Methods and devices of forming a tensioned stringer for a vehicle

1. A method of fabricating a composite stringer for a vehicle, the method comprising:

positioning first and second charges at a die cavity with first ends of each of the first and second charges extending over the die cavity and with the first and second charges spaced away from a punch die;

securing second ends of each of the first and second charges away from the die cavity;

inserting the punch die into the die cavity and driving the first ends of each of the first and second charges into the die cavity while the second ends remain secured away from the die cavity;

moving the punch die out of the die cavity; and

moving together first and second form blocks that form the die cavity and applying lateral force to blades of the first and second charges.

2. The method of claim 1 , further comprising releasing the second ends of the first and second charges prior to moving the first and second form blocks together.

3. The method of claim 1 , wherein securing the second ends of each of the first and second charges away from the die cavity comprises compressing the second ends between a holding member and a support member.

4. The method of claim 1 , further comprising bending the first and second charges into the die cavity and forming blades in the first and second charges.

5. The method of claim 4 , further comprising maintaining a section of each of the first and second charges at the second ends on a support member and forming flanges in the first and second charges.

6. The method of claim 1 , further comprising tensioning the first and second charges at different tension levels by driving the punch die into the die cavity.

7. The method of claim 1 , further comprising overlapping the first ends of the first and second charges over the die cavity prior to inserting the punch die into the die cavity.

8. The method of claim 7 , further comprising inserting the punch die into the die cavity and forming a scarf joint at the first ends of the first and second charges.

9. The method of claim 1 , further comprising continuing to secure the second ends of the first and second charges while moving the form blocks towards one another.

10. The method of claim 1 , further comprising positioning the second ends of the first and second charges under plates and securing the second ends of each of the first and second charges away from the die cavity.

11. The method of claim 1 , further comprising inflating bladders that are positioned at the second ends of the first and second charges and securing the second ends of each of the first and second charges away from the die cavity.

12. A method of fabricating a composite stringer for a vehicle, the method comprising:

positioning first and second charges at a die cavity formed between first and second form blocks with a first section including first ends of each of the first and second charges cantilevered over the die cavity and a second section including second ends of each of the first and second charges supported on support members and while a punch die is spaced away from first and second charges;

securing the second sections of the first and second charges to the support members while the punch die is spaced away from the first and second charges;

inserting the punch die into the die cavity and moving the first sections into the die cavity while the second sections remain secured on the support members;

moving the punch die out of the die cavity; and

moving together the first sections of the first and second charges.

13. The method of claim 12 , further comprising inflating a first bladder and securing the second section of the first charge to one of the support members and inflating a second bladder and securing the second section of the second charge to a second one of the support members.

14. The method of claim 12 , further comprising abutting together first ends of the first and second charges over the die cavity prior to inserting the punch die into the die cavity.

15. The method of claim 12 , further comprising overlapping first ends of the first and second charges over the die cavity prior to inserting the punch die into the die cavity.

16. The method of claim 15 , further comprising forming a scarf joint at the first ends of the first and second charges.

17. The method of claim 12 , further comprising releasing the second sections of the first and second charges after inserting the punch die into the die cavity.

18. The method of claim 12 , further comprising tensioning an entire length of each of the first and second charges while inserting the punch die into the die cavity and moving the first sections into the die cavity while the second sections remain secured to the support members.

19. A method of fabricating a composite stringer for a vehicle, the method comprising:

positioning first and second charges over a die cavity and away from a punch die;

positioning a first section of the first charge over the die cavity and securing a second section of the first charge to a first support member;

positioning a first section of the second charge over the die cavity and securing a second section of the second charge to a second support member;

moving the punch die against the first and second charges and inserting the punch die into the die cavity and driving the first sections of each of the first and second charges into the die cavity while the second sections remain secured to the first and second support members and tensioning the first and second charges;

moving the punch die out of the die cavity; and

moving together first and second form blocks that are positioned on opposing sides of the die cavity and applying a lateral force to the first sections.

20. The method of claim 19 , further comprising securing the second sections of the first and second charges while moving together the first and second form blocks.