Method and bladder apparatus for forming composite parts

A method of shaping a material on a surface having at least one protrusion, the method comprising:

• placing the material between an inflatable bladder and the protrusion;
• inflating the bladder;
• and
• moving the bladder in a direction toward the protrusion until the material is pressed against an entire surface area of the protrusion.

A method of shaping composite material to form a composite part, the method comprising:

• pumping air, liquid, or another gas into a hollow space between an inflatable bladder and a support structure comprising an elongated channel, wherein peripheral portions or edges of the inflatable bladder are sealed to the support structure at or proximate to peripheral edges of the support structure;
• placing the composite material between the bladder and a forming tool, wherein the forming tool comprises a top surface, two flange surfaces, and two side surfaces extending between the top surface and the flange surfaces to form a substantially trapezoid-shaped protrusion between the flange surfaces, wherein the width of the trapezoid-shaped protrusion is approximately equal to a width of the elongated channel;
• heating the composite material;
• actuating the support structure toward the forming tool such that the bladder first presses the material against the top surface of the forming tool, then progressively presses the material against the two side surfaces of the forming tool, and finally presses the material against the flange surfaces of the forming tool as the support structure moves closer to the forming tool;
• and
• curing the composite material.