The Boeing Company

Daniel M Rotter

Brad Andrew Coxon

Kurtis Shuldberg Willden

Brian Gregory Robins

Stephen Lee Metschan

Douglas Alan McCarville

Juan C Guzman

Richard V Phillips

Paul Elfes Nelson

Joseph D Anderson

Darrell Darwin Jones

Arvid J Berg

Stephen Keith Kirchmeier

Michael Robert Chapman

Khanh Mai Pham

Jennifer Sue Noel

Joseph Jay Pruss

William Stahl Hollensteiner

Barry P Van West

Todd J Washburn

Kimberlee Madden

Henry Macias

Patrick J Shephard

Adam Franklin Gross

Andrew Paul Nowak

John Dempsey Morris

Panagiotis Emanuel George

Alain A Adjorlolo

Hardik Dalal

Gabriel Zane Forston

Simon D Senibi

Jake Adam Reeves

Berryinne Decker

Martin Wayne Hansen

Kieran Patrick Davis

Marcin Artur Rabiega

Benjamin Bowen Lee

Jason A Medenciy

Paul Chih-Yung Chang

Scott Allen Boner

Stephen K Halladin

Jose L Encinosa

Samuel F Zambrana

Joshua Dee Little

Russell D Chiupka

Andrey F Yurchik

Thomas P Harper

Eugene H Jeppesen

Brian Dodgson

Steven Philip Hansen

Douglas A Mccarville

John J Vajo

Elena M Sherman

Shane Edward Arthur

Joseph Daniel Brennan

Bernhard Dopker

Lisa Christina Carlson

Benjamin Jeffrey Stephenson

Paul Chace Wilcoxson

Hyukbong Kwon

Mark E King

Scott K Frankenbery

Donald Chester Darrow

Barry P VanWest

Wallace C H Chan

Darren L Syverson

Aleksandr A Khomyak

Martin P Fritzgerald

Erik M Brazil

Harrison B Lockhart, Iii

Bradley Andrew Coxon

Nicholas W Deyo

Juan Carlos Guzman

Patrick Shephard

William S Hollensteiner

Adam F Gross

Brian G Robins

Kurtis Willden

Kurtis S Willden

Donald C Darrow

Douglas Alan Mccarville

Scott K Frankenberry

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Systems and methods for assembling elongate composite structures

Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.

Contoured composite stringers

Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting at least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.

Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts

Methods and devices of fabricating a stringer for a vehicle. The stringer can be constructed from two charges that are formed together into the stringer. During fabrication, the charges are placed over support members with the ends of each charge extending over a die cavity. The charges are secured and a punch die forces the first ends into the die cavity forming blades of the stringer. The charges are secured thus tensioning the charges during the punch process.

Methods and devices of forming a tensioned stringer for a vehicle

Composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems.

Composite structure fabrication systems and methods

An example system for processing composite material includes a cure tool, a source of pressurized gas, and a vacuum bag forming an enclosed volume between the cure tool and the vacuum bag. The system further includes composite material positioned on the cure tool within the enclosed volume. The source of pressurized gas is configured to inflate the vacuum bag, thereby moving a portion of the vacuum bag away from the cure tool and the composite material. An example method includes placing composite material onto a cure tool, placing a vacuum bag over the composite material and the cure tool to form an enclosed volume between the cure tool and the vacuum bag, processing the composite material while the composite material is within the enclosed volume, and inflating the vacuum bag to move a portion of the vacuum bag away from the cure tool and the composite material.

System and method for processing composite material

The present disclosure is directed to a method of making a composite part. The method comprises covering a mold tool for a composite part with a parting film. The method further comprises laying up at least one layer of pre-preg on the parting film covering the mold tool to form a laid-up composite part and removing the laid-up composite part from the parting film. The parting film comprises a polymer sheet having a first major surface and a second major surface; and a first adhesive disposed on the first major surface of the polymer sheet, the first adhesive adhering the polymer sheet to the mold tool.

Method for pre-preg manufacturing

A method of making a composite part comprises covering a mold tool for a composite part with a parting film, the parting film comprising a polymer sheet and a pressure sensitive adhesive. The parting film is positioned so that the polymer sheet is between the mold tool and the pressure sensitive adhesive. At least one layer of pre-preg is layed up on the parting film covering the mold tool to form a layed-up composite part. The pre-preg comprises an adhesive. The layed-up composite part is removed from the parting film.

A composite mandrel includes a generally elongated mandrel body comprising a resilient mandrel core and an elastomeric mandrel outer layer disposed outside the mandrel core. A method for fabricating a contoured stiffened composite panel is also disclosed.

Composite mandrel for autoclave curing applications

A composite layup is formed on a tool and placed on a contoured part. The tool is contoured to substantially match the contour of the part. A set of location data is generated which represents the location of the part in space relative to the tool. An automated manipulator uses the location data to move the tool into proximity to the part and place the contoured layup on the part.

Method for forming and applying composite layups having complex geometries

Devices, systems and methods for compacting a charge of composite material across an edge are disclosed herein. The devices include a vacuum compaction device including a compaction force transfer structure, a sealing structure, and a vacuum distribution manifold. The compaction force transfer structure includes a first barrier structure, a second barrier structure, and a junction support that extends at least partially between the first barrier structure and the second barrier structure. The junction support is configured to maintain the first barrier structure and the second barrier structure at an angle with respect to one another and to permit limited angular motion of the first barrier structure and the second barrier structure relative to one another. The systems include composite structure fabrication systems that include the vacuum compaction device. The methods include methods of operating the vacuum compaction device.

Devices, systems, and methods for compacting a charge of composite material across an edge

Methods and tools for forming contoured composite structures are disclosed. Methods include positioning a sheet of composite material relative to a structure of shape memory alloy, heating the structure of shape memory alloy to deform the structure of shape memory alloy to a deformed conformation and thereby conform the sheet of composite material to a desired contour corresponding to the deformed conformation of the structure of shape memory alloy. Tools include a structure of shape memory alloy and a heat source for heating the structure of shape memory alloy to conform a sheet of composite material to a desired contour corresponding to the deformed conformation of the structure of shape memory alloy.

Methods and tools for forming contoured composite structures with shape memory alloy

A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.

Compaction system for composite stringers

Growing community of inventors

Lake Forest Park, WA, United States of America

Daniel M Rotter