A deburr tool has a flexible drive shaft and an expandable burr removal head. The expandable burr removal head is selectively collapsible and expandable. While collapsed, the burr removal head can navigate through the lumen of a non-straight tube, including across the abrupt right angle turn from an inlet tube section to an outlet tube section in an aircraft Piccolo tube. When expanded, the burr removal head engages the inner wall of the tube. The flexible drive shaft operatively connects the burr removal head to a prime move such that the prime mover drives rotation of the burr removal head while expanded. The rotating, expanded burr removal head removes burrs from inside the tube.
A wrench assembly tightens a fastener for a latch mechanism of an openable body panel to a specified torque at a specified rotational position. A keyed socket head couples to a head of the fastener in one and only one rotational orientation. An adapter body connects a torque wrench to the keyed socket head. The torque wrench rotates the wrench assembly to turn the fastener via the keyed socket head. The adapter body defines a wrench reference surface that aligns with a panel reference surface of the openable body panel when the fastener is tightened to the specified rotational position. The torque wrench indicates when the wrench assembly applies the specified torque on the fastener.
B25B 23/142 - Arrangement of torque limiters or torque indicators in wrenches or screwdrivers specially adapted for hand operated wrenches or screwdrivers
B25B 13/48 - SpannersWrenches for special purposes
3.
CERAMIC MATRIX COMPOSITE SANDWICH STRUCTURE AND METHOD OF MANUFACTURE
In one aspect, a ceramic matrix composite sandwich structure has a ceramic honeycomb core structure, a first face sheet on a first surface of the ceramic honeycomb core structure, and a second face sheet on a second surface of the ceramic honeycomb core structure. Methods of preparing the ceramic matrix composite sandwich structure involve applying ceramic matrix composite prepregs to a honeycomb core to form an unbonded sandwich structure, subjecting the unbonded sandwich structure to an autoclave process to form an intermediate bonded sandwich structure, and subjecting the intermediate bonded sandwich structure to a sintering process to produce the ceramic matrix composite sandwich structure.
B32B 3/12 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
Methods and systems for forming a composite part and controlling an amount of time heat is applied for curing composite material. The method may include applying thermocouples to a plurality of locations on a composite material, applying curing heat to the composite material, determining a predicted percentage of cure of the composite material, and removing heat from the composite material when the predicted percentage of cure reaches a predetermined percentage of cure. Determining the predicted percentage of cure may be performed at predetermined time intervals and determined based on a current temperature sensed by one of the thermocouples and a curing model corresponding to the type of material the composite material comprises. The method may also include training the curing model for a range of different thermal ramp up speeds and hold temperatures via differential scanning calorimetry (DSC) of a polymer sample of a known weight or other training methods.
A part is positioned between a display and an image capturing device pointed toward the display. A visual feedback loop is conducted using the display and the image capturing device to refine a part profile picture on the display corresponding to a profile of the part in an image captured by the image capturing device. The visual feedback loop recursively projects on a display screen an input picture containing a pattern region; captures images of the part while the display is displaying the input picture; based on the captured image, refines a picture that more closely corresponds to the profile of the part; and sets the refined image to be a next input image. The feedback loop iteratively refines the picture projected on the display screen until it becomes the part profile picture.
A topographical inspection device that employs one or both of a photometric stereo system for determining surface normal for individual pixel locations in an image space and/or dot pattern projection. A device body supports light elements at spaced apart locations to illuminate an inspection region and a dot pattern projector for projecting a dot pattern onto the inspection region. A camera captures images of the surface when illuminated by the light elements and/or dot pattern projector. Controlling the light elements and camera, a first topographical measurement of the inspection region is made based on light intensity in images taken by the camera. A second topographical measurement may be made based on dot pattern projection.
G01N 21/88 - Investigating the presence of flaws, defects or contamination
G01B 11/25 - Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures by projecting a pattern, e.g. moiré fringes, on the object
G01B 11/30 - Measuring arrangements characterised by the use of optical techniques for measuring roughness or irregularity of surfaces
7.
MAXIMIZING THE LAMINATE QUALITY AND STRENGTH OF CURVED COMPOSITE STRUCTURAL COMPONENTS MANUFACTURED WITH AUTOMATED FIBER PLACEMENT (AFP) TECHNOLOGIES
Methods and systems for forming a composite part. The methods include providing a layup model and characterizing the specific overlap ratio (SOR) in discretized sections of the layup model. The layup model can be modified until an acceptable range of SOR values is achieved along the length of the part. Once an acceptable range of SOR values is achieved, the resulting production model is used to produce the part, for example, using an automated fiber placement (AFP) process.
