The Boeing Company

John B Moser

Marc Rollo Matsen

Jeffery Lee Marcoe

Aaron William Bartel

Brett Ian Lyons

Kay Youngdahl Blohowiak

Sahrudine Apdalhaliem

Waeil M Ashmawi

Moushumi Shome

Jaime C Garcia

Robert James Miller

William Chet Dykstra

Lee Charles Firth

Noel Timothy Gerken

Kim E Peterson

Steven W Morgan

Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting. A second load fitting may be positioned on the first plurality of inner layers of thermoplastic composite material.

Thermoplastic composite structures embedded with at least one load fitting and methods of manufacturing same

An induction welding system is provided. The system includes at least one induction coil configured to generate an alternating magnetic field, and a smart susceptor film sized to be positioned between a first component and a second component to be welded to the first component. The smart susceptor film includes a thermoplastic resin, and a plurality of metal alloy wires disposed in the thermoplastic resin such that the plurality of metal alloy wires are oriented substantially parallel to the generated alternating magnetic field.

Systems and methods for use in induction welding

A method of forming a structural tube may include urging a substantially flat thermoplastic sandwich sheet against a mandrel and heating the thermoplastic sandwich sheet to a temperature below a glass transition temperature. The method may further include allowing the thermoplastic sandwich sheet to cool and removing the mandrel, thereby forming a tube portion.

Method of forming a tube from a thermoplastic sandwich sheet

An apparatus and method are presented. An apparatus comprises a composite structure, a plurality of cavities extending into the composite structure, and a plurality of mandrels located within the plurality of cavities. The composite structure comprises a thermoplastic material that is consolidated. The plurality of mandrels comprises a first material that is configured to generate heat in response to a magnetic field.

Thermoplastic sandwich structures

An apparatus may comprise a first tool die and a second tool die, each having a tool base. Each tool base may have a laminated structure that has a plurality of spaced metallic laminations. The laminated structure may have a truncated portion forming a cavity configured to receive a tool insert, and at least one opening for receiving an induction coil. The first tool die and the second tool die may also have a tool insert configured to be received in the cavity of the tool base. The tool insert may have a die susceptor capable of being heated by the induction coil. The apparatus may also have an actuator for moving the first tool die and the second tool die toward one another for forming a component between the die susceptor of the tool insert of the first tool die and the die susceptor of the tool insert of the second tool die.

Tooling inserts for laminated tooling

Growing community of inventors

Bonney Lake, WA, United States of America

John B Moser