The Boeing Company

Frederick L Knoll

Noel Timothy Gerken

Thomas Andrew Dean

Wesley L Holman

James G Allen

Kurt Walter Withnell

Honeycomb cores for use in aerospace applications include two honeycomb core sections operably joined at a splice joint, the splice joint defined by a foam adhesive that is sandwiched between a sheet of film adhesive. Methods of assembling honeycomb cores also are disclosed herein.

Honeycomb cores with splice joints and methods of assembling honeycomb cores

A method and apparatus are disclosed for providing an electrical ground path on a structure such as a commercial aircraft. The method includes inserting a stud through a hole in a grounding plate or structure; riveting the head of the stud to the grounding plate or structure; and applying an electrically compatible build-up of washers, threaded nuts, and an electrical connector over the stud to hold the build-up in electrically conductive contact with the grounding plated or structure. In a preferred embodiment, the stud is threaded and the build-up includes a nut to hold the components in electrically conductive contact with the structure. The stud preferably has an enlarged and flattened head or spade portion with a hole for receiving a rivet. The stud acts as a self-retaining, anti-spin, grounding stud-fastener.

Method and apparatus for producing a grounding path on a structure

An insulating blanket for a bulkhead in an engine nacelle comprises a fabric backing layer, a central insulating core, a ceramic precursor-impregnated hot-side fabric layer and, as required, erosion-preventing wire mesh. The backing layer comprises a fiberglass fabric. The insulating core comprises a ceramic felt. The hot side layer comprises one or more layers of resin-impregnated fiber glass fabric. The blanket is precured to provide a predetermined geometric shape.

High temperature insulation system

One method of forming a workpiece made of thermoformable material includes the steps of: (a) supporting a raw workpiece on a suspension tray; (b) moving a pair of relatively hot forming dies into position above the workpiece; (c) closing the hot forming dies against the workpiece to heat the workpiece and to form and shape the workpiece into the desired configuration; (d) opening the hot forming dies and removing the hot forming dies away from the workpiece; (e) moving a pair of relatively cold forming dies into position above and below the workpiece; (f) closing the cold forming dies against the workpiece to cool the workpiece while maintaining the workpiece in the desired configuration; and, (g) opening the cold forming dies and removing the finished workpiece form the suspension tray. Other methods are also disclosed.

Hot/cold press forming methods for shaping thermoformable materials

One apparatus for forming a workpiece made of thermoformable material includes: (a) a base member; (b) a positioning frame supported by the base member; (c) a suspension tray for supporting a raw workpiece, the suspension tray being supported by the positioning frame; (d) a first pair of forming dies supported by the base member; (e) a press platen; (f) a second pair of forming dies moved by the press platen; (g) an actuator for moving the suspension tray whereby the suspension tray may be moved to a first position and to a second position between the pairs of forming dies; and (h) a cylinder for moving the press platen whereby the first pair of forming dies and the second pair of forming dies may be closed against the raw workpiece and the suspension tray. Other apparatus are also disclosed.

Hot/cold press forming apparatus for thermoformable materials

Fiber-reinforced resin composites or other materials are consolidated in a noncontact-frictionless manner through the use of a pressurized plenum chamber (20) of a fluid bearing (10). The fluid bearing (10) is flexible and floats relative to the material (16) to be consolidated so that ply drop-offs and other variations in the thickness or surface contour of the material are easily accommodated. While within the plenum chamber, the material is locally heated by radiant energy from a source (30) positioned within the chamber. This localized heating enables the material to solidify in cooler zones of the plenum chamber under a uniform pressure.

Method for consolidating composite materials

One apparatus for forming a workpiece made of thermoformable plastic material includes: (a) a base member; (b) a positioning wheel or a positioning frame supported by the base member; (c) a suspension tray for supporting a raw workpiece, the suspension tray being supported by the positioning wheel or the positioning frame; (d) a pair of relatively hot dies; (e) a first support arm positioning the hot dies, the first support arm being supported by the base member; (f) a first cylinder mounted on the base member for moving the first support arm whereby the hot dies may be positioned above and below the raw workpiece; (g) a pair of relatively cold dies; (h) a second support arm positioning the cold dies, the second support arm being supported by the base member; (i) a second cylinder mounted on the base for moving the second support arm whereby the set of cold dies may by positioned above and below the workpiece; (j) a press platen; and, (k) a cylinder for moving the press platen whereby the hot dies may be closed upon the workpiece when the pair of hot dies is in position above and below the workpiece and the cold dies may be closed upon the workpiece when the pair of cold dies is in position above and below the workpiece.

Hot/cold press forming apparatus for thermoformable plastic materials

Fiber-reinforced resin deposits or other materials are consolidated in a noncontact-frictionless manner through the use of a pressurized plenum chamber (20) of a fluid bearing (10). The fluid bearing (10) is flexible and floats relative to the material (16) to be consolidated so that ply drop-offs and other variations in the thickness or surface contour of the material are easily accommodated. While within the plenum chamber, the material is locally heated by radiant energy from a source (30) positioned within the chamber. This localized heating enables the material to solidify in cooler zones of the plenum chamber under a uniform pressure.

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Kent, WA, United States of America

Frederick L Knoll