The Boeing Company

Doan Dinh Pham

Mark William Tollan

William Brent Harlow

John C Lockleer

Michael A Lee

John Dempsey Morris

Christopher Gary Harris

Richard M Outzen

Mark W Tollan

Gregory Robert Gleason

Mark Charles Iden

A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the failing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

Method and system of forming a composite laminate

A composite structure such as a stringer is produced by laying up composite charges at a layup station, spooling the charges onto a roll and transporting the roll to a forming station where the charges are unrolled and formed into individual components of the stringer. The components are then transferred to an assembly station where they are assembled together and vacuum bagged in preparation for curing.

Method and apparatus for forming contoured stiffeners

A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.

Efficient sub-structures

A mandrel for composite fabrication includes an open cell foam carrier and at least one vacuum bag enclosing the open cell foam carrier.

Bagging process and mandrel for fabrication of elongated composite structure

A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the fairing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.

A jig apparatus and associated systems and methods for forming a composite wing skin is presented, including providing a frame with a working surface. A plurality of indexing blocks are coupled to the working surface of the frame. Each of the plurality of indexing blocks has a first indexing surface oriented perpendicular to the working surface of the frame and a second indexing surface oriented approximately parallel to the working surface of the frame. A plurality of clamping blocks are also each moveably coupled to one of the plurality of indexing blocks. Each of the plurality of clamping blocks has a clamping surface oriented perpendicular to the working surface of the frame and in facing relation to the first indexing surface of an adjacent indexing block thereby defining a plurality of channels.

Method, system and apparatus for assembling a composite wing skin with stiffeners

A method and apparatus for manufacturing a composite structure. The apparatus comprises a base section and a locking section. The base section of a mandrel has a channel with an opening that receives a portion of a bagging material wrapped around an exterior surface of the base section. The locking section of the mandrel engages the channel such that the portion of the bagging material in the channel is held inside the channel.

Two piece mandrel manufacturing system

A method for forming a composite structure on an assembly jig includes assembling an anchor member and block member on a support plate, arranging composite materials on the support plate adjacent to the anchor member, placing a shroud over the anchor member and block member, and applying heat and pressure to the bond assembly jig to cure the composite materials.

Bond assembly jig and method

The present disclosure provides an apparatus and method for forming a composite structure. The apparatus comprises a bond assembly jig having a support plate, an anchor member attached to the support plate, and a block member connected to the anchor member such that the block member is permitted to move in a vertical direction. The bond assembly jig can be arranged within an autoclave and may further comprise a shroud that is arranged to shield the anchor member and the block member from the pressures exerted within the autoclave. The method is accomplished by assembling the anchor member and block member on the support plate, arranging the composite materials, placing a caul component over the composite materials and a shroud over the anchor member and block member, and applying heat and pressure to the bond assembly jig to cure the composite materials.

A stabilizing mechanism for resisting relative movement of upper and lower laminates of a composite structure having a core comprises a lower grip strip and at least one upper grip strip. The lower grip strip may be mounted to a tool upon which the composite structure may be processed. The lower grip strip may include an outer surface having at least one engagement feature for engaging at least one of the upper and lower laminates which make up the composite structure. The upper grip strip may have opposing outer surfaces which may include at least one engagement feature for engaging the lower strip and at least one of the upper and lower laminates.

Composite ply stabilizing system

A mandrel for processing a part comprises an outer sleeve and a generally flexible inner core. The outer sleeve includes at least one flexible portion along its length allowing the sleeve to flex to a desired contour.

Lightweight flexible mandrel and method for making the same

A mandrel for manufacturing a unitary seamless section of an aircraft fuselage comprises a thin lay-up mandrel element disposed onto the outer shell surface of an inner mandrel shell, forming a mandrel with a substantially continuous lay-up surface. A unitary pre-cured section of an aircraft fuselage is formed by laying up a plurality of resin impregnated skin fibers onto the mandrel's lay-up surface while the mandrel rotates.

Growing community of inventors

Tacoma, WA, United States of America

Doan Dinh Pham