公开(公告)号：US09701067B2

公开(公告)日：2017-07-11

申请号：US14048009

申请日：2013-10-07

Applicant: The Boeing Company

Inventor： Robert D. Hawkins ,  Kurtis S. Willden ,  Andrew E. Modin ,  Edoardo Depase ,  Michael L. Glain ,  Benjamin Adam Mussi ,  Max U. Kismarton

IPC: B29C70/20 ,  B29C70/02 ,  B29C70/54 ,  B29C70/30

CPC classification number: B29C70/021 ,  B29C70/20 ,  B29C70/30 ,  B29C70/541

Abstract: A method is presented. The method comprises identifying a desired shape of a ply on a tool, in which the ply has a fiber orientation; identifying a cut shape for the ply, in which the cut shape is different than the desired shape; cutting a composite prepreg ply to have the cut shape, the composite prepreg ply having the fiber orientation; using a deformable carrier to apply the composite prepreg ply having the cut shape to the tool such that the composite prepreg ply has the desired shape on the tool.

公开(公告)号：US20160214330A1

公开(公告)日：2016-07-28

申请号：US15089399

申请日：2016-04-01

Applicant: The Boeing Company

Inventor： James N. Buttrick ,  Dennis Wayne Stewart ,  Andrew E. Modin ,  David Paul Banks ,  Edoardo Depase ,  Jesus Sanchez

IPC: B29C70/38 ,  B29C70/06 ,  B29C70/54

Abstract: A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.

Abstract translation: 多个相同的制造模块连接在一起并且可配置为在具有共同特征的一系列结构中制造多个不同层压结构中的任何一个。 每个制造模块局部地适于在相应的工具上制造层压结构的一部分。 控制器控制和协调制造模块的自动化操作。

公开(公告)号：US20150231834A1

公开(公告)日：2015-08-20

申请号：US14698841

申请日：2015-04-28

Applicant: The Boeing Company

Inventor： Andrew E. Modin ,  Jack A. Woods ,  Robert D. Hawkins

IPC: B29C70/34 ,  B29C70/54

CPC classification number: B32B38/0004 ,  B29C70/202 ,  B29C70/34 ,  B29C70/54 ,  B29C70/545 ,  B29L2031/005 ,  B29L2031/3076 ,  B32B5/12 ,  B64C1/1492 ,  Y02T50/43 ,  Y10T156/1026 ,  Y10T156/1028 ,  Y10T156/1052 ,  Y10T156/1057 ,  Y10T156/1062 ,  Y10T156/1082 ,  Y10T428/24124 ,  Y10T428/24628

Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, −45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.

Abstract translation: 具有弯曲台阶表面的纤维增强复合结构通过在具有阶梯式工具特征的工具上铺设纤维增强材料层来制造。 当它们铺设成基本上形成固定轴玫瑰花纹图案时，帘布层围绕固定轴线旋转。 层片成角度定向，使得至少某些层具有不同于0，+ 45，-45和90度的纤维取向。 通过在阶梯形特征区域中切割层中的狭缝来减少或消除纤维在阶梯式工具特征上的潜在桥接，使得层可以完全压实。

公开(公告)号：US11697255B2

公开(公告)日：2023-07-11

申请号：US17684535

申请日：2022-03-02

Applicant: The Boeing Company

Inventor： Richard A. Prause ,  Allen J. Halbritter ,  Andrew E. Modin

IPC: B29C70/54 ,  B29C43/36 ,  B29C70/34 ,  B29C70/44

CPC classification number: B29C70/541 ,  B29C43/3642 ,  B29C70/342 ,  B29C70/44 ,  B29C2043/3644

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

公开(公告)号：US20230063884A1

公开(公告)日：2023-03-02

申请号：US17461606

申请日：2021-08-30

Applicant: The Boeing Company

Inventor： James R. Kendall ,  Raviendra S. Suriyaarachchi ,  Andrew E. Modin

IPC: B29C70/34 ,  B29C70/54

Abstract: There is provided a forming apparatus for forming a high contour composite structure. The forming apparatus includes an upper die and a lower die between which a composite charge is formed. The forming apparatus further includes a plurality of load cells, a control system, and an overlay tool assembly coupled to the upper die. The overlay tool assembly has scalloped sections positioned between pairs of the plurality of load cells, and positioned against portion(s) of the composite charge. The composite charge has ply discontinuity features through the one or more portions. The overlay tool assembly denies pressure and a through thickness compaction to the one or more portions of the composite charge during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure in post-forming operations.

公开(公告)号：US20220143938A1

公开(公告)日：2022-05-12

申请号：US17503226

申请日：2021-10-15

Applicant: The Boeing Company

Inventor： Richard E. Heath ,  Andrew E. Modin ,  Richard A. Prause ,  Paul D. Shaw ,  Raviendra S. Suriyaarachchi

IPC: B29C70/54 ,  B29C70/34

Abstract: There is provided a forming apparatus for constraining a composite charge and forming the composite charge into a highly contoured composite structure. The forming apparatus includes a first die and a second die between which the composite charge is formed. The first die has pairs of first die portions spaced apart to define a die cavity into which the composite charge is formed into a contoured hat section having a cap. The forming apparatus includes a constraining assembly having a constraining device positioned in the die cavity. The constraining device is designed to constrain a cap portion, and to apply an upward resistive force against the cap portion, and against a downward compressive force applied by the second die, to provide wrinkle prevention in the cap as the contoured hat section is formed. The constraining assembly has a retaining element to retain the constraining device.

公开(公告)号：US11318689B2

公开(公告)日：2022-05-03

申请号：US16229024

申请日：2018-12-21

Applicant: The Boeing Company

Inventor： Richard A. Prause ,  Allen J. Halbritter ,  Andrew E. Modin

IPC: B29C70/54 ,  B29C43/36 ,  B29C70/34 ,  B29C70/44

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

公开(公告)号：US20220118720A1

公开(公告)日：2022-04-21

申请号：US17384440

申请日：2021-07-23

Applicant: The Boeing Company

Inventor： Andrew E. Modin ,  Dorekia Martin ,  Richard E. Heath ,  Eric C. Anderson ,  Caleb J. Handolescu ,  Richard Alexander Prause ,  Michael C. Hargrove ,  Justin H. Register

IPC: B29C70/44

Abstract: A method of forming a composite part from a mufti-ply prepreg composite charge comprises reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure. The method also comprises placing the multi-ply prepreg composite charge, having a first shape, in the chamber and reducing pressure inside the chamber below the atmospheric pressure. The method additionally comprises, while maintaining pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing pressure inside the bladder to the atmospheric pressure, so that the multi-ply prepreg composite charge is compressed between the bladder and a forming tool, which is located inside the chamber, and the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape. The method also comprises curing the multi-ply prepreg composite charge, having the second shape.

公开(公告)号：US11214021B2

公开(公告)日：2022-01-04

申请号：US16811262

申请日：2020-03-06

Applicant: The Boeing Company

Inventor： Richard E. Heath ,  Richard A. Prause ,  Andrew E. Modin

IPC: B29C70/44 ,  B29L31/30

Abstract: A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.

公开(公告)号：US20200254701A1

公开(公告)日：2020-08-13

申请号：US16862010

申请日：2020-04-29

Applicant: The Boeing Company

Inventor： Andrew E. Modin ,  Darrell D. Jones ,  Kurtis S. Willden

IPC: B29C70/38 ,  B29C70/54

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station.