# US 10,245,793 B2 · Method and an apparatus for forming profile elements

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- Number: US 10,245,793 B2
- Document ID: US10245793B2
- Status: Granted
- Kind: B2
- Application number: 14/825,338
- Filed: 2015-08-13
- Published: 2016-02-18
- Granted: 2019-04-02
- Earliest claimed: 2014-08-14
- Assignees: Airbus Operations GmbH
- Applicants: Airbus Operations GmbH
- Inventors: Tassilo Witte; Hannes Winter
- Web page: https://patentgrep.com/patent/US10245793B2

## CPC

- B29D 99/0003: {Producing profiled members, e.g. beams}
- B29C 53/043: {using rolls or endless belts}
- B29C 70/222: {the structure being shaped to form a three dimensional configuration}
- B29C 70/504: {using rollers or pressure bands (for corrugating B29C53/22)}
- B29C 70/506: {and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence)}
- B65H 3/04: Endless-belt separators
- B65H 5/023: {between a pair of belts forming a transport nip}
- B65H 5/224: {by suction belts (B65H11/005 takes precedence)}
- B29K 2105/0872: {Prepregs}
- B29K 2105/256: {Sheets, plates, blanks or films}
- B29K 2307/04: Carbon
- B65H 2406/32: Suction belts
- Y02T 50/40: Weight reduction
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B65H: HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

For forming profile elements, in particular trapezoidal or Ω-shaped profile elements, from a multilayer stacking of pre-impregnated fibers, the stacking is moved in feed direction with feed speed by sets of conveyor belts which engage with the upper and lower surfaces of the lateral edge sections of the stacking and hold the edge sections in a starting plane. The sets of conveyor belts are arranged so that the distance between the sets engaging with opposite edge sections decreases in feed direction. To conduct the forming step a middle portion of the stacking is moved over a ramp upwardly inclined in feed direction with respect to the starting plane.

## Claims

### Claim 1

A method for forming profile elements from a multilayer stack of pre-impregnated fibers, the method comprising:
moving the multilayer stack in a feed direction at a feed speed by a first set of conveyor belts and a second set of conveyor belts, wherein the first set of conveyor belts engage with an upper surface and a lower surface of a first lateral edge section of the multilayer stack, wherein the second set of conveyor belts engage with an upper surface and a lower surface of a second lateral edge section of the multilayer stack, wherein the second lateral edge section is opposite to the first lateral edge section, wherein the first and second sets of conveyor belts hold the first and second lateral edge sections in a starting plane, and wherein the first and second sets of conveyor belts are arranged so that a distance between the first and second sets of conveyor belts decreases in the feed direction; and
moving a middle portion of the multilayer stack over a ramp upwardly inclined in the feed direction with respect to the starting plane.

### Claim 2 (depends on 1)

The method according to claim 1, comprising forming trapezoidal, Ω-shaped, semi-circular (gauβ-wave-form), or hat-shaped profile elements.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the ramp is formed by a central conveyor belt, a respective belt of the central conveyor belt moving at the feed speed.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the middle portion of the multilayer stack is held in engagement with the ramp by an arrangement of idle rollers engaging with an upper surface of the middle portion.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the middle portion of the multilayer stack is held in engagement with the ramp by a conveyor belt which engages with an upper surface of the middle portion.

### Claim 6 (depends on 1)

The method according to claim 1, comprising applying a vacuum to a lower side of the middle portion of the multilayer stack.

### Claim 7 (depends on 1)

The method according to claim 1, comprising, after leaving the ramp, placing the middle portion of the multilayer stack, including lateral walls formed, on a support member.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the first and second sets of conveyor belts are arranged in a shape of a V.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the distance between the first and second sets of conveyor belts that decreases in the feed direction is measured in a direction orthogonal to the feed direction, such that the distance between the first and second sets of conveyor belts decreases as the multilayer stack moves in the feed direction.

### Claim 10

An apparatus for forming profile elements from a multilayer stack of pre-impregnated fibers, the apparatus comprising:
a first set of conveyor belts;
a second set of conveyor belts;
wherein each of the first and second sets of conveyor belts comprise two cooperating conveyor belts having respective cooperating belt sections thereof located in parallel to a starting plane,
wherein the first and second sets of conveyor belts are spaced from each other to commonly advance a stack of material in a feed direction by:
engagement of the first set of conveyor belts with a first lateral edge section of the stack of material; and
engagement of the second set of conveyor belts with a second lateral edge section of the stack of material;
wherein a distance between the first and second sets of conveyor belts decreases in the feed direction; and
a ramp located between the first and second sets of conveyor belts, wherein the ramp is upwardly inclined in the feed direction.

### Claim 11 (depends on 10)

The apparatus according to claim 10, comprising inclined lateral guide surfaces extending from lateral ends of the ramp in a direction to inner rims of the two cooperating belt sections of the first and second sets of conveyor belts.

### Claim 12 (depends on 10)

The apparatus according to claim 10, wherein the ramp comprises a conveyor belt having an upper belt section moving in the feed direction.

### Claim 13 (depends on 10)

The apparatus according to claim 10, comprising, above the ramp, an arrangement of idle rollers for engaging with an upper surface of a middle portion of the stack of material.

### Claim 14 (depends on 10)

The apparatus according to claim 10, comprising, above the ramp, a conveyor belt for engagement with an upper surface of a middle portion of the stack of material.

### Claim 15 (depends on 10)

The apparatus according to claim 10, comprising a vacuum apparatus for applying a vacuum to a middle portion of the stack of material in an area of the ramp.

### Claim 16 (depends on 10)

The apparatus according to claim 10, comprising a support member for supporting the formed profile, wherein the support member is behind the ramp.

### Claim 17 (depends on 10)

The apparatus according to claim 10, wherein the profile elements comprise trapezoidal, Ω-shaped, semi-circular (gauβ-wave-form), or hat-shaped profile elements.

### Claim 18 (depends on 10)

The apparatus according to claim 10, wherein the first and second sets of conveyor belts are arranged in a shape of a V.

### Claim 19 (depends on 10)

The apparatus according to claim 10, wherein the distance between the first and second sets of conveyor belts that decreases in the feed direction is measured in a direction orthogonal to the feed direction, such that the distance between the first and second sets of conveyor belts decreases as the multilayer stack moves in the feed direction.