and a lofted portion positioned between the axial ends of the forming tool interrupting the forming surface of the tapered structure, the tapered structure extending from the one or more of the bump out, the bump in, and the lofted portion in two opposing axial directions; a forming mechanism configured to apply at least one force to at least a portion of the at least two plies of material to conform the at least a portion of the at least two plies of material to the forming surface of the forming tool including the one or more axial and circumferential discontinuities in the tapered structure; and at least two material feed assemblies positioned on opposing radial sides of the forming tool and each of the at least two material feed assemblies having a feed assembly longitudinal axis offset from a tool longitudinal axis of the forming tool, wherein each of the at least two material feed assemblies are configured to hold a supply of a ply of the at least two plies of material and to provide the ply of the at least two plies of material onto the forming tool, each of the material feed assemblies configured to pivot the respective supply of the ply of the at least two plies of material relative to the forming tool.