US 12,138,868 B2
Drape forming apparatus and device, and method of forming a composite structure
David John Sundquist, St. Peters, MO (US); Trevor Lee Howard, St. Louis, MO (US); Steven J. Burpo, St. Charles, MO (US); and Kurtis Shuldberg Willden, Kent, WA (US)
Assigned to The Boeing Company, Chicago, IL (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Dec. 10, 2021, as Appl. No. 17/547,365.
Claims priority of provisional application 63/133,556, filed on Jan. 4, 2021.
Prior Publication US 2022/0212423 A1, Jul. 7, 2022
Int. Cl. B29C 70/44 (2006.01); B29C 35/02 (2006.01); B29C 43/12 (2006.01); B29C 43/36 (2006.01); B29C 43/52 (2006.01); B29C 53/02 (2006.01); B29C 53/84 (2006.01); B29C 70/54 (2006.01)
CPC B29C 70/44 (2013.01) [B29C 43/52 (2013.01); B29C 53/02 (2013.01); B29C 53/84 (2013.01); B29C 70/54 (2013.01); B29C 70/543 (2013.01); B29C 2035/0211 (2013.01); B29C 43/12 (2013.01); B29C 43/36 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A drape forming apparatus for use in forming a composite structure, the drape forming apparatus comprising:
a forming tool having a first forming surface and a second forming surface nonplanar with the first forming surface;
a tray spaced apart from the forming tool and having a first side and a second side, the tray having a hinged end and a distal end, the tray configured to pivot about a pivot axis at the hinged end from a first position to a second position under an applied force such that the distal end moves away from the forming tool;
wherein the distal end is disposed at the first side of the tray furthest from the pivot axis;
a first heat source and a second heat source;
a membrane disposed over the forming tool and the tray on the first side of the tray and configured to exert the applied force on the tray in response to a pressure differential on opposing sides of the membrane;
an end wall coupled to the tray, extending further therefrom than the second heat source, and disposed between the membrane and the second heat source; and
a standoff spaced apart from the forming tool, the standoff coupled to and supporting the hinged end of the tray;
wherein the end wall extends from the standoff to the distal end and spans an entire distance from an edge of the standoff to the distal end when the tray is in the first position;
wherein the first heat source is fixed in position relative to the forming tool;
wherein the first side of the tray faces the first heat source when the tray is in the first position;
wherein the second heat source is disposed on and fixed to the second side of the tray and moves with the tray; and
wherein the first side of the tray moves further away from the first heat source during pivoting of the tray at a rate of pivoting such that composite material disposed on the tray is incrementally withdrawn from the tray at the distal end at a rate corresponding with the rate of pivoting such that a portion of the composite material furthest from the first heat source and nearer to the hinged end than to the distal end is heated by the second heat source longer than a portion of the composite material nearer to the first heat source and nearer to the distal end than to the hinged end.