The Boeing Company

Allen James Halbritter

Andrew Elmer Modin

Richard Alexander Prause

Luis Felipe Velasquez

Richard E Heath

Edward Ray Duncan

Ivan Gilberto Ramirez

John R Nibe

Tu N Hoang

Darrell Darwin Jones

Roger W Engelbart

Daniel R Smith

James William Fonda

Robert William Whiting

Richard E Heath, Iii

Meredith P Nix

Daniel J Johnson

Caleb J Handolescu

Andrew J Maass

Eric Carlton Anderson

Adam D Lee

Daniel Johnson

Emily E McDonald

Amy E Cooper

Kevin W Kaufman

James W Fonda

Emily E Mcdonald

A method for configuring a shape of a tool from an initial shape to a reconfigured shape includes localized heating a portion of the tool to yield a heated portion of the tool and mechanically manipulating the heated portion of the tool to achieve the reconfigured shape.

Methods for configuring a shape of a tool and associated systems and methods for manufacturing a composite structure

An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.

Methods, devices, and systems for forming a composite structure using an expandable pallet

An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.

Conveyor forming composite stringers

A rotating manifold includes an axle, a hub rotatable relative to the axle about an axis of rotation, and a compressed air line in fluid communication housed in the axle. The rotating manifold further includes a vacuum line in fluid communication with the hub. The rotating manifold further includes a plurality of conduits connected to the hub. Each conduit of the plurality of conduits is in fluid communication with the vacuum line and houses a compressed air line arm in fluid communication with the compressed air line.

Rotating manifolds and associated systems and methods for vacuum bagging large composite structures

Systems and methods are provided for compacting objects onto tools. One embodiment is a method for compacting an object onto a rigid tool. The method includes placing an object onto a surface of a rigid tool, disposing an end effector over the object, spreading linkages of the end effector, causing a scroll of material between the linkages to be disposed atop the object while surrounding the object, and applying a negative pressure to the scroll that offsets air leaks between the scroll and the object, thereby forming a suction hold that compacts the object onto the rigid tool.

Scrolls that vacuum secure objects to complex surfaces

A pliable structure includes a first impermeable layer, a second impermeable layer opposed from the first impermeable layer to at least partially define an internal volume between the first impermeable layer and the second impermeable layer, and a flow media layer disposed in the internal volume.

Methods for replicating a contour of a surface and transporting a composite material

Systems and methods are provided for handling objects. One embodiment is an apparatus for handling objects. The apparatus includes a vacuum securement head. The vacuum securement head includes a strongback, and an array of end effectors arranged at the strongback in conformance with a contour. The contour is complementary to a pickup tool. The array of end effectors is configured to pickup objects at the pickup tool. The vacuum securement head also includes an impermeable membrane that is penetrated by the end effectors, and a vacuum system configured to provide suction through the end effectors. The suction is configured to remove air between the impermeable membrane and a rigid tool, and offset air leaks between the impermeable membrane and the rigid tool.

Placement and compaction of multiple objects via vacuum heads with floating end effectors

A method for initiating separation of a first layer from a second layer of a multilayer composite structure having a free edge, the method includes steps of securing the multilayer composite structure to a work surface; and applying cyclic pressure to at least a portion of the free edge of the multilayer composite structure.

Methods and systems for initiating layer separation within a multilayer composite structure

A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Bladder mandrel package

Tape layup systems and associated methods. A tape layup system includes a feed spool and an uptake spool. The feed spool is configured to carry a tape roll of tackifier tape that includes a tackifier material and a backing material, and the uptake spool is configured to carry a backing material roll of the backing material. The tape layup system further includes a torque transmission system configured to convey a torque from the feed spool to the uptake spool. The tape layup system is configured such that conveying a torque from the feed spool to the uptake spool operates to draw the backing material onto the backing material roll. A method of operating a tape layup system includes generating tension in a tackifier tape to rotate a feed spool and consequently rotating an uptake spool to draw a backing material onto a backing material roll.

Tape layup systems and associated methods

Described herein are flexible truss systems and methods of transferring flexible composite parts using these systems. A flexible truss system comprises a flexible truss mechanism and composite pick-and-place mechanisms supported on the flexible truss mechanism and designed to attach to various composite parts. The flexible truss mechanism comprises flexible elongated members and slidable ribs coupled to each flexible elongated member. Specifically, each rib is slidably coupled to at least one flexible elongated member. In some examples, each rib is also fixedly coupled to another flexible elongated member. The slidable coupling allows the flexible truss mechanism to bend and follow the shape of a supported part, such that the composite pick-and-place mechanisms are able to contact and support different areas of the composite part. As such, the same flexible truss mechanism is able to support flexible composite parts having different shapes.

Flexible truss systems and methods of transferring flexible composite parts using such systems

Described herein are methods and systems for manufacturing composite stringers using independently movable pallets with independent vacuum controls. Specifically, a stringer forming system comprises a base plate and a plurality of sets of pallets (e.g., two or more sets of pallets), slidably coupled to the base plate and forming an adjustable cavity. Each pallet comprises a primary vacuum zone, fluidly connected to a separate vacuum port. The system allows for independent application of a reduced pressure to the primary vacuum zone of each pallet. For example, a reduced pressure is applied only to pallets that are already covered with a composite layup and to pallets that are being covered. Any pallets that are exposed are kept at an ambient pressure and decoupled from a vacuum source, thereby reducing the vacuum leakage through the overall system. As the composite layup is being formed over new pallets, these new pallets are subjected to the reduced pressure.

Method and systems using independently controlled pallets for fabricating composite stringers

A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

Growing community of inventors

Summerville, SC, United States of America

Allen James Halbritter