The Boeing Company

Jason J McBain

Max Marley Osborne

Paul David Evans

Weidong Song

Stephen Lee Metschan

Jeffrey Hayden Olberg

Richard V Phillips

Peter J Lockett

Gwen Marie Lanphere Gross

Manning James Scarfe

Jamie J Langabeer

Hugh A Yap

Nicholas J Zayas

Kaustubh Dongre

Gerard J Gallo

A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Method for forming a composite structure

Systems and methods for fabricating composite parts. One embodiment is a method that includes selecting a caul plate having a body and a trough disposed at a side of the body which defines a channel that hangs beneath the body, the caul plate further having an opening disposed between the trough and the lower surface to form a fluid pathway for resin within the channel to exit into a preform. The method also includes placing the caul plate atop a preform of dry fiber and aligning the channel with a periphery of the preform, placing resin into the trough, and impregnating the preform with resin from the trough.

Method for impregnating a preform with resin utilizing a caul plate having a channel for distributing resin

A method of infusing liquid resin into a preform involves positioning a preform on a planar section of a tool surface and a trough section of the tool surface, where the planar section of the tool surface is positioned vertically above the trough section of the tool surface and with there being a plurality of grooves in the planar section of the tool surface and a bottom of the trough section of the tool surface. At least one of a fluid impervious sheet, a second tool and a vacuum bag is secured on the tool surface over the preform forming a sealed volume on the tool surface. A pressure differential and a flow of resin is supplied onto the tool surface and the liquid resin is infused into the preform by the pressure differential.

Apparatus and method for manufacturing liquid molded composites using a discrete network of tool surface resin distribution grooves

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Melbourne, Australia

Jason J McBain