Spirit Aerosystems, Inc.

Spirit Areosystems, Inc.

Delbert Leon Strelow

David Ernest Havens

Matthew C Everhart

Jeffrey W Priest

Carl Ray Fiegenbaum

Randy Rex Kysar

Joel James Everhart

Kevin John Ford

Kristin Dru Pickell

Thomas Wood Margraf

Kodi Elizabeth Ann Caster

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 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

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Wichita, KS, United States of America

Delbert Leon Strelow