Abstract: A composite forming station for forming a T-profile composite part from a planar laminate. The composite forming station includes in-line rollers arranged along a forming direction, wherein a thickness and/or edge angle each roller is greater than the preceding roller, wherein the rollers gradually splay apart feet sections of the planar laminate to convert the laminate to the T-profile composite part.

Abstract: A manufacturing system (1) for manufacturing shaped laminates including: forming tools (2.1, 2.2) extending along a longitudinal direction X, located parallel to one another and configured to receive a laminate (4) between the forming tools; a shaping tool (3) extending along the longitudinal direction X and along a transversal direction Z, and configured to receive the laminate (4) on an external surface of the shaping tool, wherein the forming tools (2.1, 2.2) or the shaping tool (3) are movable in the longitudinal direction X and in the transversal direction Z, relative to the at least one of the shaping tool (3) and the two forming tools (2.1, 2.2).

Abstract: A method for manufacturing curved composite material omega stringers, comprising: automatic tape laying-up in an ATL machine, an AFP machine or a FLU machine and automatic cutting of the contour, to achieve a straight preform with reinforcements; flat forming to obtain an omega shape on the straight preform to transform it into a straight omega shaped preform; and curve forming the straight omega shaped preform by placing it in a flexible tool comprising a longitudinally embedded stiff band and a laminate clamping arrangement, the laminate clamping arrangement being located in extreme positions of the flexible tool, the flexible tool being covered by a mechanical closing arrangement, such that a head of the straight omega shaped preform has reinforcements on both extremes, the reinforcements being held by the laminate clamping arrangement during the forming process, and afterwards the straight omega shaped preform is heated and transformed into a curved omega stringer.

Abstract: A method for manufacturing a structure by curing together a base laminate and structural components placed thereon. Particularly, the uncured structural component has a peripheral tapered foot edge so that the vacuum bag placed thereon follows all the uncured plies without an abrupt leap from the structural component foot to the base laminate.

Abstract: A composite forming station for forming a T-profile composite part from a planar laminate. The composite forming station includes in-line rollers arranged along a forming direction, wherein a thickness and/or edge angle each roller is greater than the preceding roller, wherein the rollers gradually splay apart feet sections of the planar laminate to convert the laminate to the T-profile composite part.

Abstract: A method for manufacturing curved composite material omega stringers, comprising: automatic tape laying-up in an ATL machine, an AFP machine or a FLU machine and automatic cutting of the contour, to achieve a straight preform with reinforcements; flat forming to obtain an omega shape on the straight preform to transform it into a straight omega shaped preform; and curve forming the straight omega shaped preform by placing it in a flexible tool comprising a longitudinally embedded stiff band and a laminate clamping arrangement, the laminate clamping arrangement being located in extreme positions of the flexible tool, the flexible tool being covered by a mechanical closing arrangement, such that a head of the straight omega shaped preform has reinforcements on both extremes, the reinforcements being held by the laminate clamping arrangement during the forming process, and afterwards the straight omega shaped preform is heated and transformed into a curved omega stringer.

Abstract: A hybrid tool for curing composite structures for aircrafts, such as stringers, torsion boxes, skin panels, wing surfaces, horizontal tail or vertical stabilizers, etc. The hybrid tool comprises a metallic portion and an elastic portion arranged on a surface of the metallic portion. The elastic portion and the metallic portion are permanently joined to each other so that the metallic portion and the elastic portion together define a surface having a shape which copies at least part of a surface of a piece of composite material to be cured. The tool is capable of satisfactorily curing pieces of composite material which have a minimum thickness and/or a very aggressive change of thickness.

Abstract: A method for manufacturing a stiffened panel made from composite material comprising a skin and elongated reinforcing elements wherein some of the elongated reinforcing elements cross each other. The method comprises the steps of (a) laying up a flat laminate comprising stacked plies of composite layers for forming a structure comprising the elongated reinforcing elements of the panel, (b) cutting the flat laminate along intersection lines of planes defining the webs of two crossing reinforcing elements, (c) cutting in the flat laminate the outline of the elongated reinforcing elements, (d) forming the structure comprising the elongated reinforcing elements of the panel, (e) laying up plies of composite layers for forming the skin, and (f) curing the laid-up plies of the skin and the formed structure comprising the elongated reinforcing elements.

Abstract: An apparatus for manufacturing composite stringers from a composite laminate comprising a male mold, a main caul plate, two fixed female mold halves, two secondary movable caul plates and a retention device. The main caul plate is located below the male mold, the female mold halves are located at both sides of the main caul plate and the secondary movable caul plates, each of them located respectively over each one of the two female mold halves. The male mold, the main caul plate, the two female mold halves and the two secondary caul plates are non-developable surfaces. The retention device keeps each secondary movable caul plate at a predetermined distance of its respective female mold half.

Abstract: A method for manufacturing a stiffened panel made from composite material comprising a skin and elongated reinforcing elements wherein some of the elongated reinforcing elements cross each other. The method comprises the steps of (a) laying up a flat laminate comprising stacked plies of composite layers for forming a structure comprising the elongated reinforcing elements of the panel, (b) cutting the flat laminate along intersection lines of planes defining the webs of two crossing reinforcing elements, (c) cutting in the flat laminate the outline of the elongated reinforcing elements, (d) forming the structure comprising the elongated reinforcing elements of the panel, (e) laying up plies of composite layers for forming the skin, and (f) curing the laid-up plies of the skin and the formed structure comprising the elongated reinforcing elements.

