Method and apparatus for manufacture of a profile element

Abstract

A method and an apparatus for manufacturing of a profile element including a web portion, a first and second flange portion, which extend from the web portion and are disposed essentially opposite each other. The method includes folding a blank of composite material about a first and second flange forming surface of a forming tool. The method includes setting at least one flange forming surface of a forming tool a distance from another flange forming surface greater than a desired distance between inner surfaces of the flange portions of a finished profile element. The folded blank is cured and a gradual decrease of the distance between the flange forming surfaces is simultaneously controlled. The cured profile element is removed from the forming tool.

1 . A method for manufacturing of a profile element comprising a web portion, a first flange portion and a second flange portion, which extend from the web portion and are disposed essentially opposite each other, the method comprising:
 folding a blank of composite material about a first flange forming surface and a second flange forming surface of a forming tool;   setting the first flange forming surface a distance from the second flange forming surface greater than a desired distance between an inner surface of the first flange portion and an inner surface of the second flange portion of a finished profile element;   curing the folded blank and simultaneously controlling a gradual decrease of the distance between the flange forming surfaces; and   removing the cured profile element from the forming tool.   
   
   
       2 . The method according to  claim 1 , further comprising:
 applying the blank onto the forming tool, wherein curing the blank comprises heating the blank.   
   
   
       3 . The method according to  claim 1 , further comprising:
 applying the blank onto the forming tool;   attaching a sensing device to the blank to detect material properties of the blank; and   controlling the rate of gradual decrease of the distance between the flange forming surfaces from the actual composite material properties of the blank being detected by the sensing device during curing.   
   
   
       4 . The method according to  claim 1 , wherein curing of the blank comprises:
 sealing the blank in a vacuum bag;   evacuating air from the vacuum bag; and   heating the blank a heater.   
   
   
       5 . The method according to  claim 1 , further comprising:
 controlling the forming tool to also decrease the distance between the first and second flange forming surfaces after curing and before removing the finished cured profile element.   
   
   
       6 . The method according to  claim 1 , wherein controlling the first and second flange forming surface of a first and a second flange forming tool portion respectively, from and towards each other, is performed by inflation and deflation of air bags being arranged between the first and second flange forming tool portions. 
   
   
       7 . The method according to  claim 1 , wherein controlling the at least one flange forming surface comprises angularly moving at least one of the flange forming surfaces relative to a vertical. 
   
   
       8 . An apparatus for manufacturing of a profile element, comprising a web portion, and a first flange portion, which extends from the web portion, the apparatus comprising:
 a web forming surface,   a first flange forming tool portion for forming a blank of composite material, the first flange forming tool portion comprising a first flange forming surface wherein the first flange forming tool portion and the web forming surface are movable relative each other, and   a control unit for controlling a gradual motion of the first flange forming tool portion and the web forming surface towards each other from a start position, taking account of composite material properties of the blank during curing.   
   
   
       9 . The apparatus according to  claim 8 , further comprising:
 a sensing device attachable to the blank for detecting of the composite material properties of the blank during curing, the sensing device being connected to the control unit.   
   
   
       10 . The apparatus according to  claim 8 , further comprising:
 a second flange forming tool portion;   a web forming tool portion; and   flexible junctions configured to connect the web forming tool portion to the first flange forming tool portion and to the second flange forming tool portion.   
   
   
       11 . The apparatus according to  claim 10 , further comprising:
 at least an inflatable air bag arranged between the flange forming tool portions, and   an air pressure source connected to the air bag, wherein the air pressure source is controlled by the control unit.