The Boeing Company

Aaron Ross Cowin

Randall Dow Wilkerson

Gregory James Schoepen Hickman

Justin Joseph Schell

Trevor David Charest

Thaddeus M Jakubowski, Jr

Cory Gordon Keller

Paul Gabriel Werntges

Michael H Larson

Eileen E Miller

Daniel A Charles

Greg M Reyneke

Todd J Palmer

Joshua Paul Koehn

Emma L Morrissey

Gregory M Sisti

Kenndy San

Jack William Henry

Samuel Jerome Huhman

David Michael Paruleski

Steven Michael Schoen

Richard Raymond Kreutzman, Jr

Andrew D Wilkerson

Daniel DiDomenico

Mike Heller

Daryl D Carpenter

Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.

Continuous compression molding machines and methods of continuous compression molding a consolidated thermoplastic matrix composite material

A method of manufacturing a wrinkle coupon includes providing a thermoplastic laminate having a laminate outer surface and opposing laminate side edges, and comprised of multiple plies. Each ply is comprised of reinforcing fibers pre-impregnated with thermoplastic resin. The method additionally includes placing a wrinkle-forming element across the laminate outer surface such that the wrinkle-forming element extends between the laminate side edges. In addition, the method includes applying heat to the thermoplastic laminate, and applying compaction pressure on the wrinkle-forming element against the laminate outer surface in a manner urging the wrinkle-forming element into the thermoplastic laminate, and causing the wrinkle-forming element to form a wrinkle as an out-of-plane deformation in one or more of the plies. The method also includes allowing the thermoplastic laminate to cool, and cutting a wrinkle coupon out of a region of the thermoplastic laminate containing the wrinkle.

Apparatus and method for manufacturing thermoplastic wrinkle coupons

A composite skin is attached to an underlying structure by fasteners that are countersunk into the structure. The composite skin comprises a thermoplastic material that has been melted and formed into a countersink in the structure using a heated tool.

Countersinks in thin gauge thermoplastic skins

A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.

Method and apparatus for rapid continuous consolidation of thermoplastic components

An assembly to manufacture a roll of prepreg material. The assembly includes a moving system for picking a sheet of prepreg material from a stack of sheets and moving the sheet along a feed path. An alignment system aligns a leading edge of the sheets with a trailing edge of a roll of the prepreg material. A welding system connects the sheet to the roll.

Assembly to manufacture a roll of prepreg material

A cover for an empty rail missile launcher that can be used in flight. The cover is shaped to reflect radar signals transmitted by a radar transmitter away from the radar transmitter to reduce detectibility by radar. The cover may also be coated with radar absorbent material to reduce detectibility by radar. Hangers are used to mount the cover to the rail missile launcher. The cover is provided with a grounding mechanism to dissipate precipitation static. A restraint mechanism is provided to prevent the cover from inadvertently sliding off the rail missile launcher.

Aircraft missile launcher cover

Growing community of inventors

Dardenne Prairie, MO, United States of America

Aaron Ross Cowin