The Boeing Company

Spirit Aerosystems, Inc.

William Tod Ross

Bradley J Blonigen

Jeffery Max Buxman

William Joseph Bryant

Steven R Blencoe

Steven Blencoe

A roller device for use in an automated fiber placement process for creating composite parts on a contoured tool. A helical spring provides a bendable axle, and a roller cover fits over the spring axle. A tension mechanism is arranged through the spring axle along a centerline axis, and is adjustable to control a bendability of the spring axle so as to more closely conform to particular contours of the tool. The tension mechanism may include a cable extending through the spring axle, a threaded portion at an end of the cable, and a screw received within the threaded portion and turnable to adjust a length of the tension mechanism and thereby adjust the bendability of the spring axle. The tension mechanism may be adjustable manually, semi-manually with a motor controlled by a user, or automatically with a motor controlled by an electronic controller.

Roller device with tailorable compliance for automated fiber placement

A sealing device for forming an airtight seal between a first body, such as a cure tool, and a second body, such as a vacuum bag, without the use of adhesives. The sealing device may comprise an outer surface attached to the second body, an inner surface configured to face the first body, and two cusps located at opposite edges of the inner and outer surfaces. The sealing device may form a continuous boundary around an area of any shape or size. The sealing device may have a substantially crescent-shaped cross-section, allowing the sealing device to suction to the first body when compressed against the first body. The sealing device may also comprise a tab portion protruding from the inner surface between the first and second cusp for providing a more secure seal between the sealing device and the first body.

Reusable sealing device

A reusable apparatus and method for forming a composite part through vacuum assisted resin transfer molding (VARTM). The reusable apparatus may be configured to vacuum seal a curable material, such as composite material, against a tool and disperse a permeating substance such as liquid resin through the curable material. The reusable apparatus may comprise a sheet of material such as rubber having a plurality of surface deviations facing the curable material and the tool. The surface deviations may provide paths for evenly distributed air flow as air is evacuated from between the sheet of material and the tool. Additionally, the surface deviations may allow the permeating substance to be evenly dispersed throughout the curable material. A vacuum outlet of the tool may be positioned between two sealing apparatuses to provide continuous vacuum suction proximate a perimeter of the sheet of material to prevent air from leaking in.

Reusable infusion bag

A reusable vacuum bag apparatus for use in a compaction operation by which composite parts are formed. The apparatus includes a flexible, inflatable support structure which is secured to a reusable flexible mat vacuum bag. When inflated, the support structure maintains the vacuum bag in the orientation it needs to assume when placed on a forming tool associated with a compaction apparatus. The support structure is formed by a plurality of intercoupled linear and curving tubing segments which form a grid-like support structure. The support structure is shaped in accordance with the configuration and contours of the reusable vacuum bag portion, which is in turn shaped in accordance with a forming tool. The support structure can be de-inflated, which allows the vacuum bag secured thereto to be stored in a compact arrangement when not in use. The hollow tubular support structure also provides a very light support framework which is much more easily manipulated and handled by a lay-up mechanic when positioning the apparatus on a forming tool.

Flexible inflatable support structure for use with a reusable compaction bag

A method of shaping a layer of settable material such as honeycomb core (24) including placing the core on a flexible support (38); translating the flexible support (38) and core into an oven (28); heating the core to a desired forming temperature in the oven; translating the flexible support (38) and core (24) horizontally from the oven into a forming area (26); lowering a contoured upper die (32) onto the core (24); tensioning the flexible support (38); pressing the core between the tensioned flexible support and the upper die so that the core (24) is forced to conform to the shape of the die (32); cooling the core to set temperature; and raising the die (32) to remove the finished shaped core, is provided. Additionally, a shaping apparatus (22) located in a forming area (26) adjacent an oven (28), for shaping a settable material such as honeycomb core (24) is provided, including: an upper die (32); first and second tensioning assemblies (70), (72) each including a torque supply system; first and second guide assemblies (50), (52) for translating the tensioning assemblies into and out of the oven (28); at least one flexible support (38) wrapped around and between the tensioning assemblies (70), (72) upon which the core may be placed; a regulation system for equalizing tension about the core during pressing; and optional support rollers (166) for focusing the flexible support (38) against the upper die (32) during pressing. A tensioning assembly including a roller (76) and a torque supply system having an air motor (84), is provided. Alternatively, a tensioning assembly including a number of short rollers (92) each powered by a torque supply system having an air motor (108); and a like number of tensioning sub-assemblies (90) each having multiple flexible belts (96) attached thereto, is provided.

Method for shaping honeycomb core

A process of forming and shaping a preheated workpiece made of honeycomb core material using a press including complementary male and female dies. The first step of the process is providing a carrier sheet for supporting the workpiece. The carrier sheet is suspended over the female die by two shafts supported by support towers. The next step is loading the preheated workpiece onto the carrier sheet. The next step is applying rotational torque to each of the two shafts whereby the carrier sheet is wrapped around the said shafts thereby applying tension to the carrier sheet and pulling the shafts toward each other and into pressing contact with the sides of the workpiece while said carrier sheet means supports the bottom surface of said workpiece. The next step is closing the male die and the female die against the workpiece while maintaining the shafts in pressing contact with the sides of the workpiece and while the carrier sheet supports the bottom surface of the workpiece, whereby the workpiece is formed and shaped by the complementary male and female dies into a formed workpiece of the desired shape. The final step is opening the male and female dies and removing the formed workpiece.

Honeycomb core forming process

Apparatus for shaping honeycomb core

A portable version of a honeycomb core forming restricter (20) for forming and shaping a workpiece made of stiff honeycomb core material, the apparatus (20) to be used in combination with a press including a male die (70) and a female die (72), the apparatus (20) including: (a) a base plate (62); (b) four support tower assemblies (24a, 24b, 24c, 24d) supported by the base plate (62); (c) two shafts (22a, 22b) supported by the support tower assemblies (24a, 24b, 24c, 24d), the shafts (2a, 22b) being arranged in a generally parallel relationship to each other and to the longitudinal axis of the female die 72; (d) a carrier sheet (74) for supporting the workpiece, the carrier sheet (74) being attached to the two shafts (22a, 22b); (e) four air motors (26a, 26b, 26c, 26d) for applying rotational torque to the shafts ( 22a, 22b); and (f) the support tower assemblies including a double acting air cylinder (36a) for moving the shaft (22a) in a transverse direction with respect to the longitudinal axis of the female die (72) and a pivoting mount (48a) for allowing the centerpoint of the shaft (22a) to move in an arc in a plane transverse to the longitudinal axis of the female die (72). A dedicated version of the honeycomb core forming restricter is also disclosed.

Growing community of inventors

Cheney, KS, United States of America

William Tod Ross