Method and bladder apparatus for forming composite parts

摘要

A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

主权项

1. A method of shaping a material, the method comprising:
placing the material between an inelastic inflatable bladder and a convex protrusion, the inelastic inflatable bladder having a proximal end and a distal end opposite the proximal end, the proximal end of the inelastic inflatable bladder being connected to a support structure, the distal end of the inelastic inflatable bladder being unsupported, the inelastic inflatable bladder having a thickness such that the inelastic inflatable bladder is configured to conform to contours of the convex protrusion, the convex protrusion comprising a top surface, two flange surfaces, and two side surfaces extending between the top surface and the two flange surfaces; pumping air, liquid, or gas into the inelastic inflatable bladder; and after pumping air, liquid, or gas into the inelastic inflatable bladder is inflated, actuating the inflated inelastic inflatable bladder and the support structure in a direction toward the convex protrusion such that the inelastic inflatable bladder conforms to the contours of the convex protrusion by first pressing the material against the top surface of the convex protrusion, then progressively pressing the material against the two side surfaces of the convex protrusion, and finally pressing the material against the two flange surfaces of the convex protrusion as the inelastic inflatable bladder and the support structure move closer to the convex protrusion.