A clamping system for securing a composite charge in position relative to a forming mandrel includes an upstream hinge clamp and a downstream hinge clamp for clamping opposing ends of the composite charge in respective position relative to a mandrel upstream end and a mandrel downstream end during forming of the composite charge onto the forming mandrel. Each one of the hinge clamps is configured to fold a corresponding end of the composite charge from a generally approximately flat configuration to an angled configuration during forming of the composite charge onto the forming mandrel. At least one of the hinge axes is oriented approximately parallel to a folding axis located proximate an intersection of a mandrel top portion with at least one of opposing mandrel side surfaces.

A clamping system for securing a composite charge in position relative to a forming mandrel includes an upstream hinge clamp and a downstream hinge clamp for clamping opposing ends of the composite charge in respective position relative to a mandrel upstream end and a mandrel downstream end during forming of the composite charge onto the forming mandrel. Each one of the hinge clamps is configured to fold a corresponding end of the composite charge from a generally approximately flat configuration to an angled configuration during forming of the composite charge onto the forming mandrel. At least one of the hinge axes is oriented approximately parallel to a folding axis located proximate an intersection of a mandrel top portion with at least one of opposing mandrel side surfaces.

In an embodiment, a paint roller manufacturing system and method uses a fabric-coating applicator to apply a fabric adhesive onto a portion of a perforated paint roller cover fabric material having a plurality of perforations through which adhesive may flow, and into the plurality of perforations and into interstitial spaces of the fabric material, to yield a length of coated fabric. An inner strip and an outer strip are wound about a mandrel in offset relation. A strip-coating applicator is used to apply a strip adhesive to the outer strip as it is wound about the mandrel. Simultaneously with the step of applying the strip adhesive to the outer strip, a portion of the coated paint roller fabric material is received at the outer strip and the length of coated fabric is wound about at least the outer strip to form a paint roller tube.

A paint roller manufacturing system includes a cover dispenser for continuously dispensing a windable width of paint roller cover fabric, a fabric supporting and advancing device for supporting the fabric and maintaining a width-wise dimension of the paint roller cover fabric as the fabric advances, a fabric coating applicator for applying a coating to the back side of the paint roller cover fabric while the fabric supporting and advancing device maintains the fabric in a width-wise dimension, and a compressing roller positioned downstream of the fabric coating applicator and configured to apply a compressive force on the coating after it has been applied to the back side of the paint roller cover fabric and while the fabric is supported by the fabric supporting and advancing device. In two-strip embodiments, first and second strip dispensers continuously dispense a first and second windable width of strip material. A guide system guides the first and second strip coming from the first and second strip dispensers to be wound about a mandrel and guides the coated paint roller cover fabric from the fabric supporting device to be wound about the first and second strips. An adhesive applicator is configured to apply adhesive on substantially all of the outer side of the first and second windable strips and positioned to apply adhesive to the outer side of the first and second windable strips upstream of a location where the coated paint roller cover fabric is wound about the first and second strips.

In an embodiment, a paint roller manufacturing system and method uses a fabric-coating applicator to apply a fabric adhesive onto a portion of a perforated paint roller cover fabric material having a plurality of perforations through which adhesive may flow, and into the plurality of perforations and into interstitial spaces of the fabric material, to yield a length of coated fabric. An inner strip and an outer strip are wound about a mandrel in offset relation. A strip-coating applicator is used to apply a strip adhesive to the outer strip as it is wound about the mandrel. Simultaneously with the step of applying the strip adhesive to the outer strip, a portion of the coated paint roller fabric material is received at the outer strip and the length of coated fabric is wound about at least the outer strip to form a paint roller tube.

A drape forming apparatus for use in forming a composite structure. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool receives at least one layer of composite material over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.

A system and method are provided for conditioning paint roller cover fabric inline in a continuous paint roller manufacturing process. The system and method provide an inline fabric conditioning unit upstream of the point in the process that the paint roller fabric cover strip is wrapped about the outer side of the outer strip, the fabric conditioning unit including a fabric conditioning device that conditions the paint roller fabric cover strip as it is being fed towards the outer side of the outer strip. The fabric conditioning unit may be used to perforate the fabric, to remove loose fibers from the fabric side of the paint roller fabric cover, to buff the paint roller fabric, and to orient the paint roller cover fibers. The continuous paint roller manufacturing process includes steps of feeding an inner strip and an outer strip towards a mandrel, wrapping the inner strip and the outer strip about the mandrel in offset relation, applying a strip adhesive to at least a portion of an outer side of the inner strip and at least a portion of an outer side of the outer strip, feeding a paint roller fabric cover strip having a fabric side and a backing side towards the outer side of the outer strip, the fabric side comprising loose fibers and attached fibers, forming a paint roller tube by wrapping the paint roller fabric cover strip about the outer strip at a point in the process after the strip adhesive has been applied to the outer side of the outer strip such that the backing side contacts the strip adhesive, applying compression to the paint roller tube, and cutting the paint roller tubes into like lengths.

Provided herein is a method of manufacturing a product having a complex shape by using at least one jig and at least one mandrel. The method of manufacturing a product having a complex shape by using at least one jig and at least one mandrel is configured to include: a preparation step of preparing a prepreg sheet and a cylindrical first mandrel around which the prepreg sheet is wound; a first rolling step of forming a first stacking surface by winding the prepreg sheet around the first mandrel; a second mandrel preparation step of locating a second mandrel on the outer circumferential surface of the first stacking surface; a second rolling step of forming a second stacking surface by winding the first stacking surface and the second mandrel with the prepreg sheet; and a core removal step of removing the first mandrel and the second mandrel.

Provided herein is a method of manufacturing a product having a complex shape by using at least one jig and at least one mandrel. The method of manufacturing a product having a complex shape by using at least one jig and at least one mandrel is configured to include: a preparation step of preparing a prepreg sheet and a cylindrical first mandrel around which the prepreg sheet is wound; a first rolling step of forming a first stacking surface by winding the prepreg sheet around the first mandrel; a second mandrel preparation step of locating a second mandrel on the outer circumferential surface of the first stacking surface; a second rolling step of forming a second stacking surface by winding the first stacking surface and the second mandrel with the prepreg sheet; and a core removal step of removing the first mandrel and the second mandrel.

A method of constructing a mandrel generally complementary to a spar cavity of a spar includes connecting a first component and a second component to form a central space there between and inserting a center component within the central space such that the center component retains the first component and second component in a desired position forming an outer surface of the mandrel which corresponds to an inner surface of the spar cavity.