The Boeing Company

Michael P Thompson

Bobby Joe Marsh

Michael Robert Anderson

Noel Timothy Gerken

Grant C Zenkner

Otis Franklin Layton

Kinson D VanScotter

Gwen M Gross

Thomas J Vanderwiel

Christopher Cressy

Douglas H Cox

Stanley F Polk

Lawrence P Kucera

Disclosed systems and tooling for manufacturing flanged ducts may improve upon prior art manufacturing techniques, such as by increasing ease of manufacturing and/or quality of resulting parts formed by the systems and tooling. One example of tooling includes a first tool piece that may be coupled to a base, and a second tool piece that is selectively coupled to and removable from the first tool piece. When positioned together in a closed position, the first tool piece and second tool piece form a composite material-receiving surface and a flange surface on which composite material may be placed and cured in order to form a composite part, such as a flanged duct. Such tooling may allow for placement of composite material over a male radius of the tooling, thereby improving ergonomics of the manufacturing process, as compared to attempting to place composite material into a female radius of prior art tooling.

Systems and tooling for manufacturing composite parts and related methods

Methods and systems and components made according to the methods and systems, are disclosed relating to improved curing methods for epoxy resin-containing composite prepreg materials, wherein the composite prepreg materials are exposed to a flow of ammonia-containing compounds to fully cure the composite prepreg materials at substantially ambient temperatures and pressures.

Methods, systems and apparatuses for curing epoxy-containing prepreg composite assembly

Apparatus for processing a workpiece comprises a base adapted to have a workpiece placed thereon. A vacuum bag is placed over the workpiece, and the bag is sealed to the base using inner and outer seals. The inner and outer seals are spaced apart from each other to form a channel therebetween. A vacuum port coupled with a vacuum source is used to evacuate air from the channel.

Vacuum bag processing using dual seals

An impact resistant composite sandwich structure includes least one laminate face sheet joined to a stiffening element. The stiffening element includes a plurality of fibers and a resin for binding the fibers. The resin has a strain-to-failure greater than approximately 6%.

Impact resistant composite structures

A security alarm monitor is disclosed that uses a combination of three dimensional (3D) and two dimensional (2D) visualization to display the status of security devices and allow the operator to respond to alarms. The alarm monitor console includes 3D and 2D display areas, either in a split screen on a single monitor or on dual monitors. The 3D display area uses a photo-realistic representation of a facility and overlays iconic or 3D representations of the security devices showing their locations, coverage areas, and alarm status. The 2D display area shows a map, architectural drawing, image-based overhead view, or combination or the three for a facility and security device icons. The alarm representations in the 2D and 3D display areas are synchronized. The 3D display gives a dynamic view of the facility or compound. When an alarm occurs, the 3D display flies to preprogrammed view of the alarm location, issues a preprogrammed audio alert, and animates the alarm icon to indicate its status.

Visual security operations system

Shims used to join part assemblies are automatically designed and fabricated without the need for fitting part assemblies together in order to determine the exact dimensions of voids filled by the shims. The locations of key features on part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate the dimensions of a virtual shim. The dimensions of the virtual shim are contained in a digital file that can be used to automatically fabricate the shim using automated fabrication equipment such as a CNC machining center. The automated virtual shim design may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.

Method for fitting part assemblies

Apparatus and methods for processing composite components using an elastomeric caul are disclosed. In one embodiment, a method of curing a prepreg on a mandrel includes providing an elastomeric caul over the prepreg; providing a vacuum bag over the prepreg and the caul, with the caul between the prepreg and a film of the vacuum bag; and stretching the elastomeric caul over the prepreg while drawing down the vacuum bag over the caul. The caul is stretched to fit snuggly over the prepreg to reduce fiber deformation and wrinkling during curing.

Apparatus and methods for processing composite components using an elastomeric caul

A process and method for manufacturing fiber reinforced composite structures without trapping volatiles in the resin matrix. Volatiles from the curing cycle are absorbed into a silicone rubber layer,and a gas impermeable barrier layer outside the silicone rubber layer prevents autoclave atmosphere from permeating into the part. The process is to layer the finished ply build-up, with a ply of FEP (fluorinated ethylene propylene), a layer of silicone rubber to absorb the volatiles, and a layer of impermeable elastomer. The layer of fluoroelastomer is bonded to the silicone rubber to form a reusable, impermeable elastomeric vacuum bag, eliminating the need for disposable edge and surface breathers.

Vacuum bag not requiring disposable breathers

An automatic test apparatus calculates the amount of heat released by a material. The apparatus includes a calorimeter having a heating or burn chamber in which a sample of test material is burned by subjecting it to preselected heat flux rates. A computer automatically controls the apparatus by governing sample insertion into the chamber, and monitors the amount of heat and smoke the sample releases. Heat and smoke release data is automatically generated and provided to the user after every test.

Growing community of inventors

Tacoma, WA, United States of America

Michael P Thompson