Hexcel Corporation

Hexcel Composites Limited

Hexcel Holding Gmbh

Bruno Boursier

Jack D Fudge

Johannes Moser

Matthew Kweder

Flemming Moeller Larsen

Matthew Kweber

A composite assembly that can be cured to form a multi-component composite structure which does not have micro cracks along the boundaries between the various components. The composite assembly includes a structural component and a moldable component wherein the coefficients of thermal expansion of the structural component and the moldable component at the interface or boundary between the two components are such that micro cracks do not form along the interface when the composite assembly is cured to form the multi-component composite structure.

Multi-component composite structures

Preforms for use in molding composite parts are made directly from composite chips that are composed of fibers and an uncured thermosetting resin. Cold composite chips are formed into a stream of non-agglomerating chips that is used to fill the cavity of a preform tool. The non-agglomerating chips flow into the preform tool cavity to form a population of non-cohesive composite chips. The non-cohesive composite chips are then heated to form a preform made up of a consolidated population of cohesive composite chips in which the non-sticky uncured thermosetting resin of the non-cohesive chips has been converted to a sticky uncured thermosetting resin.

Preforms made directly from thermosetting composite chips

A load-bearing composite structure for connection to a support body or structure. The load-bearing structure includes a load-bearing element that is made up of continuous reinforcing fibers and a resin matrix. The load-bearing element has an attachment portion for connection to the support body. The load-bearing composite structure further includes a connection element that is formed using a molding material which is composed of discontinuous fibers and a resin matrix. The molding material is molded over the surface of the attachment portion of the load-bearing element.

Over-molding of load-bearing composite structures

A module () for holding at least one bushing () within a recess, wherein it comprises two side surfaces (), an upper () and a lower () surface and at least one end surface (), wherein the upper () and lower () surfaces are of different width and arcs, respectively, in their cross-section, and the side surfaces () are of equal height, and when coupled to a second module () by its side surfaces (), which second module () optionally may also hold at least one bushing (), the sum of the angle (alpha) between the optionally imaginary plane side surface () of the one module () and the tangent () to its upper surface () at the intersection (A) with the side surface () and the angle (beta) between the optionally imaginary plane side surface () of the other module () and the tangent () to its upper surface () at the intersection (B) with the side surface () is at least 180 degrees and/or a plurality of modules (), optionally when holding the bushings (), form at least a section of a circular ring or a full circular ring.

Module for holding at least one bushing

An assembly that includes a first part composed of a fibrous structure that includes fibers and a cured resin matrix. The fibrous structure has at least one surface and a layer that is located on the surface. The layer includes a discontinuous fiber composite that is composed of randomly oriented short fibers and a cured resin matrix wherein the layer has been machined to provide a machined surface. The assembly also includes a second part that is attached to the first part. The second part includes at least one surface that fits against the machined surface on the first part.

Machinable composite material

Composite pre-forms are molded at high pressure to form composite parts that can be used in place of metal-based high performance parts, such as the outlet guide vanes found in turbofan jet engines. The composite pre-forms include two different fiber orientations that are co-molded in a resin matrix at high pressures to provide composite outlet guide vanes and other high performance parts. Chambers within the composite part are optionally formed during molding of the pre-form at high pressures.

High pressure molding of composite parts

Quasi-isotropic chopped prepreg is used to make parts found in aerospace vehicles. Exemplary aerospace parts that are made using quasi-isotropic chopped prepreg include aircraft window frames, wing fairing supports, flange supports, frame gussets, rudder actuator brackets, shear ties, seat pedestals, cargo floor flange supports, storage bin fittings, antenna supports, torque tube pans, handle boxes, side guide fittings, wing box covers and intercostals.

Growing community of inventors

Dublin, CA, United States of America

Bruno Boursier