The Boeing Company

William H Ingram

Robert D Biornstad

Bruce C Blankinship

Terry J George

Karl Marius Nelson

Kenneth Marvin Dull

Byron James Autry

Gagandeep Saini

Disclosed herein is a bladder assembly for forming a part made of a fiber-reinforced polymeric material. The bladder assembly comprises a bladder comprising an interior having a hollow interior channel within the interior of the bladder. The bladder assembly also comprises an intake port fluidically coupled with the interior of the bladder and an exhaust port fluidically coupled with the interior of the bladder. The bladder assembly further comprises a pressure control device fluidically coupled with the exhaust port and configured to control a pressure drop across the interior of the bladder from the intake port to the exhaust port.

Autoclave system, bladder assembly, and associated method for forming a part

In one version there is provided a test system including a layup tool having a layup surface, and two fairing bars attached to the layup surface. The test system includes the composite laminate having a plurality of stacked plies, and positioned between the two fairing bars. The test system includes fiber distortion initiator(s) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies. The test system includes two caul plates with a gap in between, and positioned over the composite laminate. When the test system undergoes a pressurized cure process with a vacuum compaction, a restricted outward expansion of the plurality of stacked plies by the fairing bars, and a pressure differential region formed by the one or more fiber distortion initiators at the one or more locations, create the controlled and repeatable out-of-plane fiber distortion in the composite laminate.

Test system and method for creating controlled and repeatable out-of-plane fiber distortion in composite laminates

A composite strip and a method of manufacturing a pre-cured composite strip. A pre-cured composite strip having a thermoset resin may be placed on a surface of a portion of a composite component where a caul plate seam may be expected. Caul plates may be placed on the composite component after placing the pre-cured composite strip to form the caul plate seam. The composite component may be cured after placing the caul plates on the composite component.

Composite strip

Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are herein. A composite aircraft panel manufacturing assembly comprises a skin, a stiffener, a tubular bladder, and at least one ply of fabric. The stiffener comprises first and second flange portions bonded to the skin. The stiffener further comprises an interior surface, spaced apart from the skin, and extending between the first and second flange portions. The tubular bladder extends longitudinally between the interior surface of the stiffener and the skin. The at least one ply of fabric extends around the bladder and is bonded to the interior surface of the stiffener and an adjacent portion of the skin between the first and second flange portions.

Composite barrel sections for aircraft fuselages and other structures

Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are disclosed herein. A composite section configured in accordance with one embodiment of the invention includes a skin and at least first and second stiffeners. The skin can include a plurality of unidirectional fibers forming a continuous surface extending 360 degrees about an axis. The first stiffener can include a first flange portion bonded to an interior surface of the skin and a first raised portion projecting inwardly and away from the interior surface of the skin. The second stiffener can include a second flange portion bonded to the interior surface of the skin and a second raised portion projecting inwardly and away from the interior surface of the skin. A method for manufacturing a section of a fuselage in accordance with one embodiment of the invention includes positioning a plurality of uncured stiffeners on a mandrel assembly. The method can further include applying a plurality of fiber tows around the plurality of uncured stiffeners on the mandrel assembly.

Composite barrel sections for aircraft fuselages and other structures, and methods for systems for manufacturing such barrel sections

Composite barrel sections for aircraft fuselages and other structures, and methods and systems for manufacturing such barrel sections

A method and apparatus for applying a pre-cured composite strip to a composite component. A pre-cured composite strip having a thermoset resin may be placed on a surface of a portion of the composite component where a caul plate seam may be expected. Caul plates may be placed on the composite component after placing the pre-cured composite strip to form the caul plate seam. The composite component may be cured after placing the caul plates on the composite component.

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Puyallup, WA, United States of America

William H Ingram