Abstract: The present invention contemplates a method of continuously forming a layered composite material into a rigid structure as the material is moved from an upstream location to a downstream location. The uncured layered composite material is pulled from a supply at the upstream location through a forming die to form the material into a structural member having a desired shape. The member is moved downstream into a heating die where it is at least partially cured. After it leaves the heating die it is cooled and continues to move downstream where it is cut into suitable lengths. The cooling can be accomplished by a cooling die located downstream from the heating die. A liner is provided within the dies having the same shape as the structural member through which the structural member slides as it moves in the downstream location.

Abstract: The present invention contemplates a method of continuously forming a layered composite material into a rigid structure as the material is moved from an upstream location to a downstream location. The uncured layered composite material is pulled from a supply at the upstream location through a forming die to form the material into a structural member having a desired shape. The member is moved downstream into a heating die where it is at least partially cured. After it leaves the heating die it is cooled and continues to move downstream where it is cut into suitable lengths. The cooling can be accomplished by a cooling die located downstream from the heating die. A liner is provided within the dies having the same shape as the structural member through which the structural member slides as it moves in the downstream location.

Abstract: A method and an apparatus for forming elongated composite parts having constant cross sections. The apparatus comprises a form having a cross section, a portion of which is complementary to a first portion of the desired cross section of the elongated part. The apparatus further comprises a holding means having a cross section, a portion of which is complementary to a second portion of the desired cross section of the elongated part. Plies of preimpregnated composite material are held within a slip tape, which, in turn, is forced against the complementary cross section of the form by the holding means. The apparatus is then passed lengthwise along the slip tape enclosing the preimpregnated plies of composite material to cause the slip tape to tighten around the preimregnated plies and to generate a slip tape-enclosed, elongated part which is appropriately shaped to pass through a pultrusion die.

Abstract: A method and apparatus for forming a fillet to fill a void between two L-shaped structural members which reinforce a composite material skin. A leg of one of the structural members is placed against a leg of the other member, with the second legs of the two members extending outwardly from the adjacent legs. The void is formed between the adjacent rounded outer edges between the legs of each of the members. The apparatus measures the radii of curvature of each of the rounded edges along the length of the member, stores the radii data in an electronic memory, and calculates the area of the void as a function of length along the member. The apparatus then controls a knife to trim an edge from a composite tape so that the trimmed tape has a cross-sectional area equal to the area of the void. The apparatus then forms the fillet from the trimmed tape.