The Boeing Company

John F Spalding

Gary E Georgeson

Michael Walter Evens

David Mitchell Anderson

Aydin Akdeniz

Marc Rollo Matsen

Dhananjay B Vasa

Dan Perron

Ebonni J Adams

Steve Blanchard

Jeffrey Reyner Kollgaard

Diane C Rawlings

Shane Edward Arthur

Jeffrey Lynn Duce

Matthew H Mellin

David Walter

Bennett M Moriarty

Nihar Ashokkumar Desai

Shekar Vimala

Jeffrey Hayden Olberg

Adriana Willempje Blom-Schieber

Christopher John Hottes

Raymond C Eng

Kyle Steven Biondich

Ryan M Trumbo

Genesis Marvin Pilarca

Justin T Hoehn

Caitlin Elizabeth Kerr

Nicole Titus

Timothy S Barrett

Landon Keith Henson

Steven Donald Blanchard

James R Jones

Bret A Voss

Darrell M Storvick

Larry Dean Ridgeway

Meredith M Bird

Jason A Degaetano

Mohamed Azdamou

David M Anderson

Kristen Sharp

Kelsi M Hays

Derek Huang

Jeffrey H Olberg

Marc R Matsen

David M Walter

Bret Alan Mcginness Voss

Melissa Lutz

Robert J Miller

A method eliminates voids in the bond line and manipulates a thickness of the bond line. This method includes: applying an adhesive at a center of an area of a structure; placing a doubler on the adhesive over the area of the structure, wherein the doubler has a peripheral edge; and maintaining a negative pressure at the peripheral edge of the doubler while simultaneously maintaining a positive pressure at the doubler to purge entrapped gases and control a thickness of the bond line at the peripheral edge of the doubler.

Double vacuum and positive pressure for paste bond joints

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

Vacuum bag-less composite repair systems and methods

A heat blanket system including a blanket including a first sub-area and a second sub-area. The heat blanket system also includes heating elements printed on the blanket. First spacings between first ones of the heating elements in the first sub-area varies relative to second spacings between second ones of the heating elements in the second sub-area. The first spacings and the second spacings vary according to a design. The design is configured for use on a uniquely defined rework area on a uniquely defined composite material object including a third area including a heat sink region and a fourth area including a non-heat sink region. The first sub-area is sized and dimensioned to be placed over the third area. The second sub-area is sized and dimensioned to be placed over the fourth area.

Print on demand heat blanket system

A method including receiving a model of a composite structure having an inconsistency. The model includes a pre-calculated heating model that specifies areas of the inconsistency for which corresponding different amounts of heating are applied to an uncured composite material that is applied to the inconsistency. A design for heating elements of varying density across the areas is generated from the model. The design is configured to cause the heating elements in a first sub-area of a heat blanket system to generate a first amount of heat in a third area in the areas, and to cause the heating elements in a second sub-area of the heat blanket system to generate a second, different amount of heat in a fourth area of the areas. The heating elements are printed according to the design on a blanket to manufacture the heat blanket system.

Heating apparatus and methods for forming a part with a non-planar shape include a table formed of a thermally conductive material and defining a table surface. A tool, also formed of a thermally conductive material, has a base surface configured to engage the table surface of the table and a tooling surface opposite the base surface, wherein the tooling surface has a contoured shape that is non-planar. A heating blanket is provided above the table and defines a heating surface. The tooling surface of the tool is configured to engage a first surface of the part and the heating surface of the heating blanket is configured to engage a second surface of the part opposite the first surface of the part. The table and the heating blanket are heated to a processing temperature so that the part at least partially conforms to the tooling surface of the tool.

Smart susceptor induction heating apparatus and methods for forming parts with non-planar shapes

Described are methods and systems for a composite structure that allows for out of autoclave curing. Due to the layout of the composite structure, voids within the composite structure, formed out of autoclave, is reduced. The composite structure includes a composite laminate and one or more infusion films. The composite laminate includes a plurality of fiber tows that each include a plurality of fiber strands and a resin. The resin has a first viscosity within a first temperature range. The infusion film is disposed on a surface of the composite laminate and has a second viscosity lower than the first viscosity within the first temperature range. Methods of curing the composite structure are also described.

Composite with infusion film systems and methods

Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular acoustic and non-acoustic panels are disclosed.

Structural rework of cellular core panels

An assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.

Assembly and method to repair thermoplastic composites

A method of applying a surface treatment on a contoured surface includes attaching a surface treatment repair assembly to the contoured surface that includes a robotic unit and an array of applicator heads, each applicator head being configured to apply a repair treatment to the contoured surface. A location of the surface treatment relative to the surface treatment repair assembly is determined using an optical sensor configured to scan the contoured surface and generate an image data set of the contoured surface. A damaged portion of the surface treatment is identified and a target area for surface treatment repair is defined based on comparing the image data set generated by the optical sensor and a pristine image data set. The surface treatment repair assembly is positioned with the array of applicator heads adjacent to the surface treatment, and each applicator head is selectively operated to repair the surface treatment.

Adaptable surface treatment repair system

Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular non-acoustic panels are disclosed.

A surface treatment repair assembly for applying a surface treatment to a contoured surface includes an attachment device configured to removably attach to the contoured surface and a robotic unit is coupled to the attachment device. Furthermore, a treating unit is operably mounted on the robotic unit and including a plurality of applicator heads forming a treatment array and each applicator head is configured to apply a surface repair treatment. At least one sensor is mounted on the treating unit and configured to identify a target area for the surface repair treatment and a controller is operably coupled to the robotic unit and the treating unit. The controller is programmed to control a movement of the robotic unit to position the treatment array adjacent to the target area and to selectively operate the treatment array to apply the surface repair treatment on the target area of the contoured surface.

A method and assembly are provided in order to inspect a partially cured repair patch prior to installation. For example, an assembly for inspecting a repair patch is provided that includes a partially cured repair patch comprised of a composite material. The assembly also includes an acoustic facilitation layer disposed proximate of the surface of the repair patch through which ultrasonic signals will be introduced. The assembly further includes a vacuum bag surrounding the repair patch and the acoustic facilitation layer. The acoustic facilitation layer has an acoustic impedance that is closer to the respective acoustic impedances of the repair patch and the vacuum bag than the acoustic impedance of air is to the respective acoustic impedances of the repair patch and the vacuum bag.

Method and assembly for inspecting a partially cured repair patch prior to installation

A patch may be used to rework a composite structure in the field. The patch is bonded to the structure by a layer of adhesive and includes perforations that allow the escape of air from the adhesive as the patch is compressed against the structure. A spacer may be introduced between the patch and the structure to control the thickness of the adhesive layer.

Bonded patches with bond line control

A patch is used to rework an area of a structure. The patch is bonded to the structure by a layer of adhesive. A spacer placed between the patch and the structure is used to control the thickness of the adhesive and/or a bondline.

Growing community of inventors

Tukwila, WA, United States of America

John F Spalding