A system and a method for locating and visualizing camera images in relation to a large-scale manufacturing product with repetitive structures are disclosed. The system includes a trackable camera device, a tracking subsystem, and an image overlay module. The trackable camera device can capture images of surface features of the large-scale product. The tracking subsystem is configured to generate a tracking record that contains the position and location of the trackable camera device over time. The image overlay module is configured to precisely overlay the captured images on a three-dimensional model of the large-scale product based on where the trackable camera device was tracked when each image was captured. A method is disclosed for using the components of the system to overlay the captured images, and a method of auditing the large-scale product by comparing a region of interest to previously captured images overlaid on a respective three-dimensional model.
H04N 13/279 - Image signal generators from 3D object models, e.g. computer-generated stereoscopic image signals the virtual viewpoint locations being selected by the viewers or determined by tracking
H04N 13/361 - Reproducing mixed stereoscopic imagesReproducing mixed monoscopic and stereoscopic images, e.g. a stereoscopic image overlay window on a monoscopic image background
A robot automation system facilitates automated robotic manufacturing processes by employing a teaching subsystem including a tracking assembly that tracks movement of the mapping tool in a teaching workspace. A computing device in communication with the tracking assembly and the mapping tool receives tracking data from the tracking assembly and the mapping tool indicating movement of the mapping tool along a working path. Based on the tracking data, the computing device automatically generates robot instructions. A robot controller receives the robot instructions from the computing device and executes the robot instructions whereby the robot controller controls a robot and an end effector to conduct the automated robotic manufacturing process.
A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.
B29B 11/06 - Making preforms by moulding the material
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B64F 5/00 - Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided forHandling, transporting, testing or inspecting aircraft components, not otherwise provided for
B64F 5/10 - Manufacturing or assembling aircraft, e.g. jigs therefor
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
11.
METHOD FOR ACTIVELY COOLING AND SUPPORTING COMPONENTS DURING THERMOPLASTIC COMPOSITE WELDING
A method for welding thermoplastic composite parts while actively cooling includes placing a first composite part onto a surface of a tooling, placing a second composite part onto the first composite, pressing the second composite part toward the first composite part with an induction welding end effector, and providing a flow of air or gas through an opening extending through the shaping surface while induction welding the second composite part to the first composite part. The first composite is sandwiched between the surface of the tooling and the second composite. The flow of air or gas impinges on a bottom surface of the first composite part and is sufficient to press the first composite part toward the second composite part. Induction welding the second composite part to the first composite part is performed by applying induction heating while the flow of air is provided through the at least one opening.
B29C 65/00 - Joining of preformed partsApparatus therefor
B29C 65/36 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
12.
INDEXING BOLT FOR JOINING COMPOSITE FORM PIECES TOGETHER
A connection between form assemblies of a form for a composite part is disclosed. The connection includes an indexing bolt for connecting first and second form assemblies of a form for a composite part to one another. The indexing bolt includes a head and a shank extending from the head. The shank has a first barrel portion, a second barrel portion spaced apart from the first barrel portion, and an indexing section extending between the first barrel portion and the second barrel portion. The indexing section includes a tapered portion that is receivable within the tapered opening of the alignment plate of the second form assembly. The first barrel portion has a first diameter and the second barrel portion has a second diameter. The first diameter is different than the second diameter. The first and second barrel assemblies each include external threading.
F16B 35/04 - Screw-boltsStay boltsScrew-threaded studsScrewsSet screws with specially-shaped head or shaft in order to fix the bolt on or in an object
F16B 39/24 - Locking of screws, bolts, or nuts in which the locking takes place during screwing down or tightening by means of washers, spring washers, or resilient plates that lock against the object
An engine support assembly for operatively connecting an engine to an aircraft, the aircraft, the aircraft having a support frame surrounded by opposing first and second skins. The engine support assembly broadly comprises first and second support structures. The first support structure is secured to the support frame and extends away from the first skin. The second support structure is releasably connected to the first support structure and releasably connected to the engine.
A sealing structure seals a space between first and second parts of a fan duct and a fairing of an aircraft engine. The sealing structure comprises first and second seal portions for positioning between the first and second parts of the fan duct and the fairing. The first seal portion includes an elongated middle region and a first coupling mechanism. The elongated middle region can be secured to the first part of the fan duct and abutting the fairing and includes a forward end from which the first coupling mechanism extends. The second seal portion includes an elongated middle region and a second coupling mechanism. The elongated middle region can be secured to the second part of the fan duct and abutting the fairing and includes a forward end from which the second coupling mechanism extends. The second coupling mechanism is operable to couple to the first coupling mechanism.
An additive build assembly broadly includes a modular build plate and a plurality of build parts. The build parts are formed via an additive build process. The modular build plate includes a substrate and a plurality of build plate sections supported by the substrate to cooperatively define an additive build surface to receive the build parts. At least one of the build plate sections is removably attached relative to the substrate to permit selective detachment of the at least one build plate section from the remainder of the build plate sections.
