The Boeing Company

Richard B Evans

Darrell Darwin Jones

Kurtis Shuldberg Willden

Michael A Lee

John Heigl

Matthew K Lum

C Warren Turner

Matthew KS Lum

A cutting system includes a cutting assembly and an anvil. The cutting assembly includes an ultrasonic cutting tool having a stylus with a tip and an actuator to move the tip along a path. The path is oriented in a transverse manner relative to movement of a backed ply material. The anvil includes a rigid base for securing the anvil to the cutting assembly and a surface coinciding with the path. The system is configured to drive the tip into the surface and draw the tip along the path to generate a groove disposed upon the surface. The groove being in cooperative alignment with the tip.

Cutting anvil and method

To cut a backed ply material with an ultrasonic blade, an anvil is utilized to provide support. The backed ply material travels in a first direction, the ultrasonic blade includes a tip, and the ultrasonic blade is operable to travel along a path. This path is oriented in a transverse manner relative to the first direction. The anvil includes a rigid base for securing the anvil to a cutting assembly and a surface coinciding with the path. The surface is secured to the base. The anvil further includes a groove disposed upon the surface. This groove is in cooperative alignment with the tip.

Anvil for supporting cuts in sheet and roll stock

A layered material includes a ply material and a backing film to support the ply material. The backing film includes a polyester film. The layered material is generated by disposing the backing film upon the ply material. A composite layup is generated by tacking the layered material to a tool, disposing the layered material upon the tool along a path, and removing the backing film.

Backing film and method for ply materials

To generate a bevel in an uncured composite layup, an edge of part cut through the composite layup is performed at about 90&#xb0; relative to the composite layup and a bevel cut is performed on the edge of part.

Cutting sequence for net trimming a composite layup at an oblique angle

A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.

Apparatus for forming structural members

Method and apparatus for forming structural members

An apparatus and method for securing a plurality of stringers to a mandrel during lay-up is provided, the plurality of stringers and mandrel forming a lay-up surface. The apparatus includes a vacuum source and a first vacuum attachment assembly in communication with said vacuum source to tightly secure the first vacuum attachment assembly down against the lay-up surface. A second vacuum attachment assembly is provided in communication with the vacuum source to force it tightly down against the lay-up. A flexible spacer is in rigid communication with the second vacuum attachment assembly and includes an extended end in communication with the first vacuum attachment assembly such that the flexible spacer presses one of the stringers against the mandrel.

Stringer holding device

A hybrid composite structure is formed from layers of gore strips (12), polymeric matrix composite (71) comprising a resin impregnated slit tape or tow, and a central honeycomb layer formed from a plurality of rectangular sections (72). The first two steps include forming a plurality of the gore strips and providing a mold, or lay-up mandrel (10). Thereafter, a first set of gore strips is applied to the lay-up mandrel to form a first gore strip layer. Subsequently, the composite material in form of resin impregnated slit tape or tow is applied to the first gore strip layer to form a first composite material layer. Next, a second set of gore strips is applied to the first layer of polymeric matrix composite, opposite the first gore strip layer, to form at least one other gore strip layer. This creates a first sandwich structure having gore strips as the first and last layers of the structure. Thereafter, the layer of honeycomb material is applied to the last layer of the first sandwich structure. Finally, a second sandwich structure, substantially identical to the first sandwich structure, is formed on the side of the honeycomb layer opposite the first sandwich structure. Thus, a hybrid composite structure is formed having first and second sandwich structures separated by a central honeycomb layer.

Growing community of inventors

Maple Valley, WA, United States of America

Richard B Evans