The Boeing Company

Ths Boeing Company

James R Kendall

Raviendra Sidath Suriyaarachchi

Paul D Shaw

Byron James Autry

Darrell Darwin Jones

Samuel James Knutson

Santiago M Mejia

Brian Timothy Peters

Sergio Urzainqui

Samantha Eberhardt

Brian S Carpenter

Kurtis Shuldberg Willden

Andrew Elmer Modin

Daniel R Smith

Matthew S Stauffer

Andrew Michael Huckey

Steven P Wanthal

Steven J Plummer

David Raines

Patrick James Macko

Stephen J Dostert

Lance O McCann

Sadie Lee Fieni

Thomas Joseph Gonze

Sara Murphy

James F Mitman

Manuel Motilva

David C Jackson

Michael J Bailey

Brian Bentley Reid

David H Curry, Iii

Raviendra S Suriyaarachchi

David M Raines

David H Curry Iii

Paul Daniel Shaw

Sergio Urzainqui Mugica

Darell Darwin Jones

Manuel Motilva Casado

Lance O Mccann

Thomas J Gonze

A method of processing a composite structure includes a step of positioning a first processing tool of a tooling assembly and a second processing-tool of the tooling assembly from an open position, in which the first processing-tool and the second processing-tool are spaced apart, to a closed position, in which the first processing-tool and the second processing-tool are sealed to each other and are sealed to a mandrel-tool, supporting the composite structure, to form a vessel that surrounds the composite structure. The method also includes a step of processing the composite structure.

Apparatus and method for processing a composite structure

Systems () for assembling stiffened composite structures comprise a layup mandrel () and a network () of fluid lines () configured to be selectively and fluidically coupled to string bladders () positioned relative to the layup mandrel ().

Systems and methods for assembling stiffened composite structures

An apparatus, system, and methods for providing flowable material to a part-forming fixture. The apparatus comprising a tool manifold and a fixture manifold. The tool manifold comprises a tool-manifold base and a plurality of tool fittings extending through the tool-manifold base. The fixture manifold comprises a fixture-manifold base and a plurality of fixture fittings extending through the fixture-manifold base. An interface end of each one of the plurality of tool fittings is removably attachable to an interface end of a corresponding one of the plurality of fixture fittings such that, when attached, a seal is created between the tool fittings and the corresponding fixture fitting and flowable material is flowable from each one of the tool fittings into the corresponding one of the fixture fittings.

Quick connect manifold for flowable material delivery to a part-forming fixture and associated systems and methods

A part transfer system includes a movable support, a plurality of arms coupled to the movable support, and an end effector coupled to each of the plurality of arms. The end effector includes a body and a plurality of dividers each coupled to the body. The plurality of dividers divides the body into a plurality of partitions. The end effector includes a plurality of vacuum ports each in fluid communication with one of the plurality of partitions. The part transfer system further includes a vacuum source in fluid communication with at least one of the plurality of vacuum ports. Each of the plurality of vacuum ports is configured to draw a fluid from the plurality of partitions to establish a vacuum between the end effector and a part that is engaged with the end effector, thereby securing the part to the end effector.

Part transfer system

Provided are methods and devices for supporting of variety of different pre-cured composite stringers after forming and prior to curing. A post-forming processing device comprises a base with a channel for receiving hat portions of different stringers. The device also comprises a support structure, at least partially extending within the channel. The support structure is configured to conform to different hat portions and to retain the shape of these hat portions. For example, the support structure is made from a flexible material, which conforms to any shape variations. In some examples, the support structure is made from a jamming material that is reshaped together with each of the pre-cured composite stringers. A post-forming processing device is used for supporting different pre-cured composite stringers while various operations are performed on these stringers, such as stringer trimming, inspection, installation of bladders and noodles, and the like.

Methods and devices for supporting of variety of different pre-cured composite stringers

An apparatus for processing a composite structure includes a mandrel that includes a tooling surface and vacuum bagging that includes an elastomeric membrane and a bagging surface. The apparatus also includes a surface interface formed between the mandrel and the elastomeric membrane. The surface interface includes a suction channel formed in at least one of the tooling surface of the mandrel and the bagging surface of the elastomeric membrane. The elastomeric membrane is configured to be sealed to the mandrel along the suction channel in response to a vacuum applied to the suction channel.

