Spectrum Aeronautical, LLC

Rocky Mountain Composites, Inc.

E.i. Dupont De Nemours and Company

Toyota Motor Sales, U.s.a., Inc.

Little Giant Industries Inc.

Aerotrans Corporation

Chemicals & Materials Enterprise Assoc.

Larry Jed Ashton

Craig Bjamson Simpson

Mike Glen Allman

Troy Larry White

Michael G Allman

Steven Taylor Tuttle

John F Sollinger

Benko S Ta'ala

Alan H Anderson

Benko Samasoni Ta'ala

Todd H Ashton

Kendall James Fowkes

Ronald R Grimes

William T McCarvill

Rex W Kay

Danny L Stark

Craig Bjarnson Simpson

Benko Ta-Ala

A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.

Method for manufacturing a reinforced panel of composite material

A composite material made of multiple filament bands is disclosed. The filament bands are wound to create a composite material. The filament bands may be impregnated with a solid or semi-solid resin. The filament bands are wound in multiple orientations to form a sheet of composite material. Additionally, the composite material may be made to have a varying number of layer and fiber orientations throughout the sheet of composite material. In another embodiment, a composite component requiring multiple layers and fiber orientations may be substantially manufactured during a filament winding process.

Resin impregnated multi orientation composite material

A reinforced panel, made of a composite material, includes a single base layer. A first plurality of mutually parallel ridges is affixed to the surface of the base layer. A second plurality of mutually parallel ridges is also affixed to the surface of the base layer, but oriented transverse to the first plurality. Structurally, the ridges and the base layer are co-cured to create an integral, continuous structure that provides stiffness and rigidity to the panel.

Reinforced composite panel

A cabin door assembly is provided for use with a pressurized aircraft. The assembly includes two door halves for engaging the fuselage of the aircraft. Structurally, each door half includes a waist section integral with an adjoining tapered section. Further, the assembly includes an activator that is mounted on the fuselage and attached to the door halves. Specifically, the activator is attached to each door half to concertedly move each door half between a closed configuration and an open configuration. In the closed configuration, the door halves are sealed to the fuselage and to each other for pressurization of the aircraft. In the open configuration, the door halves extend outwardly from the fuselage to allow for aircraft ingress and egress.

Aircraft door

A method and device are provided for manufacturing a unitary caul sheet to be used in creating a composite material fuselage for an airplane. Specifically, a generally tubular shaped tool having a hollow interior cavity defining a fuselage IML surface is provided. In the method, a caul sheet material such as polyurea is applied to the IML surface before an armature is inserted into the interior cavity of the tool. Then, a filler material is introduced between the armature and the caul sheet material. Further, steam is injected to form the filler material into an infrastructure. Then, the caul sheet material is cured before the tool is removed from the caul sheet material to expose the caul sheet to receive composite material.

Method and device for manufacturing a unitary caul sheet

An aircraft wing made of a composite material, and its method of manufacture, require a plurality of kabobs (i.e. substantially rectangular shaped hollow tubes having an open end and a closed end). Of these kabobs, several are aligned end-to-end, to create a section. Several sections are then positioned side-by-side and covered by a layer of composite material to define an aerodynamic surface for the wing. The juxtaposed sections also establish spar webs for the wing, and the closed ends of the juxtaposed sections establish transverse ribs for the wing. Thus, the kabobs form the main load-bearing member of the wing. The sections of composite material are co-cured with the composite material of the aerodynamic surface.

Wing with sectioned tubular members

The present invention relates to apparatus and methods for winding filament to create a structure. In one embodiment, the invention includes the application of filament to a rotating mandrel to create a desired shape. The invention includes the filament winding of both simple and complex shapes.

Filament winding apparatus and methods of winding filament

A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame. A single piece co-cured composite structure is also disclosed that includes an outer skin, and inner skin, a frame, and a stringer.

Single piece co-cure composite wing

A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Process for forming a single piece co-cure composite wing

A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Method of assembling a single piece co-cured structure

A vacuum waste containment system to operate in situations where limited water is available and discharge of liquid and waste is undesirable. The system is powered by an external vacuum source. The vacuum draws the waste into a holding tank through an air water separator. The majority of the liquid and waste is deposited into the tank while the residual water is separated and drained back into the tank before reaching the vacuum source. The system has been designed for low weight to be reliable and require minimum maintenance.

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Mapleton, UT, United States of America

Larry Jed Ashton