The Boeing Company

Scott D Hartshorn

Keith Daniel Humfeld

Donald T Powell

Dean Leon Parham

Christopher E Hullman

A method and apparatus for manufacturing a carbon fiber. Pressure is applied to a filament to change a cross-sectional shape of the filament and create a plurality of distinct surfaces on the filament. The filament is converted into a graphitic carbon fiber having the plurality of distinct surfaces. A plurality of sizings is applied to the plurality of distinct surfaces of the graphitic carbon fiber in which the plurality of sizings includes at least two different sizings.

Method and apparatus for manufacturing carbon fibers

Systems and methods are provided for fabricating composite parts. One embodiment is a method of forming a composite part. The method includes laying up opposing composite facesheets, placing a viscous material between the facesheets, increasing a distance between the facesheets, and solidifying the facesheets and the viscous material into an integral composite part.

Composite paneling having multiple facesheets and a core

Autonomous craft capable of extended duration operations as lighter-than-air craft, having the ability to alight on the surface of a body of water and generate hydrogen gas for lift via electrolysis using power derived from a photovoltaic system, as well as methods of launching an unmanned aerial vehicle (UAV) having a deployable envelope from a surface of a body of water.

Extended duration autonomous craft

An engine shaft assembly for an engine is provided. The engine shaft assembly includes a shaft and a thermal distribution layer. The thermal distribution layer is provided on the shaft, and is configured to minimize the effect of distortion of the shaft caused by asymmetric cooling on shutdown of the engine.

Engine shaft assembly and method

A dimmable window apparatus is provided. The dimmable window apparatus includes a window including a first linear polarizing film and a second linear polarizing film, the first linear polarizing film and the second linear polarizing film having respectively a first axis of polarization and a second axis of polarization, the second axis of polarization being electronically-controllable. The apparatus further includes a processor coupled to the second linear polarizing film, and configured to control the second axis of polarization to thereby control the opacity of the window that is defined by the first axis of polarization and the second axis of polarization relative to one another.

Dimmable window apparatus and vehicle including the same

Systems and methods are provided for fabricating composite parts that include both chopped fiber and continuous fiber components. One embodiment is a method that includes laying up a laminate comprising at least one ply of continuous fiber-reinforced polymer onto a first surface of a mold, filling a cavity of the mold with chopped fibers and resin that contact the laminate, curing the chopped fibers and the laminate together into an integral composite part, and separating the integral composite part from the mold.

Fabrication of composite parts having both continuous and chopped fiber components

An aircraft propulsor that includes a load bearing moveable panel is described herein. In one example, the moveable panel can be coupled to a propulsor structure to receive loads from the propulsor structure. Such loads can include roll and/or torque loads generated by rotation of a core engine of the aircraft propulsor. The moveable panel can be coupled to the propulsor structure through a plurality of coupling portions on one or both of the moveable panel and the propulsor structure.

Roll load bearing aircraft propulsor moveable panel systems and methods

Multi-layer thermal insulator apparatus and methods are described. An example multi-layer thermal insulator includes a first thermally insulating layer, a second thermally insulating layer, and a thermally conductive layer positioned between and adjacent to the first thermally insulating layer and the second thermally insulating layer.

Multi-layer thermal insulator apparatus and methods

An apparatus includes a first composite support structure and a second composite support structure. The first and second composite support structures are in a predetermined position relative to one another. The apparatus further includes an uncured pre-preg ply, wherein: the uncured pre-preg ply overlies at least a portion of the first composite support structure; the uncured pre-preg ply overlies at least a portion of the second composite support structure; and the first and second composite support structures are each stiffer than the uncured pre-preg ply.

Composite support structures for composite integrated structure

Systems and methods are provided for ultrasonic image generation. One embodiment is a method that includes capturing a first ultrasound image that represents a first volume within a part, and capturing a second ultrasound image that represents a second volume that partially overlaps the first volume. The method also includes identifying a first constellation comprising at least three inconsistencies in the part that are depicted in the first ultrasound image, identifying a second constellation, comprising a reoriented version of the first constellation, in the second ultrasound image, and generating an aggregate image that combines the first ultrasound image with the second ultrasound image.

Generation of aggregate ultrasound images based on detection of constellations in overlapping ultrasound images

The present disclosure relates to methods and systems for making thermoplastic resin materials and composite resin systems and materials made from the thermoplastic resins, by seeding one melted thermoplastic material with a second thermoplastic material in a crystalline state that comprises an amount of ferromagnetic material.

Materials and methods for nucleating aligned thermoplastic crystals while fabricating thermoplastic carbon fiber reinforced polymer structures

A method and system for inspecting a structure. The method may comprise sending a pulsed wave signal into the structure from a transmitter array. The method may detect a response signal in response to sending the pulsed wave signal into the structure at a group of receivers in a receiver array. The method may identify a group of time delays between sending the pulsed wave signal and may detect the response signal generated in response to the pulsed wave signal at the group of receivers. The method may identify a group of intensities for the response signal detected at the group of receivers. The method may determine a distance to a reflector within the structure using the group of time delays and the group of intensities.

Ultrasound inspection system

A carbon nanotube yarn is coated with polyacrylonitrile to form a coated carbon nanotube yarn. The polyacrylonitrile is converted to crystalline carbon to form a layered carbon fiber with a sheath of the crystalline carbon and a core of the carbon nanotube yarn.

Layered carbon fiber

A method of decoupling an adhesive system from a contact surface of an object is disclosed. The adhesive system has a full adhesive strength in a de-energized state. The adhesive system comprises a backing, carbon nanotubes, each having a first end region, coupled to the backing, and a second end region, opposite the first end region, and charged nanoparticles, each coupled to the second end region of at least one of the carbon nanotubes. The method comprises steps of electrically charging the backing and disengaging the adhesive system from the contact surface. Electrically charging the backing creates an electrical repulsion force between the backing and the charged nanoparticles, so that the full adhesive strength of the adhesive system is decreased to a reduced adhesive strength. Disengaging the adhesive system from the contact surface comprises applying a disengagement force to the adhesive system sufficient to overcome the reduced adhesive strength.

Growing community of inventors

Bellevue, WA, United States of America

Scott D Hartshorn