The Boeing Company

Donald A Jensen

Joel M Thomas

Maxine E Duncan

Andrew Elmer Modin

Oliver James Groves

Val G Brustad

Thomas S Nelson

David L Hoshor

Joel L Morphis

Hassan Faraz

A composite hot drape vacuum forming method and apparatus. The apparatus includes an elongate vacuum chamber (12) having a lid (14) and a housing (16). An inflatable seal (26) is disposed between the lid (14) and the housing (16). Inflation of the inflatable seal (26) creates on airtight vacuum chamber. A heating blanket (36) is located in the bottom of the vacuum chamber (12). An inflatable bladder (28) is located on top of the heating blanket and extends approximately over the length of the vacuum chamber. The interior of the inflatable bladder is in fluid connection with the exterior of the vacuum chamber. Composite charges (40) are placed within the vacuum chamber on top of the vacuum bladder (28). Lay-up mandrels (42) are placed on top of the unformed composite charges and the vacuum chamber is closed and sealed. The composite charges (40) are heated using the heating blanket (36). The interior of the vacuum chamber is then evacuated. As the interior is evacuated, the inflatable bladder expands forming the composite charges (40) around the lay-up mandrels (42). After forming, the pressure in the interior of the vacuum chamber (12) is equalized and the lid (14) is opened. The formed composite charges and mandrels are then removed.

Method of vacuum forming a composite

A machine (20) for positioning a jig (22) relative to another surface (28) is disclosed. The machine includes a truss (24) for supporting the jig. A support stand (26) connected to each end of the truss supports the truss at a first position spaced apart from the surface, and at a second position adjacent the surface. Each support stand includes a first linear movement assembly (72) and (74) for respectively acting upon the first and second ends of the truss to move the truss from the first position to the second position, and from the second position to the first position. Each support stand additionally includes a rotating assembly (48) for rotating the truss along an axis substantially passing through both ends of the truss.

Composite stringer and skin panel assembly machine

A machine (28) for use in removing first and second mandrels (20) from a stringer assembly (26) that includes a composite I-beam and the mandrels is disclosed. The mandrels are located in channels on opposite sides of the composite I-beam. The machine includes a framework (30) having an elongate platform (36) for supporting the stringer assembly (26). Mounted on the framework are a plurality of stations (32) located long the longitudinal platform (36). Each station includes first and second movable platforms (42) mounted to opposite sides of the longitudinal platform from one another. Each platform includes a clamp (38 and 40) for sequentially clamping the stringer assembly to the framework when the mandrels are being removed. The movable platforms are attached to the mandrels. A jackscrew mechanism moves the movable platforms with respect to one another when the sides of the stringer assembly are clamped to the platform. The force created by the jackscrews pulls the mandrels away from the composite I-beam, first from one side of the stringer assembly then from the other side. A third clamp (76), mounted to one side of the framework, is used to clamp the one side of the composite I-beam to the framework after the mandrel has been removed from that side of the beam.

Composite stringer disassembly machine

A machine (34) for use in assembling a stringer (32) from two C-shaped charges (22), each channel charge being draped about a mandrel (20), is disclosed. The machine includes a framework (36) having a first platform (40) for supporting the mandrels and C-shaped charges such that the C-shaped charges are back to back. A U-shaped anvil (48), connected to the framework, is rotatable between an engaged position overlying the mandrels and the C-shaped charges, and a disengaged position away from the mandrels and C-shaped charges. The anvil (48) includes a side bladder (58) for compacting the C-shaped charges against one another by pressing the mandrels and C-shaped charges together and against a wall of the anvil opposite to the side bladder, and a top bladder (62) for aligning the mandrels and C-shaped charges by compressing the mandrels and C-shaped charges against the platform. The machine further includes a rotation mechanism for moving the mandrels and C-shaped charges from the first platform to a second platform and rotating the mandrels and C-shaped charges through 180 degrees as they are moved to invert the mandrels and the C-shaped charges draped over the mandrels. Also included with the machine are alignment devices (42) for aligning the ends of the mandrels and the C-shaped charges with one another.

Composite stringer assembly machine

An overhead mandrel manipulator for handling two composite lay-up mandrels. The manipulator includes two opposing brackets (124) having arms (135) that engage the composite lay-up mandrels using lift pins (150). The opposing brackets (124) are rotated approximately 90.degree. each between an open position and a closed position. In the open or closed positions, the brackets are easily attached to the composite lay-up mandrels. When the brackets are moved between the open and closed positions, they rotate the lay-up mandrels approximately 90.degree. . The brackets can be used to apply a compressive force to the two lay-up mandrels when the brackets are in the closed position. The brackets (124) are rotated by a push plate (80) that is driven up and down by a Thomson ball screw (98) connected to a drive motor (30). As the push plate (80) moves up and down, it moves two pairs of drive links (128) upward and downward. The drive links are pivotally connected to the opposing brackets such that movement of the drive links causes the brackets to rotate when the push plate moves up or down.

Growing community of inventors

Kent, WA, United States of America

Donald A Jensen