The Boeing Company

Theboeing Company

Gabriel Zane Forston

Christopher Gary Harris

Elise Rae Ermitano Castorina

Daniel M Rotter

Brad Andrew Coxon

John Dempsey Morris

Stephen Lee Metschan

William Thomas Kline

Charles William Thomas

Khanh Mai Pham

Scott Edward Krajca

Hyukbong Kwon

Jake Adam Reeves

Patrick J Shephard

Brian Dodgson

Steven Philip Hansen

Joshua P Tyndall

Carolyn Schmidt

Joseph L Sweetin

Patrice K Ackerman

Benjamin Jeffrey Stephenson

Erik Lund

Nicholas Boroughs

America Olsen Schaaf

Thomas Dean Wilson

Bruno Zbinden

Dalton C Bergan

Matt Christner

Joseph Fount Warren, Jr

Russell Rufino

Elise Rae E Castorina

Benjamin Wen-Jun Su

Patrick Shephard

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Systems and methods for assembling elongate composite structures

A method of making a joint for a structure comprises forming a thermoplastic filler, applying an uncured first thermoset layer into direct contact with the thermoplastic filler, applying an uncured second thermoset layer into direct contact with the thermoplastic filler, and applying an uncured third thermoset layer into direct contact with the thermoplastic filler. The method additionally comprises curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bonding together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.

Method of making joint for structure

There is provided a conductive radius filler system and method. The system has a composite assembly with one or more composite structures having one or more radius filler regions. The system further has one or more conductive radius fillers filling the one or more radius filler regions. Each of the conductive radius fillers has a conductive element of electrically conductive material. The system further has one or more conductive radius filler connections connecting the conductive radius fillers to one of, a fastener system, a fuel tank system, and a current generating system, to form one or more current handling systems of the system. The one or more current handling systems provide one of, edge glow mitigation of edge glow as a secondary effect of lightning strikes, electrostatic discharge mitigation of electrostatic discharge caused by refueling electrification and fuel slosh, and current return handling to provide a minimized dedicated conductive system.

Conductive radius filler system and method

A system and method for forming a composite filler. The method comprises applying a pressure to a first portion of a composite material blank with a pair of forming dies of a composite filler forming apparatus, the pair of forming dies having a pair of convex radii, each forming die of the pair of forming dies having a respective convex radius of the pair of convex radii. The method also repeats the applying step to a subsequent portion of the composite material blank to incrementally form the composite material blank into a desired cross-section along its length.

Composite filler forming apparatus

An apparatus includes a first thermoset layer that includes a first fibrous material embedded in a first thermoset matrix. The apparatus also includes a second thermoset layer that includes a second fibrous material embedded in a second thermoset matrix. The second thermoset layer is coupled to the first thermoset layer to form a joint. Further, a gap is defined between the first thermoset layer and the second thermoset layer. The apparatus also includes a thermoplastic filler that is made from a thermoplastic material. The thermoplastic filler is positioned within the gap.

Pre-formed thermoplastic filler for thermoset structure

Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.

Systems and methods for forming radius fillers for composite structures

A composite radius filler include a base portion and a tip portion. The base portion is formed of composite plies varying in overall width along an overall lengthwise direction and defining a variable cross-sectional shape of the base portion along the lengthwise direction. The base portion includes at least one transition zone having a transition start and a transition end along the lengthwise direction. The composite plies of the base portion are arranged in one or more stacks each stack having a predetermined fiber orientation angle sequence and a stack width that changes within the transition zone. The tip portion includes a plurality of composite plies formed into a generally triangular cross-sectional shape and stacked on top of the base portion.

Advanced variable radius laminated composite radius filler

Apparatuses and methods of the present disclosure relate to efficient sealing of vacuum bag seams for vacuum bag processing of composite parts. Vacuum bags may enclose a composite part and form a first sealed region around the composite part. The first sealed region may be sealed by vacuum bag seams to a base supporting the composite part and/or to other vacuum bags. The vacuum bag seams may be sealed with an edge sealing frame that forms a compression seal and that defines a second sealed region including the sealed seam. Vacuum applied to the second sealed region forms a vacuum moat adjacent to the seam and/or at least partially surrounding the first sealed region. Hence, minor leaks in the compressively sealed seam are mitigated by the vacuum moat and the vacuum integrity of the first sealed region is maintained despite some potential leaks in the sealed seam.

Apparatuses and methods for efficient sealing of vacuum bag seams

Devices and methods for handling uncured radius fillers are disclosed. The devices, i.e., radius filler transport tools, generally are configured to load a radius filler from above, to index the radius filler to a desired location (e.g., a cavity), and to downwardly unload (e.g., drop) the radius filler at the desired location. Radius filler transport tools comprise at least two trough portions, coupled together to form a trough to carry the radius filler, and a plurality of hanger assemblies configured to transversely span the trough. The radius filler transport tool may have a transport state, where the trough and the hanger assemblies are in closed states, a load state, where the trough is in the closed state and at least one hanger assembly is in an open state, and an unload state, where the trough is in an open state and the hanger assemblies are in closed states.

Devices and methods for handling radius fillers

A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the base portion and may be formed of a plurality of substantially constant width composite plies defining a substantially constant cross-sectional shape of the keyway portion. The tip portion may be stacked on the keyway portion and may be formed of composite plies.

Variable-radius laminated radius filler and system and method for manufacturing same

Growing community of inventors

Lake Stevens, WA, United States of America

Gabriel Zane Forston