The Boeing Company

University of South Alabama

Gregory J Hickman

Paul Gabriel Werntges

Marc Rollo Matsen

William Chet Dykstra

Lee Charles Firth

David S Nansen

Samuel James Knutson

Carey E Wilkinson

Alexander Rubin

Byron James Autry

Kuang-Ting Hsiao

Greg M Reyneke

Emma L Morrissey

Kenndy San

Alice R Arnold

Zachary T Verran

Ying Shi

A method for joining a first thermoplastic substrate and a second thermoplastic substrate, each including a polyaryletherketone material having a first melting temperature. The method includes co-consolidating a first semicrystalline thermoplastic film with the first thermoplastic substrate to yield a first co-consolidated structure. The first semicrystalline thermoplastic film defines a first bonding surface of the first co-consolidated structure and includes a polyaryletherketone material having a second melting temperature that is less than the first melting temperature. The method further includes co-consolidating a second semicrystalline thermoplastic film with the second thermoplastic substrate to yield a second co-consolidated structure. The second semicrystalline thermoplastic film defines a second bonding surface of the second co-consolidated structure and includes a polyaryletherketone material having a third melting temperature that is less than the first melting temperature. The method further includes fusing the first bonding surface to the second bonding surface. The method yields a stacked structure.

Methods for joining a first thermoplastic substrate with a second thermoplastic substrate

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 system for joining a first thermoplastic component of a workpiece with a second thermoplastic component of the workpiece includes a first joining plate assembly comprising a housing, a heat plate, and a thermal insulator disposed between the housing and the heat plate, wherein the heat plate defines a heating surface; a second joining plate assembly opposed from the first joining plate assembly; and a clamping assembly engaged with both the first joining plate assembly and the second joining plate assembly.

Systems and methods for joining thermoplastic components

A system for manufacturing a part includes a mold having a contoured forming surface. The system also includes at least one tension strap, configured to attach to a consolidated laminate sheet, and a heating assembly, positioned relative to the mold and configured to supply heat to the consolidated laminate sheet, when attached to the at least one tension strap, to form a heated consolidated laminate sheet. The system additionally includes a strap retraction mechanism, configured to retract the at least one tension strap, when attached to the consolidated laminate sheet, to force the heated consolidated laminate sheet against the contoured forming surface of the mold. The heating assembly includes a flexible heating element configured to flex to conform to a shape of the heated consolidated laminate sheet as the heated consolidated laminate sheet is forced against the contoured forming surface of the mold.

Systems and methods for manufacturing large contoured parts from thermoplastic laminate sheets

A stamp-forming system includes a lower die formed of elastomeric material and having lower die lateral sides. In addition, the stamp-forming system includes a die wall configured to encircle the lower die lateral sides, and move vertically relative to the lower die. Also included in the stamp-forming system is an upper die configured to move between an open position in which the upper die is separated from the die wall and the lower die, and a clamped position in which the upper die is in contact with the die wall and applying clamping pressure to a blank against the lower die, to thereby form the blank into a formed article. The die wall is sized and configured to prevent lateral expansion of the lower die when the lower die is vertically compressed by the clamping pressure applied by the upper die.

Stamp-forming system and method

A joining system includes a holding fixture assembly configured to hold a fuselage skin. The stringers are temporarily attached to the fuselage skin. The joining system includes an upper beam assembly including an upper beam and a lower beam assembly. The lower beam assembly includes a lower beam and at least one lower heating element. The holding fixture assembly is coupled to the upper beam assembly. The holding fixture assembly is coupled to the lower beam assembly. The upper beam is movable relative to the lower beam to clamp the at least one of the plurality of stringers and the fuselage skin together prior to and during welding.

Method and apparatus for bonding stringers to a fuselage skin

A system for manufacturing a part that includes a mold, a first fixation component, fixed to the mold, second fixation components, each configured to be fixed to a consolidated laminate sheet, third fixation components, each fixed to the mold. The system also includes tension straps. The first fixation component is configured to attach the consolidated laminate sheet to the mold so that the consolidated laminate sheet does not translationally move relative to the forming surface of the mold. Each one of the second fixation components is configured to attach the tension straps to the consolidated laminate sheet. Each one of the third fixation components is configured to attach the tension straps to the mold so that the tension straps are movable relative to the mold. The system also includes a heating assembly and a strap retraction mechanism, configured to retract the tension strap.

Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Induction heating cells including pressure bladders

Induction heating cells including pressure bladders and methods of using thereof

A method whereby nanostructures aligned within a matrix material to define an aligned admixture are transferred into a receiving porous medium while substantially maintaining the nanostructure alignment such that the nanostructures may be aligned predominantly in a common direction within receiving porous medium. Resulting composite structures are also provided.

Growing community of inventors

University City, MO, United States of America

Gregory J Hickman