The Boeing Company

Theboeing Company

Neal A Froeschner

Steven J Burpo

Michael P Renieri

Nicholas B Segobiano

Randall Dow Wilkerson

Brett Ian Lyons

Charles Richard Prebil

Matt Wallen

Jens Rossfeldt

Karen M Jost

Ronald J Byington

Philip O Chrissos

Derek J Fox

Jeffrey D Martin

Jim S Piszar

Keith Rupel

Jimmy S Piszar

James M Ogonowski

Gary D Renieri

Daniel R Benjey

Keith E Rupel

A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

System for manufacturing monolithic structures using expanding internal tools

Continuous compression molding process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.

Staggered bevel for continuous compression molding tooling dies

A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.

Bead-stiffened composite parts

System and method for manufacturing monolithic structures using expanding internal tools

Continuous compression molded process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.

A pressure debulking system includes a debulking chamber having a debulking chamber interior, a pressure bladder having a bladder interior provided in the debulking chamber interior, a vacuum port disposed in fluid communication with the debulking chamber interior and a pressure port disposed in fluid communication with the debulking chamber interior. A pressure debulking method is also disclosed.

Pressure debulking system

Pressure debulking system and method

An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is provided that permits differential expansion of different portions of the tool.

Apparatus for forming hat stiffened composite parts using thermally expansive tooling cauls

An apparatus for curing a composite assembly may include a base tool, a growth control apparatus, and at least one engagement fitting. The base tool may have a different thermal expansion growth rate than a composite assembly to be cured using the apparatus. The growth control apparatus may have a different thermal expansion growth rate than the base tool. The engagement fitting may be moveably disposed relative to the base tool and connected to the growth control apparatus. The engagement fitting may hold a composite assembly being cured against the engagement fitting. The growth control apparatus may grow a pre-determined amount during curing of a composite assembly to produce a cured composite assembly having a pre-determined design dimension.

Cure growth control apparatus

Method of making bead-stiffened composite parts and parts made thereby

In one embodiment, an apparatus for curing a composite assembly may include a base tool, a growth control apparatus, and at least one engagement filling. The base tool may have a different thermal expansion growth rate than a composite assembly to be cured using the apparatus. The growth control apparatus may have a different thermal expansion growth rate than the base tool. The engagement fitting may be movably disposed relative to the base tool and connected to the growth control apparatus. The engagement filling may hold a composite assembly being cured against the engagement filling. The growth control apparatus may grow a pre-determined amount during curing of a composite assembly to produce a cured composite assembly having a pre-determined design dimension.

An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is also provided that permits differential expansion of different portions of the tool.

Apparatus and methods for forming hat stiffened composite parts using thermally expansive tooling cauls

A system for supporting a bond jig comprises a plurality of planar panels including at least one mounting hole for fasteners in each panel, wherein a first panel is arranged in a non-orthogonal position to a second panel. The system further comprises a coupling element for coupling panels, comprising a first and second planar portion, a hinge element connecting the first and second planar portion, wherein the first planar portion and the second planar portion rotate around the hinge element to form an angle, and at least one mounting hole for fasteners in the first and second planar portion. The system further comprises at least one fastener for fastening the first planar portion to the first panel via a mounting hole in the first planar portion and a mounting hole in the first panel and at least one fastener for fastening the second planar portion to the second panel via the mounting hole in the second planar portion and the mounting hole in the second panel.

Assembly of eggcrate substructure for bond jigs

A tool for trimming the ends of stiffeners on aircraft composite skin panels accurately, rapidly and without damaging the underlying skins includes an expandable guide frame adapted to straddle and clamp to the stiffener at a selected longitudinal position thereon. The frame includes a pair of planar guide faces disposed on opposite sides of the stiffener and lying in a common plane transverse thereto. The rotatably supported opposite ends of a rotating abrasive drum are slid along respective ones of the guide faces such that the drum grinds away the stiffener in a plane parallel to the plane of the guide faces and thereby forms a trimmed end on the stiffener. The frame includes mechanisms for adjusting the angular inclination of the plane of the guide faces relative to the plane of the composite skin, and for preventing the grinding mechanism from cutting into the composite skin.

Growing community of inventors

Florissant, MO, United States of America

Neal A Froeschner