A method of managing additive manufacturing powder used for three-dimensional printing of one or more printed parts, including printing a printed part and a canister covering the printed part on a build plate using a single additive manufacturing process. The method also includes transporting the canister and the printed part, along with the build plate, to a second location. The second location may be outfitted for removal of the canister from the build plate and removal of powder left behind in the canister from the printing of the printed part and the canister. Additional or alternative method steps can include receiving the printed part into a de-powdering machine at the second location, removing the canister from the build plate in the de-powdering machine, and removing powder left behind in the canister from the printing of the printed part and the canister to be recycled for printing another printed part.
A method of fabricating a ceramic matrix composite material into a part, including applying a semi-permeable membrane over a stack of composite plies pre-impregnated with ceramic matrix. The semi-permeable membrane comprises a porous plastic material and may have a thickness of approximately 0.002 to 0.008 inches. The method may include compressing the semi-permeable membrane and the stack together and heating the semi-permeable membrane and the stack to cure the stack into the composite part. The semi-permeable membrane may be a porous plastic having pores large enough to allow volatile gasses to escape therethrough during curing but equal to or smaller than solid ceramic particles or clusters of the solid ceramic particles suspended in the ceramic matrix. The composite plies may contain approximately 35 percent to 45 percent of the ceramic matrix by weight relative to an overall weight of the stack of the composite plies pre-impregnated with the ceramic matrix.
A swivel access structure for an engine nacelle, including a door plate, a first fastener, second fasteners, a door frame, and one or more flame shields. The door plate is selectively rotatable about the first fastener, and the second fasteners selectively release the door plate to allow its rotation about the first fastener from a closed configuration to an open configuration. The door plate is rotatably attached to the door frame via the first fastener. The door frame has a frame opening covered by the door plate when the door plate is in the closed configuration and exposed when the door plate is in the open configuration. The one or more flame shields cover an inner side of the door plate and/or an inner side of the door frame. The swivel access structure provides access within the nacelle without spring arrangements that are more susceptible to fail fire testing.
A drill guide bushing assembly for use with a drill and a bit to drill a hole in an object comprises a bushing holder and a drill guide bushing. The bushing holder includes at least one upper wall, at least one lower wall, and a body connected to the at least one upper wall and the at least one lower wall. The body includes a bushing channel oriented along the axis thereof and having a hollow cylindrical shape. The drill guide bushing includes a central passage configured to receive the bit. The drill guide bushing is positioned within the bushing channel and configured to move axially therein. The drill guide bushing is coupled to the body of the bushing holder such that the drill guide bushing does not rotate within the bushing channel when the hole is being drilled.
A sight-viewing structure for an engine nacelle, including a sight glass that is translucent or semi-translucent, a mounting frame, and a flame shield. The sight glass allows checking of oil levels of an aircraft engine accessory gearbox within the nacelle without doors and springs that can be more susceptible to fail fire testing. The mounting frame has an outer side, an inner side opposite the outer side, and a frame opening formed through the mounting frame. The frame opening is covered by the sight glass, and the mounting frame is configured for attachment to an inner surface of the engine nacelle at a location with a hole through the engine nacelle, such that the sight glass can be viewed through the hole. A flame shield may be made of composite materials and covers the inner side of the mounting frame and peripheral edge regions of the sight glass.
An apparatus for roll forming thermoplastic composites comprises a plurality of thermoplastic composite material spools, a plurality of thermoplastic composite material rollers, a plurality of sheet metal spools, a plurality of welding rollers, an oven, a forming roller, a pair of pinch rollers. The thermoplastic composite material spools retain plies of thermoplastic composite material. The plies flow through the thermoplastic composite material rollers to form a layup. The sheet metal spools retain metal sheets. The metal sheets and the layup flow through the welding rollers to form a metal composite material laminate. The oven heats the metal composite material laminate. The forming roller imparts a curvature to the metal composite material laminate. The pinch rollers receive the metal composite material laminate from the forming roller, pull the metal composite material laminate, and output the metal composite material laminate in a heated and compressed state.
B29C 51/14 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor using multilayered preforms or sheets
B29C 51/22 - Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
B29C 51/26 - Component parts, details or accessoriesAuxiliary operations
22.
Method to produce low-cost metal matrix composites for industrial, sports, and commercial applications
A method of forming a metal matrix composite component includes positioning a preform including an electrically non-conductive fibrous material in a shaping tool. The fibrous material is pre-coated. The method includes flowing a molten metal comprising zinc into the shaping tool so that at least a portion of the preform is enveloped by the molten metal to form the metal matrix composite component; and cooling the metal matrix composite component.