Abstract: Method for manufacturing a base structure (8) of an aeronautical torsion box (1) for an aircraft (11) characterized in that it comprises the steps of: a.—providing at least a fresh skin (3), at least one fresh stringer (4), at least a fresh front spar (5) and fresh rear spar (6), b.—positioning the fresh skin (3), the at least one fresh stringer, the fresh spars (5, 6) in a curing tool in a configuration corresponding to that of a base structure (8), c.—subjecting the structure (8) to a single curing cycle, obtaining a cured base structure (8).

Abstract: Method for manufacturing a base structure (8) of an aeronautical torsion box (1) for an aircraft (11) characterized in that it comprises the steps of: a.—providing at least a fresh skin (3), at least one fresh stringer (4), at least a fresh front spar (5) and fresh rear spar (6), b.—positioning the fresh skin (3), the at least one fresh stringer, the fresh spars (5, 6) in a curing tool in a configuration corresponding to that of a base structure (8), c.—subjecting the structure (8) to a single curing cycle, obtaining a cured base structure (8).

Abstract: An injection interface device comprising a wedge having a first surface mountable over the joint between the mold and the terminal element and a second surface being inclined with respect to the first surface. A fixation element is mountable against the second surface and an attachment element. The device is configured so that it avoids or prevents the movement of the wedge in a direction parallel to the mold and the movement of the fixation element in a direction perpendicular to the mold so that a displacement of the fixation element parallel to the mold makes a displacement of the wedge in a direction perpendicular to the mold so that the wedge presses against the terminal element to seal it.

Abstract: An apparatus for manufacturing composite stringers from a composite laminate comprising a male mould, a main caul plate, two fixed female mould halves, two secondary movable caul plates and a retention device. The main caul plate is located below the male mould, the female mould halves are located at both sides of the main caul plate and the secondary movable caul plates, each of them located respectively over each one of the two female mould halves. The male mould, the main caul plate, the two female mould halves and the two secondary caul plates are non-developable surfaces. The retention device keeps each secondary movable caul plate at a predetermined distance of its respective female mould half.

Abstract: An injection interface device comprising a wedge having a first surface mountable over the joint between the mold and the terminal element and a second surface being inclined with respect to the first surface. A fixation element is mountable against the second surface and an attachment element. The device is configured so that it avoids or prevents the movement of the wedge in a direction parallel to the mold and the movement of the fixation element in a direction perpendicular to the mold so that a displacement of the fixation element parallel to the mold makes a displacement of the wedge in a direction perpendicular to the mold so that the wedge presses against the terminal element to seal it.

Abstract: A hybrid tool for curing composite structures for aircrafts, such as stringers, torsion boxes, skin panels, wing surfaces, horizontal tail or vertical stabilizers, etc. The hybrid tool comprises a metallic portion and an elastic portion arranged on a surface of the metallic portion. The elastic portion and the metallic portion are permanently joined to each other so that the metallic portion and the elastic portion together define a surface having a shape which copies at least part of a surface of a piece of composite material to be cured. The tool is capable of satisfactorily curing pieces of composite material which have a minimum thickness and/or a very aggressive change of thickness.

Abstract: A method for manufacturing pieces of composite material having varied thicknesses is disclosed. The method includes a first stacking stage and a second forming and drying stage. In the second stage, a forming tool, which is adapted to the configuration of the piece, except in the zone affected by the change in thickness, is used. In the first stage, one or more pre-forms of the piece are stacked successively with some cloths having the dimensions needed for producing the change of thickness, some laminates of a peelable material, and some supplementary cloths in such a way that the resulting layers have the thickness needed to be adapted to the forming tool. At the end of the second stage, laminates resulting from the supplementary cloths and laminates of a peelable material are removed.

Abstract: Aircraft component, such as an aircraft wing, that comprises at least one panel (11) of a composite material formed by a skin (13) and at least a stiffening stringer (15) configured by a web (17) and a foot (19) bonded to said skin (13); the stringer (15) having a run-out zone inside said panel (11) subjected to a high load level; the stringer (15) having a web (17) of decreasing height in said run-out zone and a foot (19) having a first section (31) of variable width from an initial value W1 to a final value W2 and a second section (33) with a width W2 in said run-out zone; the foot (19) and the web (17) of said stringer (15) having a decreasing thickness in said run-out zone for improving the load transfer from the stringer (15) to the skin (13).

Abstract: The system has special application in the manufacture of aircraft wing covers (10 made of carbon fiber and the stringers (3) cured jointly with the wing cover during the polymerization in autoclave. The tool pieces (4) being used are defined by angular elements (5, 6) copying the geometry of the stringers (3). The shape of these stringers corresponds to the “T” section. The angular elements (5, 6) comprise, in their upper part, a pair of battlements (7) in order to be caught by part of the clamps (9) of a head (10) linked to a robot (11) of the spherical type with articulated arm with six axes. The angular elements (5, 6) are made of INVAR material and they are used to keep in position the stringers during the curing cycle in the autoclave.

Abstract: A process for manufacturing stiffened structures (11) in composite materials formed by an outer coating (13) and a plurality of stiffeners (15) the cross-section of which has a closed form delimiting an inner opening (23), comprising the following steps: a) Providing a shaping tool (31); b) Providing auxiliary male tools (37) with an inert material inside them coated with membranes suitable for curing c) Providing stiffeners (15) in fresh or cured condition; d) Arranging the stiffeners (15) in the tool (31) and the auxiliary male tools (37) in their inner openings (23); e) Laminating the outer coating (13); f) Curing the stiffened structure (11) with high temperature and pressure; g) Removing the auxiliary male tools (37) after reducing their volume by withdrawing the inert material thereof; h) Separating the cured stiffened structure (11) from the tool (31). The invention also relates to the auxiliary male tools.