The Boeing Company

Nibco Incorporated

Richard E Heath

Andrew Elmer Modin

Richard Alexander Prause

Raviendra Sidath Suriyaarachchi

Allen James Halbritter

Paul D Shaw

Ivan Gilberto Ramirez

Michael C Hargrove

Justin H Register

Byron James Autry

Caleb J Handolescu

Eric Carlton Anderson

Jennifer F Branton

John R Nibe

Dorekia Martin

An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.

Methods, devices, and systems for forming a composite structure using an expandable pallet

A composite-part manufacturing method comprises placing a bladder against a trough surface of a tool that has a tool radius portion elongating between the trough surface and a major surface of the tool, and placing a radius filler in vicinity of the tool radius portion. The method also comprises applying a peel-away ply over the radius filler, and applying at least one material layer on the peel-away ply. The method further comprises after the at least one material layer has been applied on the peel-away ply, moving the peel-away ply away from the bladder and the major surface of the tool and thereby to move the radius filler along with the peel-away ply away from the tool radius portion to form a composite part having a smooth join surface in vicinity of the tool radius portion.

Apparatus and method for manufacturing a composite part to provide smooth join surfaces of the composite part

A method of forming a composite part from a mufti-ply prepreg composite charge comprises reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure. The method also comprises placing the multi-ply prepreg composite charge, having a first shape, in the chamber and reducing pressure inside the chamber below the atmospheric pressure. The method additionally comprises, while maintaining pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing pressure inside the bladder to the atmospheric pressure, so that the multi-ply prepreg composite charge is compressed between the bladder and a forming tool, which is located inside the chamber, and the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape. The method also comprises curing the multi-ply prepreg composite charge, having the second shape.

Methods and apparatuses for forming composite parts from multi-ply prepreg composite charges

There is provided a forming apparatus for constraining a composite charge and forming the composite charge into a highly contoured composite structure. The forming apparatus includes a first die and a second die between which the composite charge is formed. The first die has pairs of first die portions spaced apart to define a die cavity into which the composite charge is formed into a contoured hat section having a cap. The forming apparatus includes a constraining assembly having a constraining device positioned in the die cavity. The constraining device is designed to constrain a cap portion, and to apply an upward resistive force against the cap portion, and against a downward compressive force applied by the second die, to provide wrinkle prevention in the cap as the contoured hat section is formed. The constraining assembly has a retaining element to retain the constraining device.

Forming apparatus and method for forming highly contoured composite structures

A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Bladder mandrel package

Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Methods and systems for forming composite stringer assemblies

A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.

Method and system for manufacturing a cured composite structure

An illustrative embodiment of the present disclosure provides a method. A composite charge is placed over a forming and cure mandrel, a first radius filler, and a second radius filler. Mechanical pressure is applied to shape the composite charge to the forming and cure mandrel and a rigid base to form a stringer layup having a hat-shaped cross-section. Vacuum pressure is applied to the stringer layup to form a compacted stringer package.

Compacted stringer packages

An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Foam mandrel assembly

A radius filler material positioned at an intersection of a mandrel and a placement surface is heated to form a heated radius filler material. Mechanical pressure is applied to the heated radius filler material to shape the heated radius filler material to a shaped radius filler having a desired shape against a radius of the mandrel. A composite ply is applied over the mandrel and the shaped radius filler.

Shaping a radius filler against a mandrel

A film tube installed and sealed in a hollow composite part acts as an internal vacuum bag that eliminates the need for an internal mandrel to react compaction forces applied by autoclave pressure during curing of the part.

Heat shrinkable film tube and method for manufacturing hollow composite parts

Composite materials comprising at least one ply of dry fiber prepreg material comprising encapsulated resin-containing particles, components made from such composite materials, and methods of making such composite materials and dry fiber prepreg materials are set forth herein.

Force responsive pre-impregnated composite methods, systems and apparatuses

Provided are end effectors and methods of using such end effectors for handling various composite structures. An end effector includes a support structure bendable relative the principal axis of the end effector. The support structure is disposed within a cavity partially formed by an engaging portion of the end effector. The engaging portion is formed from a flexible material and includes multiple openings in fluid communication with the cavity. When the engaging portion contacts a composite structure and when the pressure inside the cavity is reduced below the ambient level, the composite structure is forced against the engaging portion due to this pressure differential. The flexibility of the support structure and of the engaging portion allows the end effector to conform to the shape of the composite structure. At the same time, the support structure maintains the shape of the cavity in the directions normal to the principal axis.

Growing community of inventors

Mount Pleasant, SC, United States of America

Richard E Heath