B22D 18/06 - Vacuum casting, i.e. making use of vacuum to fill the mould
B22D 17/00 - Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
B22D 19/14 - Casting in, on, or around, objects which form part of the product the objects being filamentary or particulate in form
B22D 30/00 - Cooling castings, not restricted to casting processes covered by a single main group
C22C 47/04 - Pretreatment of the fibres or filaments by coating, e.g. with a protective or activated covering
C22C 47/08 - Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
23.
METHODS AND APPARATUSES FOR FORMING CORRUGATED THERMOPLASTIC SHEETS AND CELLULAR STRUCTURES
A method of forming a corrugated thermoplastic matrix composite sheet includes preheating a thermoplastic matrix composite sheet including a thermoplastic matrix and a reinforcement material to at least about a melting temperature of the thermoplastic matrix; preheating at least one of a pair of complementary corrugating tools to at least about a glass transition temperature of the thermoplastic matrix; compressing the preheated thermoplastic matrix composite sheet between the pair of complementary corrugating tools to form a corrugation in the thermoplastic matrix composite sheet; and holding the corrugation between the pair of complementary corrugating tools until a portion of the thermoplastic matrix composite sheet having the corrugation is below the melting temperature of the thermoplastic matrix to form the corrugated thermoplastic matrix composite sheet.
A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.
A foreign object debris (FOD) collection drill attachment for attaching to a drill includes with a drill guide bushing holder, a chip breaker bushing, an air supply line, a chip evacuation line, a chip collection hopper, and an air manifold. The drill guide bushing holder includes an inlet channel receiving air from the air supply line, an outlet channel, and a holder center channel. The inlet channel and the outlet channel each open into the holder center channel through which an end protrusion of the chip breaker bushing extends to break up FOD on a drill bit of the drill. The cross-sectional area of the inlet channel is smaller than the cross-sectional area of the outlet channel, creating a Venturi effect between the inlet channel and the outlet channel to pull FOD away from the drill bit and through the chip evacuation line to the chip collection hopper.
B23Q 11/00 - Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling workSafety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
26.
Method for using expendable flexures for forming composite laminates
A system and method for forming a composite part with multiple bends or curves, including placing an unformed composite laminate material onto a flexure and placing the flexure onto an engagement surface of a first forming tool. The flexure is a sheet of bendable material. The first forming tool has a first side surface, the first engagement surface, and a first corner between these surfaces. The flexure may have at least one thinned region aligned with the first corner. The method further includes sealing an impermeable membrane around the unformed composite laminate material, the flexure, and at least a portion of the first forming tool and heating them in an oven or autoclave. The method also includes applying a pressure differential to the impermeable membrane, pressing the unformed composite material and/or the flexure against the first side surface and to press the thinned region against the first corner.
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
A method for manufacturing a composite part includes forming an initial radius filler on a composite panel. The initial radius filler is formed from a plurality of plies of composite material stacked on the composite panel. The method includes forming a radius of curvature on at least one side of the initial radius filler, positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel, positioning the composite stiffener against the at least one side of the initial radius filler, compressing the composite stiffener, composite panel, and initial radius filler via vacuum bag, and heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap.
B29C 70/84 - Moulding material on preformed parts to be joined
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
Disclosed are methods and apparatus for use in composite manufacturing, to facilitate cooling of composite parts. The methods and apparatus disclosed are of particular use in thermal joining methods. A magnetic field is applied to a magnetocaloric material to induce a magnetic phase change. Heat is exhausting heat from the magnetocaloric material while the magnetic field is applied and, when the magnetic field is disapplied, heat is flowed from the composite assembly to the magnetocaloric material, reversing the magnetic phase change and cooling the composite part. An induction coil for inductively heating the composite part may be used to apply the magnetic field.
B29C 65/36 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
B29C 35/00 - Heating, cooling or curing, e.g. crosslinking or vulcanisingApparatus therefor
A method of manufacturing a complex-shaped composite part, including the steps of applying a metallic sheath around a composite laminate workpiece and applying an electric current through the metallic sheath to heat the workpiece. The metallic sheath may be sealed around the composite laminate workpiece, with air or atmosphere evacuated therefrom. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped composite part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped composite part and removing the metallic sheath from the complex-shaped composite part. This method minimizes cycle times and reduces breakage of fiber reinforcement of the composite laminate. The method also helps avoid tearing, buckling, or wrinkling of the workpiece during formation via the structural support provided.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
30.
SYSTEM AND METHOD FOR PRODUCING SUPERALLOYS UTILIZING ELECTRO-METALLURGY
A system and method for producing a rigid, heat-resistant part, such as a superalloy, via electrodeposition. The method can include the steps of coating a secondary alloy particulate with a superior alloy, forming a pre-coated particulate, dispensing a quantity of the pre-coated particulate into a container of an electrolytic solution, and applying a charge to the electrolytic solution such that the pre-coated particulate is electrodeposited onto a cathode or an external casing of the cathode. The pre-coated particulate can include particulate of non-uniform size and/or shape. The secondary alloy particulate is protected in the catalytic solution by the superior alloy coated thereon, such as nickel, iron, cobalt, and/or copper. The method also includes a step of vibrating or agitating the electrolytic solution before and/or during applying the charge to the electrolytic solution for even distribution of the pre-coated particulate onto the cathode or an external casing thereof.
