Spirit Aerosystems, Inc.

Cornerstone Research Group, Inc.

Spintech, Inc.

Spirit Areosystems, Inc.

David Ernest Havens

Matthew C Everhart

Carl Ray Fiegenbaum

Jeffrey W Priest

Joel James Everhart

Randy Rex Kysar

Delbert Leon Strelow

Patrick J Hood

Steven Fillmore Hanson

Thomas Wood Margraf

Eric W Traxler

Joel J Everhart

Brandon Charles Kirby

Thomas J Barnell

Michael Jeffrey Fisher

Craig S Jennings

Kevin John Ford

Kristin Dru Pickell

Robert V Graziano

Kodi Elizabeth Ann Caster

Thomas W Margraf, Jr

Kristin M Cable

Bryan Michael Pelley

Christopher Douglas Hemmelgarn

Benjamin Dietsch

Teresa Havens

Jaime Beverly Vanderhorst

John Lewis Reed

Logan Wayne Snyder

Anthony Louderbough

Jamie B Vanderhorst

Scott Robert Huelskamp

Kevin J Heitkamp

Aaron M Schneider

Kristin Pickell

Delbert Leon Stretlow

Kodi Elizabeth Caster

Cauls and methods of using the same are provided. The caul includes a reinforcement material having one or more elastic fibers and a polymer having one or more shape memory polymers. The caul is operable to transition from a rigid state to an elastomeric state and from an elastomeric state to a rigid state in response to stimuli. Methods of using cauls to produce composite articles involve positioning one or more fiber layers between a caul and a cure mold surface when the caul is in a rigid state. The fiber layers, caul, and cure mold surface may be covered with a sealed barrier and a pressure gradient may be applied. Before, after, or before and after performing the vacuum the fiber layers may be impregnated with resin. The fiber layers may be cured, which may provide a stimulus to transition the caul from a rigid to an elastomeric state.

Cauls and methods of using cauls to produce composite articles

Cauls and methods of using cauls to produce composite articles are provided. The caul transitions from a rigid state to an elastomeric state and from an elastomeric state to a rigid state in response to a stimulus and has a reinforcement density of from 100 kg/mto 500 kg/m. Methods of using cauls to produce composite articles involve positioning one or more fiber layers between a caul and a cure mold surface when the caul is in a rigid state. The fiber layers, caul, and cure mold surface may be covered with a sealed barrier and a pressure gradient may be applied. Before, after, or before and after performing the vacuum the fiber layers may be impregnated with resin. The fiber layers may be cured, which may provide a stimulus to transition the caul from a rigid to an elastomeric state, and the composite article is produced.

An advanced reflexive structure system is disclosed. The reflexive system mimics the pain withdrawal reflex on which the human body relies. The reflexive system incorporates a continuous health and performance monitoring system via an embedded dielectric film, an adaptive composite structure based on shape memory composite material, and an intelligence system which will be interfaced with both the health/performance sensors and the adaptive structure. When activated shape memory polymer will recover its structural integrity via shape recovery and a reptation healing process. These features enable the use of SMP as an adaptive structure in the proposed reflexive system. The development of a reflexive system for structures will enable increased safety and security and demonstrate a better understanding of integrated performance systems. This reflexive technology could find immediate implementation on all current and future systems and future implementation on platforms such as the International Space Station, Lunar, and Martian habitats.

Composite self-healing system

A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.

Reconfigurable shape memory polymer tooling supports

A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. Next, composite material may be applied onto the SMP apparatus and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cured composite material and removed from within the composite part.

Methods and systems for co-bonding or co-curing composite parts using a rigid/malleable SMP apparatus

A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as a rigid lay-up tool. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material and/or nested components may be heated and compressed against the SMP apparatus. The SMP apparatus may be configured to remain rigid during the composite cure cycle. Once the composite material is cured, the SMP apparatus may be triggered to a malleable state and urged away from the cured composite material.

Methods and systems for forming integral composite parts with a SMP apparatus

A support apparatus and method for providing structural support to a shape memory polymer (SMP) apparatus during fabrication of composite parts. The support apparatus may comprise an adjustable, rigid structural member and a plurality of SMP support components transitionable between a rigid and malleable state and fixed to an outer surface of the rigid structural member. The rigid structural member may extend in at least one cross-sectional dimension toward the SMP apparatus, pressing the SMP support components, in their malleable state, against the SMP apparatus. The SMP support components may thereby conform to a first surface of the SMP apparatus, then return to their rigid state while pressed against the SMP apparatus, thus providing a rigid load path between the SMP apparatus and the rigid structural member. Then composite material may be applied to a second surface of the SMP apparatus, opposite of the first surface.

Reconfigurable shape memory polymer support tooling

A method and apparatus for removing a SMP apparatus from within a cured composite part. The method may comprise the steps of triggering the SMP apparatus from a rigid state to a malleable state, inducing a pressure differential that drives the SMP apparatus, in the malleable state, away from the cured composite part and toward an inner mandrel tool, and removing the inner mandrel tool with the SMP apparatus resting thereon out of the cured composite part. The inner mandrel tool may comprise an outer surface having varying contours such that a surface area of the outer surface is great enough to prevent the SMP apparatus from folding over onto itself or creasing when driven toward the inner mandrel tool. A maximum straight line distance between points on the outer surface may be small enough to allow the inner mandrel tool clearance for removal from the cured composite part.

Method for removing a SMP apparatus from a cured composite part

A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.

Methods and systems for fabricating composite stiffeners with a rigid/malleable SMP apparatus

A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material may be applied onto the SMP apparatus in the rigid tool configuration and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cure composite material and removed from within the composite part.

Methods and systems for fabricating composite parts using a SMP apparatus as a rigid lay-up tool and bladder

The disclosed device primarily consists of a band, ring, or other piece of shape memory polymer (SMP) or SMP composite in various embodiments that allows or disallows containment. When the SMP reaches its transition temperature (Tg) the SMP provides the means for releasing containment of the pressurized material so as to prevent ignition or explosion of hazardous material. At normal operating temperatures, the SMP is in a deformed shape maintaining an environmental seal to protect the contents of the container. When environmental conditions cause the SMP or SMP composite to exceed its Tg, specified by the operating requirements, the SMP returns to its memory shape in a controlled geometry, rather than simply melting. The return of the SMP to its memory shape causes the venting of the container in different manners depending on which embodiment is utilized.

Venting mechanisms for containers

The present invention utilizes the unique shape recovery properties of shape memory materials, especially shape memory polymers, to provide an inexpensive and easily identified method of determining when a product has been exposed to environmental conditions that would make it likely that the product has expired or is unfit for use. By allowing the shape memory material to alter its shape from a deformed shape to a memory shape in response to exposure to environmental conditions while attached to a visual indication device a viewer can easily determine if a product has expired.

Environmental condition cumulative tracking integration sensor using shape memory polymer

Growing community of inventors

Bellbrook, OH, United States of America

David Ernest Havens