# US 11,298,902 B2 · Continuous manufacturing process for composite parts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,298,902 B2 - Document ID: US11298902B2 - Status: Granted - Kind: B2 - Application number: 16/576,018 - Filed: 2019-09-19 - Published: 2021-03-25 - Granted: 2022-04-12 - Earliest claimed: 2019-09-19 - Assignees: Spirit AeroSystems, Inc. - Applicants: Spirit Aerosystems, Inc. - Inventors: Mark Anthony Wadsworth - Web page: https://patentgrep.com/patent/US11298902B2 ## CPC - B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core - B29D 99/0014: {provided with ridges or ribs, e.g. joined ribs} - B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding - B29C 70/504: {using rollers or pressure bands (for corrugating B29C53/22)} - B64C 1/064: {Stringers; Longerons} - B64C 1/12: Construction or attachment of skin panels - B29C 70/52: Pultrusion, i.e. forming and compressing by continuously pulling through a die - B29C 70/54: Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} - B29L 2031/7156: {Pressure vessels} - B64C 2001/0072: {from composite materials} - 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) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B64C: AEROPLANES; HELICOPTERS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Method of forming composite components such as aircraft stringers and the like, and tooling used to form the same. The method includes stacking plies on a forming tool and conveying the plies and the forming tool through a pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit a forming tool supporting a plurality of plies to pass through the pressure vessel. The pressure vessel includes an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part. ## Claims ### Claim 1 A method for forming a composite part, the method comprising: stacking a plurality of pre-impregnated plies on a forming tool creating a ply stack including creating at least one ply drop in the ply stack; conveying the ply stack and the forming tool through a pressure vessel; pressing the ply stack against the forming tool via a plurality of spheres located within an interior chamber of the pressure vessel thereby forming the composite part; and cutting the composite part to length after it has exited the pressure vessel. ### Claim 2 (depends on 1) The method of claim 1 further comprising inflating a diaphragm disposed within the interior chamber with compressed gas thereby pressing the plurality of spheres against the ply stack. ### Claim 3 (depends on 1) The method of claim 1 further comprising circulating air within the interior chamber while pressing the ply stack against the forming tool via the plurality of spheres. ### Claim 4 (depends on 1) The method of claim 1 further comprising placing a membrane over the ply stack prior to the conveying the ply stack and the forming tool through the pressure vessel. ### Claim 5 (depends on 4) The method of claim 4 further comprising vacuum sealing the membrane over the ply stack. ### Claim 6 (depends on 1) The method of claim 1 further comprising heating the ply stack prior to the conveying the ply stack and the forming tool through the pressure vessel. ### Claim 7 (depends on 6) The method of claim 6, wherein the heating the ply stack includes causing resin within the ply stack to liquefy. ### Claim 8 (depends on 6) The method of claim 6, wherein the heating the ply stack includes passing the ply stack through an oven. ### Claim 9 (depends on 1) The method of claim 1, wherein the stacking the plurality of pre-impregnated plies on the forming tool includes rolling the plurality of pre-impregnated plies off of a plurality of spools. ### Claim 10 (depends on 1) The method of claim 1 further comprising compacting, via a plurality of wheels, the ply stack against the forming tool prior to the ply stack entering the interior chamber of the pressure vessel. ### Claim 11 (depends on 10) The method of claim 10 further comprising heating the plurality of wheels. ### Claim 12 (depends on 3) The method of claim 3 further comprising heating the air prior to the circulating the air within the interior chamber. ### Claim 13 (depends on 3) The method of claim 3 further comprising cooling the air prior to the circulating the air within the interior chamber. ### Claim 14 (depends on 3) The method of claim 3, wherein the circulating the air within the interior chamber includes circulating the air via at least one manifold. ### Claim 15 (depends on 2) The method of claim 2 further comprising placing a liner between the diaphragm and the plurality of spheres. ### Claim 16 (depends on 15) The method of claim 15, wherein the liner includes at least one of ball transfer rollers or roller bearings. ### Claim 17 (depends on 1) The method of claim 1, wherein the plurality of spheres include a first set of spheres having a first diameter and a second set of spheres having a second diameter, and wherein the first diameter is different than the second diameter. ### Claim 18 (depends on 1) The method of claim 1, wherein the conveying the ply stack and the forming tool through the pressure vessel is performed using a cable attached to the forming tool. ### Claim 19 (depends on 1) The method of claim 1 further comprising using an electromagnet to attract the plurality of spheres to keep the plurality of spheres from escaping the interior chamber of the pressure vessel. ### Claim 20 (depends on 4) The method of claim 4 further comprising removing the membrane from the ply stack after the ply stack has exited the interior chamber of the pressure vessel.