A method of treating a cast metal matrix, the method comprising steps of depositing a self-fluxing first layer of material on an outer surface-connected void of the cast metal matrix, depositing a second layer of material on the cast metal matrix thereby closing off the outer surface-connected void so that the outer surface-connected void is an effective internal void, and hot isostatic pressing the cast metal matrix so that the self-fluxing first layer facilitates healing the effective internal void and complete metallurgical bonding of the surfaces of the outer surface-connected void.
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C21D 8/02 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
32.
COMPOSITE LAMINATE HEATING TOOL AND METHOD FOR FORMING SAME
A composite laminate heating tool broadly comprising a substructure, a facesheet, and number of expansion joints. The substructure supports the facesheet but does not need to have the same or a similar CTE as the facesheet because the facesheet is free to expand relative to the substructure. The expansion joints provide an interface between the facesheet and the substructure so that the facesheet can thermally expand relative to the substructure while being fully supported by the substructure. Each expansion joint includes a guide attached to the substructure and a support member translatable relative to the guide and aligned radially from a centroid or center of expansion of the facesheet so as to have a single degree of freedom.
A drilling apparatus and method for forming a countersunk hole into a structure. The drilling apparatus may include a drill motor housing assembly, a rotor/spindle assembly, a countersink cage, and a countersink cutter. The drill motor housing assembly may have an inlet air duct, the rotor/spindle assembly may have a first duct and the countersink cage may have a second duct. The countersink cutter may have a plurality of flutes formed into a cutting end thereof. The countersink cutter may also have a third duct formed therethrough and a plurality of exit ducts common with the flutes. Each duct of the drilling apparatus may be fluidly coupled such that inlet air may be forced through the inlet air duct, through the first duct, through the second duct, through the third duct, and then through the plurality of exit ducts during drilling via the drilling apparatus.
B23B 35/00 - Methods for boring or drilling, or for working essentially requiring the use of boring or drilling machinesUse of auxiliary equipment in connection with such methods
34.
METHOD OF MANUFACTURING FOLDED STRUCTURE WITH ADDITIVE FEATURES
A method of manufacturing a multi-sided or otherwise relatively three-dimensional formed structure for, e.g., an aerospace vehicle. A relatively planar base structure is constructed using a first construction technique. Features (e.g., ribs) are incorporated into the base structure using a second construction technique (e.g., additive or subtractive manufacturing) to create an intermediate structure. The intermediate structure is folded along fold-lines or otherwise physically formed to create the formed structure, such that some of the features are located within an internal space defined by the formed structure. Joints between the sides of the formed structure are welded, fastened, or otherwise secured. Separately constructed additional elements (e.g., bulkheads) may be incorporated into the structure. A closeout element may be added to the formed structure to further define and close the internal space. Throughout the process, the structures, features, and elements may be refined to desired tolerances.
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
F02C 7/20 - Mounting or supporting of plantAccommodating heat expansion or creep
F16B 5/00 - Joining sheets or plates to one another or to strips or bars parallel to them
B21D 39/02 - Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by platingTube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
35.
SEMI-CONFORMABLE PRESSURE APPLICATION SYSTEM AND METHOD FOR JOINING COMPOSITE PARTS
A system and method for fusing at least two thermoplastic composite components together may include placing faying surfaces of the thermoplastic composite components in contact with each other, placing a separation layer over and against one of the thermoplastic composite components, and placing a multi-layer composite pressure pad over and in contact with the separation layer. The method may also include placing an activated inductor against the multi-layer composite pressure pad for induction welding the two thermoplastic composite components to each other. The thermoplastic composite components may comprise conductive fibers while the multi-layer composite pressure pad may comprise a first layer and a second layer with non-conductive fibers. The first layer may at least partially melt during induction welding of the two thermoplastic composite components while the second layer may remain rigid throughout this welding.
B29C 65/20 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool with direct contact, e.g. using "mirror"
Embodiments of the present invention relate to a system and method for consolidating a thermoplastic composite component in situ within a thermoplastic composite deposition cell by means of heat and pressure. Heat may be applied to the thermoplastic composite component by means of an induction coil. Pressure may be applied to the thermoplastic composite component by means of a pressure applicator. An independent means may be provided for reacting at least a portion of the force directed to the pressure applicator. Consolidation may be performed in parallel with deposition within the same work cell.
Embodiments of the present invention relate to an apparatus and method for induction fusing of thermoplastic composite materials using a film of pressurized air to provide active cooling as well as consolidation pressure. The invention may be employed to weld multiple pre-consolidated thermoplastic composite laminates or to form a single laminate from individual plies of thermoplastic composite material.
