The Boeing Company

Toray Industries, Inc.

Travis James Sherwood

Joseph Daniel Brennan

Darrell Darwin Jones

Brian Gregory Robins

Karl Marius Nelson

Michael Robert Anderson

Hardik Dalal

Arvid J Berg

Felix N Nguyen

Kenichi Yoshioka

Hideo Andrew Koyanagi

Dongyeon Lee

Systems and methods of curing a thermoset composite (TSC) to a target state of cure (SOC) are disclosed herein. The methods include heating the thermoset composite to greater than a threshold temperature. During the heating, the methods further include monitoring an actual temperature of the thermoset composite, determining a maximum temperature achieved by the thermoset composite, and determining an elapsed time that the actual temperature of the thermoset composite is greater than the threshold temperature. The methods further include ceasing the heating based, at least in part, on the maximum temperature of the TSC and the elapsed time. The systems include a heating assembly, a support mandrel, a thermoset composite, a temperature detector, and a controller programmed to perform the methods.

Systems and methods of curing a thermoset composite to a desired state of cure

Methods of co-bonding a first thermoset composite (TSC) and a second TSC to define a cured composite part are disclosed herein. The methods include partially curing the first TSC to a target state of cure (SOC) to define a first partially cured TSC. The partially curing is based, at least in part, on a maximum temperature of the first TSC during the partially curing and on an elapsed time that an actual temperature of the first TSC is greater than a threshold temperature. The methods further include combining the first partially cured TSC with the second TSC to define a partially cured TSC assembly and heating the partially cured TSC assembly to bond the first partially cured TSC to the second TSC, cure the partially cured TSC assembly, and produce a cured composite part.

Methods of co-bonding a first thermoset composite and a second thermoset composite to define a cured composite part

A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.

Structures using composite modules and structures made thereby

A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.

Extrusion of adhesives for composite structures

Method of fabricating structures using composite modules and structures made thereby

A flexible compaction sheet is used to compact uncured composite plies onto the surface of a ply layup. The compaction sheet includes a peripheral seal that seals the perimeter of the sheet to the surface of the part layup and forms a vacuum chamber over the plies which is evacuated through the sheet to apply compaction pressure to the plies.

Compaction of prepreg plies on composite laminate structures

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Seattle, WA, United States of America

Travis James Sherwood