The Boeing Company

Edward McMurray Fisher, Jr

Brian Allen Carter

Dennis Lynn Coad

David Eric Gideon

Douglas Eugene Bailey

Glenn David Hardin

Jon Paul Thurber

James Robert Schnelz

Wesley L Holman

Derek J Fox

Kenneth M Harrison

Christopher T Allen

Patrick D Bertrand

Menelaos S Kafkalidis

William B H Grace

William B Grace

Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Narrow flake composite fiber material compression molding

A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism is provided. The method includes fixing a molded-in insert in a mold cavity. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, and has a substantially concave configuration, and the groove has a groove radius of 0.025 inch or greater, and greater than or equal to a groove depth. The method includes introducing a fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert, enclosing the mold cavity, heating and compressing the material in the mold cavity to consolidate the material around the molded-in insert and to form a consolidated fiber reinforced thermoplastic composite structure with the molded-in insert, cooling the structure, and removing the structure with the molded-in insert from the mold cavity.

Method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material

A fiber reinforced thermoplastic part with integral fittings is compression molded. A slug of pre-consolidated, fiber reinforced thermoplastic is heated until flowable and then injected into a mold tool to form both the part and the fitting.

Method and apparatus for compression molding fiber reinforced thermoplastic parts

A fiber reinforced part is formed from a compression molded thermoplastic resin reinforced with individual fibers of differing lengths randomly oriented substantially throughout the part.

Compression molding method and reinforced thermoplastic parts molded thereby

In an embodiment of the disclosure, there is provided a molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

Molded-in insert and method for fiber reinforced thermoplastic composite structure

A structural member such as a strut includes a composite material tube having metal end fittings that are attached to the tube by co-bonded, double shear joints. The double shear bond joint construction reduces the residual stress on the bonds that result from mismatch of the coefficients of thermal expansion of the composite tube and the metal end fittings. The ends of the fittings that are bonded to the tube may include a stepped profile that functions to limit the peak stresses in the bonds.

Growing community of inventors

Huntsville, AL, United States of America

Edward McMurray Fisher, Jr