# US 2014/0360417 A1 · System and method for producing a three-dimensional dry fiber preform

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- Number: US 2014/0360417 A1
- Document ID: US20140360417A1
- Status: Published application
- Kind: A1
- Application number: 13/910,857
- Filed: 2013-06-05
- Published: 2014-12-11
- Earliest claimed: 2013-06-05
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Patrick J. THRASH; Chad L. BOGER; Michael James FARRELL
- Web page: https://patentgrep.com/patent/US20140360417A1

## CPC

- B65H 45/12: Folding articles or webs with application of pressure to define or form crease lines (B65H20/28 takes precedence; pleating, kilting or goffering textile fabrics D06J)
- B29B 11/16: comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)}
- D05B 23/00: Sewing apparatus or machines not otherwise provided for (for making zip closures A44B19/00)
- D05B 35/02: for facilitating seaming; Hem-turning elements; Hemmers {(D05B35/062 takes precedence)}
- Y02T 50/40: Weight reduction
- B65H: HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- D05B: SEWING (appliances for the tailoring trade A41H; sewing tables A47B29/00; sewing in bookbinding B42B2/00; sewing machines modified for knitting D04B39/08)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A preform forming machine for producing a three-dimensional dry fiber preform may include a forming block assembly and a clamping plate assembly. The forming block assembly may have a forming table and a forming block and may be positionable in a series of forming block assemblies. The clamping plate assembly may have a clamping table and a clamping plate and may be positionable in a series of clamping plate assemblies arranged in opposing relation to the series of forming block assemblies. Each forming block may be configured to fold a ply stack over onto itself to form a web of a preform. Each clamping plate may be configured to clamp the ply stack to the forming table during the folding of the ply stack.

## Claims

### Claim 1

A preform forming machine for producing a three-dimensional dry fiber preform, comprising:
a forming block assembly having a forming table and a forming block and being positionable in a series of forming block assemblies;
a clamping plate assembly having a clamping table and a clamping plate and being positionable in a series of clamping plate assemblies arranged in opposing relation to the series of forming block assemblies;
the forming block being configured to fold a ply stack over onto itself to form a web of a preform; and
the clamping plate being configured to clamp the ply stack to the forming table during the folding of the ply stack.

### Claim 2 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block is configured to clamp the web against the forming table.

### Claim 3 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block is deployable from a retracted position; and
a forming block outer face being substantially flush with a forming table outer face when the forming block is in the retracted position.

### Claim 4 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block is configured to fold the ply stack along a leader wire positionable on the ply stack.

### Claim 5 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block is configured to fold the ply stack along a plate edge of the clamping plate.

### Claim 6 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block and the forming table are rotatable relative to the clamping plate assembly.

### Claim 7 (depends on 1)

The preform forming machine of claim 1, further comprising:
a lifting mechanism operatively coupled to the clamping plate assembly and configured to adjust a height of the clamping table to be substantially level with a forming table end face and a forming block end face.

### Claim 8 (depends on 1)

The preform forming machine of claim 1, wherein:
the forming block and the forming table have end faces configured such that a protruding portion of the web is foldable thereagainst to form one or more flanges of the preform while the web is clamped between the forming block and the forming table.

### Claim 9 (depends on 8)

The preform forming machine of claim 8, further comprising:
the clamping plate being configured to clamp a tear strap over the flanges and against the forming block end face and the forming table end face.

### Claim 10 (depends on 1)

The preform forming machine of claim 1, further comprising:
a plurality of lifting mechanisms operatively coupled to a corresponding plurality of the forming block assemblies and the clamping plate assemblies; and
the plurality of lifting mechanisms being configured to sequentially displace the forming block assemblies and the clamping plate assemblies and create a moving machine gap for a stitching mechanism.

### Claim 11 (depends on 10)

The preform forming machine of claim 10, further comprising:
a plurality of actuators operatively coupled to corresponding ones of the forming blocks and the clamping plates; and
the actuators being configured to sequentially unclamp the forming blocks and the clamping plates from the web in coordination with a displacement of the forming block assemblies and clamping plate assemblies by the lifting mechanisms.

### Claim 12

A preform forming machine for producing a three-dimensional dry fiber preform, comprising:
a series of forming block assemblies arranged in side-by-side relation to one another, each one of the forming block assemblies having a forming table and a forming block;
a series of clamping plate assemblies arranged in side-by-side relation to one another and in opposing relation to the series of forming block assemblies and having a clamping table and a clamping plate
each forming block being configured to fold a ply stack over onto itself to form a web of a preform; and
each clamping plate being configured to clamp the ply stack to the forming table during the folding of the ply stack.

### Claim 13

A method of producing a three-dimensional dry fiber preform, comprising the steps of:
laying up a ply stack of fabric plies on a layup surface defined by a series of forming block assemblies and a series of clamping plate assemblies positioned in opposing relation to the series of forming block assemblies;
clamping, using clamping plates, the ply stack to the layup surface; and
folding, using forming blocks, the ply stack about a web fold line to form overlapping layers of a web of a preform.

### Claim 14 (depends on 13)

The method of claim 13, further comprising:
clamping, using the forming blocks, the web against the layup surface such that a protruding portion of the web protrudes beyond forming block end faces.

### Claim 15 (depends on 13)

The method of claim 13, further comprising:
rotating the forming tables such that forming table end faces and forming block end faces are generally parallel to the clamping table outer faces; and
adjusting, using lifting mechanisms, a height of the clamping plate assemblies such that the clamping table outer faces are substantially flush with the forming block end faces and the forming table end faces.

### Claim 16 (depends on 13)

The method of claim 13, wherein the step of folding the ply stack about the web fold line comprises:
positioning a leader wire lengthwise along the ply stack to define a web fold line; and
folding, using the forming blocks, the ply stack over the leader wire.

### Claim 17 (depends on 13)

The method of claim 13, further comprising:
stitching, using a stitching mechanism, the overlapping layers of the web along a web seam; and
moving, using lifting mechanisms, the forming block assemblies and clamping plate assemblies away from the web while stitching the web seam.

### Claim 18 (depends on 13)

The method of claim 13, further comprising:
folding a protruding portion of the web along a web-flange fold line to form one or more flanges.

### Claim 19 (depends on 18)

The method of claim 18, further comprising:
applying a tear strap over the one or more flanges; and
clamping, using the clamping plates, the tear strap and the one or more flanges against the forming block end face and the forming table end face.

### Claim 20 (depends on 18)

The method of claim 18, further comprising:
stitching, using a stitching mechanism, a tear strap to the one or more flanges along a flange seam.

### Claim 21 (depends on 20)

The method of claim 20, further comprising:
moving, using lifting mechanisms, the forming block assemblies and the clamping plate assemblies away from the web while stitching the flange seam.