The Boeing Company

Greg M Reyneke

Aaron William Bartel

Randall Dow Wilkerson

David Eric Gideon

Richard R Rosman

Ian E Schroeder

Gregory J Hickman

Aaron Ross Cowin

Michael H Larson

Emma L Morrissey

Kenndy San

Kin M Ng

Megan C Kinney

Andrew D Wilkerson

Kristin L Hall

Zachary T Verran

David E Gideon

There is provided a tensioned tooling assembly for a thermoplastic composite stamp forming process. The tensioned tooling assembly includes a bottom tool having a bottom tool outer flange with a bottom end, a bottom tool outer radius, and a bottom tool outer curved surface. The bottom tool includes a plurality of tensioning protruding portions spaced apart on, and outwardly extending from, the bottom tool outer curved surface. Each tensioning protruding portion defines an angle formed from the bottom tool outer radius to the bottom end. The tensioned tooling assembly further includes a top tool having a top tool outer flange with a bottom end, a top tool outer radius, and a top tool outer curved surface. The top tool includes a plurality of corresponding portions formed in, and spaced apart on, the top tool outer curved surface, the plurality of corresponding portions corresponding to the plurality of tensioning protruding portions.

Tensioned tooling assembly for a thermoplastic composite stamp forming process, and tensioned tooling system and method of using the same

A method of manufacturing a wrinkle coupon includes providing a thermoplastic laminate having a laminate outer surface and opposing laminate side edges, and comprised of multiple plies. Each ply is comprised of reinforcing fibers pre-impregnated with thermoplastic resin. The method additionally includes placing a wrinkle-forming element across the laminate outer surface such that the wrinkle-forming element extends between the laminate side edges. In addition, the method includes applying heat to the thermoplastic laminate, and applying compaction pressure on the wrinkle-forming element against the laminate outer surface in a manner urging the wrinkle-forming element into the thermoplastic laminate, and causing the wrinkle-forming element to form a wrinkle as an out-of-plane deformation in one or more of the plies. The method also includes allowing the thermoplastic laminate to cool, and cutting a wrinkle coupon out of a region of the thermoplastic laminate containing the wrinkle.

Apparatus and method for manufacturing thermoplastic wrinkle coupons

A window frame assembly for an aircraft, includes a window frame of composite material, adapted for attachment in a window opening of an aircraft, having an outer flange with an exterior surface and an interior surface, a metal erosion shield attached to the exterior surface of the outer flange, and a polymer adapter ring, attached to the interior surface of the outer flange. The window frame has a substantially constant thickness, and the erosion shield has a substantially constant cross-sectional shape. The adapter ring has a sloped engagement surface configured for supporting a window pane assembly.

Window frame assembly for aircraft

Growing community of inventors

Bothell, WA, United States of America

Greg M Reyneke