The Boeing Company

Thomas R Cundiff

Andrew Elmer Modin

Donald Edward Wright

Henry H Bennett

Scott A Miller

Brad G Lund

Robert S Renz

Donald Lloyd Conaway

Andrew Atkins Head

Jack Allen Woods

Dennis James Hanks

Timothy David Aquino

Robert Alexander Coleman

Steven Charles Stenard

Val G Brustad

David J Kehrl

Michael L Glain

Bradley A Frye

Joo Hyun Han

Scott A Harris

Karl Marius Nelson

Dennis J Hanks

Jack A Woods

Joo H Han

Timothy D Aquino

Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Systems for manufacturing composite parts with female tools

An apparatus for tensioning a preform may include a mandrel to receive a preform. The mandrel may have a first mandrel end and a second mandrel end. The preform may have a first preform end and a second preform end. The apparatus may include an anchoring groove disposed at the first mandrel end, and an anchoring device being configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The apparatus may include a tensioning groove disposed between the first mandrel end and the second mandrel end, and a tensioning device being configured and located to urge at least a portion of the preform into the tensioning groove.

Device for tensioning a preform

An apparatus to prepare a preform for fabrication includes a mandrel, anchoring groove, anchoring device, tensioning groove, and tensioning device. The mandrel receives the preform. The mandrel has a first mandrel end and a second mandrel end. The preform has a first preform end and a second preform end. The anchoring groove is disposed at the first mandrel end. The anchoring device is configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The tensioning groove is disposed between the first mandrel end and the second mandrel end. The tensioning device is configured and located to urge a portion of the preform into the tensioning groove.

Tensioning device for composite structures

Methods and systems for manufacturing composite parts with female tools

A wind tunnel blade () connected to a base () and held in position by a two-piece cuff (). The wind tunnel blade () is formed in a resin transfer molding process in which central, fore, and aft foam core sections () are placed together to form the wind tunnel blade (). Radius fillers () are used to fill the gaps between the outer edge of the foam core sections. The radius fillers () used in the wind tunnel blade () are formed by a braided sleeve () surrounding a number of unidirectional tows (). A tip () is formed separately from the rest of the wind tunnel blade () and is glued to the top thereof. Stacked layers of braided fibers () are used to reinforce the central core section ().

Resin transfer molding process

A method for forming a plurality of composite parts via resin transfer molding in a single molding cycle. The method includes the steps of using a mold having first and second mold members that cooperate to house a plurality of shims and placing a plurality of preform workpiece into the mold cavity such that at least one of the shims is disposed between each of an adjacent pair of the preform workpieces. A liquid resin is then injected into the mold cavity and subsequently cured to thereby form a cured workpiece matrix that is composed of a plurality of semi-finished composite parts and at least one shim separating the plurality of semi-finished composite parts from one another.

Resin transfer molding multi-part/shim tooling (RTM-MPST)

A wind tunnel blade ( ) connected to a base ( ) and held in position by a two-piece cuff ( ). The wind tunnel blade ( ) is formed in a resin transfer molding process in which central, fore, and aft foam core sections ( ) are placed together to form the wind tunnel blade ( ). Radius fillers ( ) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers ( ) used in the wind tunnel blade ( ) are formed by a braided sleeve ( ) surrounding a number of unidirectional tows ( ). A tip ( ) is formed separately from the rest of the wind tunnel blade ( ) and is glued to the top thereof. Stacked layers of braided fibers ( ) are used to reinforce the central core section ( ).

The present invention relates to an index/seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/seal pin seals via replaceable O-rings on the threaded stem of the pin to prevent low viscosity resin from exiting a mold cavity and invading the threads, bolts, pins, or other elements of the internal mandrel. The pin also assures accurate positioning of a mandrel in the die cavity while it allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system.

Accurate positioning using a seal pin for RTM mold dies

The present invention relates to a seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/resin seal pin of the present invention for RTM mold dies is novel in that it provides the seal (via replaceable O-rings) on the threaded stem of the pin to prevent low viscosity resin from invading the threads, bolts pins, or other elements of the internal mandrel. The pin allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system. The invention also relates to a method for using the seal pin in a resin transfer molding process.

Resin transfer mold

A wind tunnel blade (,) connected to a base (,) and held in position by a two-piece cuff (,). The wind tunnel blade (,) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (,) are placed together to form the wind tunnel blade (,). Radius fillers (,) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (,) used in the wind tunnel blade (,) are formed by a braided sleeve (,) surrounding a number of unidirectional tows (,). A tip (,) is formed separately from the rest of the wind tunnel blade (,) and is glued to the top thereof Stacked layers of braided fibers (,) are used to reinforce the central core section (,).

Radius fillers for a resin transfer molding process

A process for making a layered product having a honeycomb core having cells filled with a foam material, the process comprising the steps of: (a) placing a first layer of an uncured, heat-expandable, foamable material on the top side of a central honeycomb core having empty cells, and placing a second layer of an uncured, heat-expandable, foamable material on the bottom side of the central honeycomb core; (b) placing a first layer of an uncured preform material above the first layer of uncured, heat-expandable, foamable material, and placing a second layer of an uncured preform material above the second layer of uncured, heat-expandable, foamable material; (c) placing the charge made by steps (a) and (b) inside a mold and closing the mold; (d) heating the mold to the cure temperature of the heat-expandable, foamable material, and holding the mold at this temperature for sufficient time to expand and cure the heat-expandable, foamable material; (e) reducing the temperature of the mold to the injection temperature of a selected resin transfer molding (RTM) resin system, and injecting the selected resin transfer molding (RTM) resin system into the mold; (f) holding the temperature of the mold at the cure temperature for the resin transfer molding (RTM) resin system for sufficient time to cure the resin system; and, (g) removing the product from the mold after curing is completed.

Resin transfer molding with honeycomb core and core filler

A process for making a layered product having a honeycomb core having empty cells, the process comprising the steps of: (a) placing a first layer of an uncured adhesive film on the top side of a central honeycomb core having empty cells, and placing a second layer of an uncured adhesive film on the bottom side of the central honeycomb core; (b) placing a first layer of an uncured prepreg material above the first layer of uncured adhesive film, and placing a second layer of an uncured prepreg material below the second layer of uncured adhesive film; (c) placing a first layer of a dry fiber preform above the first layer of uncured prepreg material, and placing a second layer of a dry fiber preform below the second layer of uncured prepreg material; (d) placing the charge made by steps (a)-(c) inside a mold and closing the mold; (e) heating the mold to the cure temperature of the adhesive film and the prepreg material, and holding the mold at this temperature for sufficient time to cure the adhesive film and the prepreg material; (f) reducing the temperature of the mold to the injection temperature of a selected resin transfer molding (RTM) resin system, and injecting the selected resin transfer molding (RTM) resin system into the mold; (g) holding the temperature of the mold at the cure temperature for the resin transfer molding (RTM) resin system for sufficient time to cure the resin system; and, (h) removing the product from the mold after curing is completed.

Growing community of inventors

Edgewood, WA, United States of America

Thomas R Cundiff