B29C 65/00 - Joining of preformed partsApparatus therefor
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
38.
THERMOPLASTIC COMPOSITE BROADGOOD AND DEPOSITION MEANS
Embodiments of the present invention relate to a thermoplastic composite broadgood and a means of depositing a thermoplastic composite broadgood onto a mold. The broadgood may comprise of a plurality of separate, parallel strips of thermoplastic prepreg attached together by a plurality of delamination arresting elements. The broadgood may be deposited onto a mold by means of an apparatus comprising a plurality of flexible metal straps, each strap being configured to be heated. The straps may temporarily adhere to the broadgood when heated, thereby allowing the broadgood to be moved by means of the apparatus.
A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.
B29C 70/56 - Tensioning reinforcements before or during shaping
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
40.
OPTICAL MEASUREMENT DEVICE FOR INSPECTION OF DISCONTINUITIES IN AEROSTRUCTURES
A handheld device for making 3D topography measurements of surface discontinuities in high performance structures, such as aerostructures (e.g., aluminum fuselages). Lights illuminate the discontinuity from multiple angles, and a camera captures images of the discontinuity. A thickness sensor generates thickness data regarding a thickness of the base material and the top protective coating. A position sensor generates position data regarding a location of the discontinuity on the structure. A processor generates geometry data regarding a geometry of the discontinuity based on the images, performs an analysis of the geometry, thickness, and position data, and communicates a result of the analysis on a display. A conforming membrane and/or a gel and an opaque lubricant may be applied over and conform to the discontinuity in order to make more uniform a reflectivity difference and a color difference between the discontinuity and an adjacent portion of the structure.
A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 33/48 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
42.
METHOD FOR FORMING AND HEAT TREATING NEAR NET SHAPE COMPLEX STRUCTURES FROM SHEET METAL
A method of manufacturing a complex-shaped metal part, including the steps of applying a metallic sheath around a sheet metal workpiece and applying an electric current through the workpiece in the metallic sheath to heat the workpiece. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped metal part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped metal part and removing the metallic sheath from the complex-shaped metal part. This method can allow reactive and refractory material to be safely heated without oxidation when heating/forming in air when the workpiece is sealed within a sacrificial stainless steel or nickel alloy envelope to protect the enclosed workpiece.
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.
A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.
A method of manufacturing metal matrix composite (MMC) parts, including the steps of applying a metallic sheath around a bundle of MMC laminates, heating the bundle of MMC laminates in the metallic sheath at a curing or fusing temperature to consolidate the bundle of MMC laminates into a single cured or fused part, and then cooling the cured or fused part. The bundle of MMC laminates may be formed by removing surface contamination from the dry reinforcement fibers, creating a plurality of individual MMC laminates by plating dry reinforcement fibers with electroless nickel, and/or electrodeposited nickel or cobalt, and stacking each of the plurality of individual MMC laminates into a bundle. Autocatalytic and/or electroplating may be used as the primary means to incorporate fiber reinforcement into the metal matrix composite by covering and bonding fiber reinforcement into MMC laminates/plies and/or 3-D woven parts.
B23K 20/00 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
B23K 1/00 - Soldering, e.g. brazing, or unsoldering
B23K 20/14 - Preventing or minimising gas access, or using protective gases or vacuum during welding
C23C 18/16 - Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coatingContact plating by reduction or substitution, i.e. electroless plating
C23C 18/32 - Coating with one of iron, cobalt or nickelCoating with mixtures of phosphorus or boron with one of these metals
C25D 3/12 - ElectroplatingBaths therefor from solutions of nickel or cobalt
C25D 7/00 - Electroplating characterised by the article coated
B23K 103/00 - Materials to be soldered, welded or cut
An aircraft propulsion system configured to be supported from an aircraft wing having a leading edge and opposing upper and lower surfaces. The aircraft propulsion system broadly comprises an engine having a core, a fan case, and a nacelle including a plurality of access panels, and an attachment assembly for securing the engine to the aircraft wing. The attachment assembly broadly comprises an upper support section including a number of spars and a number of ribs connected between the spars, a lower support section, and an aft section. The attachment assembly aerodynamically melds the nacelle and the aircraft wing together via the upper support section so that air flowing over the engine flows over the aircraft wing along the upper surface and air flowing laterally alongside the nacelle flows under the aircraft wing along the lower surface.
