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The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.

The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.

Patent No.:

US 9630390 B1

PDFFull Text
Date of Patent:
Apr. 25, 2017

Filed:

Nov. 18, 2013

Method of manufacturing curved composite structural elements

Applicant:

The Boeing Company, Chicago, IL (US);

Inventors:

Todd A. Brown, Olympia, WA (US);

Stephen Douglas Friddell, Issaquah, WA (US);

Christopher G. Harris, Auburn, WA (US);

Andrew E. Modin, Enumclaw, WA (US);

Assignee:

THE BOEING COMPANY, Chicago, IL (US);

Attorney:

Yee & Associates, P.C.

Primary Examiner:

Atul P Khare

Int. Cl.
CPC ...
B29C 70/30 (2006.01); B32B 38/18 (2006.01); B29C 43/12 (2006.01); B29C 70/34 (2006.01); B29C 70/38 (2006.01); B29C 70/54 (2006.01); B32B 38/00 (2006.01); B32B 38/04 (2006.01); B32B 27/00 (2006.01); B29C 70/48 (2006.01); B29K 63/00 (2006.01); B29K 67/00 (2006.01); B29K 307/00 (2006.01); B29K 309/10 (2006.01); B29L 31/00 (2006.01); B29L 31/30 (2006.01);
U.S. Cl.
CPC ...
B32B 38/1808 (2013.01); B29C 43/12 (2013.01); B29C 70/342 (2013.01); B29C 70/382 (2013.01); B29C 70/386 (2013.01); B29C 70/545 (2013.01); B32B 38/0004 (2013.01); B32B 38/04 (2013.01); B32B 38/1816 (2013.01); B32B 38/1858 (2013.01); B29C 70/48 (2013.01); B29K 2063/00 (2013.01); B29K 2067/00 (2013.01); B29K 2307/00 (2013.01); B29K 2309/10 (2013.01); B29L 2031/003 (2013.01); B29L 2031/3082 (2013.01); Y10T 156/1002 (2015.01); Y10T 156/108 (2015.01); Y10T 156/1051 (2015.01); Y10T 156/1067 (2015.01); Y10T 156/1075 (2015.01);
Abstract

A method of manufacturing curved composite structural elements can include fabricating a web ply in a flat curve over a removable substrate and laying up the ply on a curved web surface of a manufacturing tool. The method also can include laying up a diagonal ply with fibers oriented at +/−45° from the centerline of the web surface. The method further can include cutting a unidirectional composite tape into segments and laying up the tape segments to form a cross ply with a fiber orientation normal to the centerline of the web surface. One or both edges of the diagonal and cross plies may be folded over one or two sides of the manufacturing tool to form one or two flange surfaces. Additionally, a cap ply can be laid up on one or both flange surfaces using composite tape. The structural element layup can then be inspected and any excess composite material can be trimmed away.

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