Spirit Aerosystems, Inc.

Spirit Areosystems, Inc.

Jeffrey W Priest

Carl Ray Fiegenbaum

David Ernest Havens

Matthew C Everhart

Joel James Everhart

Steven Fillmore Hanson

Randy Rex Kysar

Delbert Leon Strelow

Thomas J Barnell

Kevin John Ford

Kodi Elizabeth Ann Caster

Kristin Dru Pickell

Kristin M Cable

Bryan Michael Pelley

Thomas Wood Margraf

Eric W Traxler

Kelvin D Nguyen

Scott Robert Huelskamp

Kristin Pickell

Delbert Leon Stretlow

Kodi Elizabeth Caster

A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.

Reconfigurable shape memory polymer tooling supports

A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. Next, composite material may be applied onto the SMP apparatus and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cured composite material and removed from within the composite part.

Methods and systems for co-bonding or co-curing composite parts using a rigid/malleable SMP apparatus

A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as a rigid lay-up tool. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material and/or nested components may be heated and compressed against the SMP apparatus. The SMP apparatus may be configured to remain rigid during the composite cure cycle. Once the composite material is cured, the SMP apparatus may be triggered to a malleable state and urged away from the cured composite material.

Methods and systems for forming integral composite parts with a SMP apparatus

A method and apparatus for removing a SMP apparatus from within a cured composite part. The method may comprise the steps of triggering the SMP apparatus from a rigid state to a malleable state, inducing a pressure differential that drives the SMP apparatus, in the malleable state, away from the cured composite part and toward an inner mandrel tool, and removing the inner mandrel tool with the SMP apparatus resting thereon out of the cured composite part. The inner mandrel tool may comprise an outer surface having varying contours such that a surface area of the outer surface is great enough to prevent the SMP apparatus from folding over onto itself or creasing when driven toward the inner mandrel tool. A maximum straight line distance between points on the outer surface may be small enough to allow the inner mandrel tool clearance for removal from the cured composite part.

Method for removing a SMP apparatus from a cured composite part

A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.

Methods and systems for fabricating composite stiffeners with a rigid/malleable SMP apparatus

A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material may be applied onto the SMP apparatus in the rigid tool configuration and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cure composite material and removed from within the composite part.

Methods and systems for fabricating composite parts using a SMP apparatus as a rigid lay-up tool and bladder

An intermediate sealing element and method for unsealing a vacuum membrane from one tool surface and transferring it to another tool surface without damaging the vacuum membrane. The intermediate sealing element forms a continuous path around the periphery of a vacuum membrane and is sealed directly to one or more vacuum membranes and a tool surface using any means known in the art to create an airtight seal between two surfaces. The intermediate sealing element is able to withstand high temperatures and high pressure without altering its structural characteristics. Because of its durability, the intermediate sealing element can be removed from the tool surface without tearing or elongating, subsequently allowing the vacuum membranes to be detached from the tool surface without tearing or elongating.

Vacuum transfer seal

Growing community of inventors

Rose Hill, KS, United States of America

Jeffrey W Priest