A system and method for thermoplastic composite processing including compressing and heating a thermoplastic composite panel having a plurality of terminal edges. The method further includes heating the thermoplastic composite panel to a melting temperature to create a melt front of the thermoplastic composite panel at a first location and heating the thermoplastic composite panel to the melting temperature in a pre-determined pattern from the first location toward the terminal edges of the thermoplastic composite panel. Extending the melt front toward the terminal edges in this way causes air constrained within the thermoplastic composite panel to escape the thermoplastic composite panel through unmelted portions of the thermoplastic composite panel located between the melt front and the terminal edges. Cooling of the panel may be similarly conducted, cooling a first region and then gradually continuing to cool the panel in a direction toward one or more of the terminal edges.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 43/12 - Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material
A system and method for thermoplastic composite processing including compressing and heating a thermoplastic composite panel having a plurality of terminal edges. The method further includes heating the thermoplastic composite panel to a melting temperature to create a melt front of the thermoplastic composite panel at a first location and heating the thermoplastic composite panel to the melting temperature in a pre-determined pattern from the first location toward the terminal edges of the thermoplastic composite panel. Extending the melt front toward the terminal edges in this way causes air constrained within the thermoplastic composite panel to escape the thermoplastic composite panel through unmelted portions of the thermoplastic composite panel located between the melt front and the terminal edges. Cooling of the panel may be similarly conducted, cooling a first region and then gradually continuing to cool the panel in a direction toward one or more of the terminal edges.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
An interspatial blocker for a thrust reverser system of a turbofan engine, and a thrust reverser system and a turbofan engine incorporating the same. The interspatial blocker includes a first and second flap that rotate from a stored position to a blocking position, and a leading-edge structure rotatably coupling the first flap to the second flap. The leading-edge structure is set up to be installed in a fan nacelle of a turbofan engine in a substantially radial orientation such that the first flap rotates in a first direction about a first axis extending in a substantially radial direction from the stored position to the blocking position, and such that the second flap rotates in a second direction about a second axis extending in the substantially radial direction from the stored position to the blocking position, with the first direction being opposite to the second direction.
F02K 1/76 - Control or regulation of thrust reversers
F02K 1/72 - Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
An interspatial blocker for a thrust reverser system of a turbofan engine, and a thrust reverser system and a turbofan engine incorporating the same. The interspatial blocker includes a first and second flap that rotate from a stored position to a blocking position, and a leading-edge structure rotatably coupling the first flap to the second flap. The leading-edge structure is set up to be installed in a fan nacelle of a turbofan engine in a substantially radial orientation such that the first flap rotates in a first direction about a first axis extending in a substantially radial direction from the stored position to the blocking position, and such that the second flap rotates in a second direction about a second axis extending in the substantially radial direction from the stored position to the blocking position, with the first direction being opposite to the second direction.
F02K 1/72 - Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
F02K 1/76 - Control or regulation of thrust reversers
F02K 1/66 - Reversing fan flow using reversing fan blades
51.
Methods of fabricating multi-region U-shaped composite structures
Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.
B29C 70/00 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
B29C 70/22 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
Tooling, systems, and methods for forming composite parts. The system includes a mold having a first mold portion with a molding surface, a second mold portion with a molding surface, and at least one laminate sheet opening. When the mold is in a closed, molding configuration, the first molding surface and the second molding surface collectively at least partially form an internal cavity defining an outer contour of the composite part. The system also comprises an injection molding nozzle that injects resin into the internal cavity and a laminate sheet supporting frame. The laminate sheet supporting frame supports at least one laminate sheet such that a portion of the at least one laminate sheet is permitted to pass through the at least one laminate sheet opening and conform to at least one of the first molding surface and the second molding surface during the forming of the composite part.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
Tooling, systems, and methods for forming composite parts. The system includes a mold having a first mold portion with a molding surface, a second mold portion with a molding surface, and at least one laminate sheet opening. When the mold is in a closed, molding configuration, the first molding surface and the second molding surface collectively at least partially form an internal cavity defining an outer contour of the composite part. The system also comprises an injection molding nozzle that injects resin into the internal cavity and a laminate sheet supporting frame. The laminate sheet supporting frame supports at least one laminate sheet such that a portion of the at least one laminate sheet is permitted to pass through the at least one laminate sheet opening and conform to at least one of the first molding surface and the second molding surface during the forming of the composite part.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
54.
Lightning strike protection surfacer and method of manufacturing the same
A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having a thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.
B29C 70/02 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements and fillers incorporated in matrix material, forming one or more layers, with or without non-reinforced or non-filled layers
B29C 70/68 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers
B32B 15/02 - Layered products essentially comprising metal in a form other than a sheet, e.g. wire, particles
B32B 15/14 - Layered products essentially comprising metal next to a fibrous or filamentary layer
B32B 15/16 - Layered products essentially comprising metal next to a particulate layer
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.
An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
A method for preparing a part using a rigid tool surface having a shape. The method includes applying a breather sheet comprising gas-permeable material over the rigid tool surface. A vacuum bag is applied over the breather sheet, and a vacuum pressure is applied underneath the vacuum bag to conform the breather sheet and the vacuum bag to the shape of the rigid tool surface. A resin pre-impregnated ply is applied over the vacuum bag, and the part is positioned over the ply.
