Spirit Aerosystems, Inc.

Darin Clay Wiley

Blaise Francis Bergmann

Glen Paul Cork

Aaron Rae Heitmann

James Edward Westerman

Roger Edmund Kornfeld

Gerard F Spexarth

Brian Charles Clapp

Johnathan Scott Klincik

Walter A Chappelle

Tobias DiGennaro

Michael J Stuckey

Scott Sellmeyer

Michael D Borgman

Richard Jacobs

A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.

Composite aerodynamic structure

A system and method for splicing multiple plies of material together during the construction of a stringer sheet. A first ply layer is laid onto a portion of a surface of a tool having a contour which defines a stringer, and the first ply layer is pressed down such that an edge of the first ply layer is located on the contour. A second ply layer is laid onto an adjacent portion of the surface, and the second ply layer is pressed down such that the edge of the second ply layer is located on the contour and overlaps the edge of the first ply layer. This process may be repeated for additional ply layers. The system may include an end-effector having a dispenser of the plies of material and a roller for pressing the plies, and a movement mechanism for moving the end-effector over the tool.

System and method for splicing plies in stringer sheets

An aircraft panel assembly including a panel, a number of open-ended composite stringers, and a number of stringer end caps. Each stringer end cap covers an open end of one of the stringers and includes a base, a vertically extending wall, and an overlap section. The base is bonded to the panel near the open end of the stringer. The vertically extending wall is angled upward from the base and includes an upper periphery. The overlap section extends horizontally from the upper periphery and is bonded to the stringer near the open end of the stringer.

Composite stringer end cap

A system and method of a method of sealing a leak in an internal bladder within a hollow uncured composite part during cure thereof. The method may include placing a rescue bladder within the internal bladder and sealing an impermeable membrane and/or rigid forming tool to the rescue bladder, such that the uncured composite part is sealed within a chamber cooperatively formed by the impermeable membrane, the rigid forming tool, and the outer surface of the rescue bladder. A vent opening of the rescue bladder and/or a vent opening of the end fitting may remain located outward of the chamber. The method may also include curing the hollow uncured composite part, introducing a pressure differential causing the rescue bladder to inflate and press the internal bladder against an inner surface of the hollow uncured composite part.

Method for bladder repair during composite part curing

A composite repair system and method for assisting in the repair of a cured composite part in which a damaged portion has been cut out and removed, exposing a plurality of composite plies and their cut edges, which are then taper sanded to expose a plurality of taper-sanded surfaces and their corresponding ply boundaries. The ply boundaries may be traced by a user with a marking device. The composite repair system may comprise an image capturing device to obtain an image of the traced ply boundaries and a computing device for processing creating a map of the traced ply boundaries based on the image. The map may be used to manufacture filler plies having peripheral edges shaped to correspond with the ply boundaries for replacing the damaged portion of the composite part.

System and method for repairing composite parts

A composite repair system and method for assisting in the repair of a cured composite part in which a damaged portion has been cut out and removed, exposing a plurality of composite plies and their corresponding composite ply edges. The composite repair system may comprise a light source to illuminate the ply edges, an image capturing device to obtain an image of the ply edges, and a computing device for processing the image of the ply edges and creating a map of the ply edges based on the image. The map may be used to manufacture filler plies having peripheral edges shaped to correspond with the composite ply edges for replacing the damaged portion of the composite part.

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Wellington, KS, United States of America

Darin Clay Wiley