The Boeing Company

Andrew M Hopkins

John R Henry

Christopher Gary Harris

James M Kestner

Donald John Sutkus, Jr

Scott Fisher

Marc Rollo Matsen

Robert James Miller

William Thomas Kline

Christopher John Hottes

Jennifer Sue Noel

Mark E King

Thomas Dean Wilson

Joshua P Carlsen

Kari P Larkin

Jeff D Eastin

Anton Troshchenovskyy

Taylor M Williamson

Bianca M Moran

Jessica Conaty

Darren R Walker

Robert D Dennis

Isaac K Jacob

Tristan E Lee

Todd S Trujillo

Robert J Miller

Jennifer S Noel

A method for use in forming a composite structure that includes dispensing a first sheet of composite material, cutting the first sheet of composite material to form one of a plurality of plies of composite material, and providing the plurality of plies of composite material to a forming tool one at a time in a ply laydown sequence. A first sequential ply in the ply laydown sequence is provided, and then a second sequential ply in the ply laydown sequence is automatically provided after the first sequential ply has been provided.

System, method, and apparatus for use in forming a composite structure

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a flange forming device at the ply of material on the forming tool, the flange forming device including an inflatable contact element pressurized to define a deformable contact surface, applying, by the deformable contact surface, the ply of material onto the forming tool with a predetermined pressure, wherein the deformable contact surface is moved across the forming tool, and wherein the inflatable contact element is configured to maintain the predetermined pressure as the deformable contact surface transitions from the web surface to the at least one flange surface.

System, method, and apparatus for use in ply compaction in forming a composite structure

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.

A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Integrated smart susceptor heater blanket and vacuum bag deployment system for large composite skin laminate debulk

A tensioning system that can be used with a heater blanket and a vacuum bag for heating a workpiece can include a tensioner including at least one flexible rod. The tensioner can further include an end cap positioned on one or both ends of the flexible rod. The tensioner can be inserted through one or more sleeves attached to the vacuum bag, and each end of the flexible rod can be positioned within a pocket and thereby attached to the vacuum bag. In one implementation, the flexible rod can be rotated relative to the one or more end caps to decrease or increase a length of the tensioner, and the length of the tensioner is thereby adjustable. The tension applied to the vacuum bag can mitigate sealing of a seal of the vacuum bag with a layup mandrel.

Semi-rigid frame for large vacuum bag deployment in composite manufacturing

A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Integrated smart susceptor heater blanket debulk system for composites

Ply wrinkling during hot drape forming of a composite laminate is reduced at outside corner radii of a forming tool. First and second tensioning materials placed between a composite laminate charge and the forming tool maintain the laminate charge in tension at the radius corners as the charge is formed down over corner radii.

Method and apparatus for reducing ply wrinkling of composite laminates during forming

A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.

Wrinkle diffuser system for composites

Growing community of inventors

Salt Lake City, UT, United States of America

Andrew M Hopkins