An apparatus for processing a composite structure includes a first processing-tool and a second processing-tool that are movable between an open position, in which the first processing-tool and the second processing-tool are separated from each other, and a closed position, in which the first processing-tool and the second processing-tool are configured to be sealed to each other. In the closed position, the first processing-tool and the second processing-tool are configured to be sealed to a mandrel-tool, located between the first processing-tool and the second processing-tool and supporting the composite structure. In the closed position, the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure.

Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Circumferential lap splices for sections of fuselage

Methods and apparatus involved in the process of hardening a composite part are disclosed herein. The methods include applying a preform to a mandrel, covering the preform with a caul plate, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel and hardening the preform into a composite part while the caul plate is held against the preform. The apparatus include a mandrel, a caul plate which defines a surface of a preform and where the caul plate may include a rigid material and seals disposed between the mandrel and the caul plate. In an additional aspect, the apparatus may include a sealed chamber with a mandrel and a caul plate and a circumferential seal between the mandrel and the caul plate.

Caul plate system for aircraft fabrication

A method for fabricating a composite structure. A first section for the composite structure is formed in which the first section has a first end with a chevron shape, wherein first composite layers in the first section has a first step pattern at the first end. A second section for the composite structure is formed in which the second section has a second end with a counterpart shape to the chevron shape and in which second composite layers in the second section have a second step pattern at the second end. The first end the second end are positioned such that a first composite layer in the first composite layers in the first step pattern overlap the second composite layers in the second step pattern at a splice location.

Composite structure splice and method

Systems and methods are provided for shaping flat charges. One embodiment is a forming system for shaping a flat charge. The forming system includes female dies that are elongate and are configured to hold the flat charge, and a male die that is elongate and is configured to press into the flat charge between the female dies to form the flat charge while the flat charge is supported, the male die includes notches that extend along a length of the male die and are dimensioned to retain gap fillers of the flat charge at widthwise locations of the flat charge corresponding to corners at the female dies while the flat charge is formed.

Application of gap fillers during layup of charges of composite material

A self-threading lamination head has a material supply drum, a backing layer collection drum, and a material threading system. The material supply drum supports a material roll of layup material backed by a backing layer. The material threading system includes at least one threading belt located on one side of the lamination head. The threading belt is supported by belt rollers driven by a belt drive motor. A belt-mounted layer engagement device is coupled to the threading belt for engaging a backing layer leading edge portion. The backing layer collection drum collects the backing layer as the lamination head applies the layup material onto a substrate. The belt drive motor drives the threading belt over the belt rollers and causes the belt-mounted layer engagement device to thread the backing layer through the lamination head, and position the backing layer leading edge portion proximate the backing layer collection drum.

Lamination head having self-threading capability

There is provided a forming apparatus for forming a high contour composite structure. The forming apparatus includes an upper die and a lower die between which a composite charge is formed. The forming apparatus further includes a plurality of load cells, a control system, and an overlay tool assembly coupled to the upper die. The overlay tool assembly has scalloped sections positioned between pairs of the plurality of load cells, and positioned against portion(s) of the composite charge. The composite charge has ply discontinuity features through the one or more portions. The overlay tool assembly denies pressure and a through thickness compaction to the one or more portions of the composite charge during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure in post-forming operations.

Apparatus and method to enable in-plane bending of high contour composite structures in post-forming operations

A membrane assembly for vacuum bagging includes an elongate sheet of flexible material capable of being rolled up into a cylindrical configuration and unrolled from the cylindrical configuration into a flattened-out configuration, a bistable tape spring attached to or captured by the elongate sheet, and an inflatable tube attached to or captured by the elongate sheet. The bistable tape spring has a first stable state which is a straightened-out state, a second stable state which is a rolled-up state, and a transition state between the first and second stable states. The inflatable tube is sealed at one end and has an orifice at the other end for admission of a fluid therethrough for inflation of the inflatable tube.

Growing community of inventors

Mt. Pleasant, SC, United States of America

James R Kendall