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
B29C 43/12 - Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 43/36 - Moulds for making articles of definite length, i.e. discrete articles
58.
System for fusing thermoplastic composite structures
A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 35/00 - Heating, cooling or curing, e.g. crosslinking or vulcanisingApparatus therefor
B64C 1/12 - Construction or attachment of skin panels
B64C 1/00 - FuselagesConstructional features common to fuselages, wings, stabilising surfaces or the like
A cap for a temporary fastener comprises a hollow, cup-shaped body and an inwardly tapered neck. The hollow body fits over a workpiece-engaging portion of the temporary fastener, and the neck extends from the hollow body. The tapered neck terminates in a hollow tip that is sized and configured to fit over aligned holes in the joined workpieces and to contact a minimal surface area of the outermost workpiece to reduce surface damage to the workpieces such that any damage will be removed when the holes are countersunk in the normal course of assembly.
A cascade assembly for a thrust reverser of an aircraft engine. The cascade broadly comprises a number of vanes formed of a pliable material and shiftable between a collapsed position when the thrust reverser is in a stowed configuration and a distended position when the thrust reverser is in a deployed configuration to redirect fan duct flow in a reverse thrust flow opening created by the thrust reverser.
F02K 1/72 - Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
61.
METHODS OF FABRICATING MULTI-REGION U-SHAPED COMPOSITE STRUCTURES
Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.
B29C 70/30 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
62.
Methods of fabricating multi-region U-shaped composite structures
Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.
B29C 70/22 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.
A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.
B23P 23/04 - Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass for both machining and other metal-working operations
B23P 19/04 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for assembling or disassembling parts
A method for fusing thermoplastic composite structures includes placing a thermoplastic substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one metal layer over the substructure and applying an insulation layer over edge portions of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure and applying a vacuum bag that at least partly encloses the skin, the substructure, and the metal layer. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
B33Y 80/00 - Products made by additive manufacturing
A system for mounting an engine on an aircraft. The system includes a lower forward element, lateral linkages, an upper forward element, and an aft element. The lower forward element couples a forward portion of an engine core with a lower forward portion of a pylon. The linkages extend laterally between the lower forward element and the forward portion of the engine core. The upper forward element couples an outer portion of the fan case with an upper portion of the pylon. The aft element is spaced aftwardly apart from the lower and upper forward elements, and couples an aft portion of the engine core to an aft portion of the pylon. The system reacts all major moments acting on the engine, and the system does not extend beyond an outer periphery of the fan case, which eliminates the need for or minimizes the height of an aerodynamic fairing.
A method and system for manufacturing composite parts free- of wrinkles and mark-offs from bagging compression. The method can.include planing composite material around a rigid mandrel and sealing opposing end of an elastomeric '.hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from, a natural state to an inflated state, in the natural state, the hollow membrane can have a cross -section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward, its natural state. Then the method can include heating the composite material to a cure temperature while the composite material Is compressed by the membrane.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 33/48 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
A cascade assembly for a thrust reverser of an aircraft engine. The cascade broadly comprises a number of vanes formed of a pliable material and shiftable between a collapsed position when the thrust reverser is in a stowed configuration and a distended position when the thrust reverser is in a deployed configuration to redirect fan duct flow in a reverse thrust flow opening created by the thrust reverser.
F02K 1/72 - Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
70.
System and method for promoting inter-ply slippage
A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.
B29C 70/56 - Tensioning reinforcements before or during shaping
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.
B29C 65/34 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
B29C 65/74 - Joining of preformed partsApparatus therefor by welding and severing
B29C 65/00 - Joining of preformed partsApparatus therefor
H01R 43/02 - Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.
B29C 70/46 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
73.
Continuous manufacturing process for composite parts
Tooling assembly and pressure vessel thereof for forming composite components such as aircraft stringers and the like. In addition to the pressure vessel, the tooling assembly may include a conveying apparatus and a forming tool for stacking plies on the forming tool and conveying the plies and the forming tool through the pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit the forming tool supporting the plies to pass through the pressure vessel. The pressure vessel may further include an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part.
An assembly for reacting a thrust load from an engine, the assembly comprising a frame, a pin, an evener bar, and left and right thrust links. The frame includes an upper pin interface and a lower pin interface. The pin extends through the upper pin interface and the lower pin interface and includes an upper end and a lower end. The evener bar engages the lower end of the pin below the lower pin interface and connects the left and right thrust links to the pin. The pin is configured to react the thrust load at the lower pin interface and the upper pin interface thereby forming a distributed force couple between the lower pin interface and the upper pin interface.
A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.
B64C 1/00 - FuselagesConstructional features common to fuselages, wings, stabilising surfaces or the like
B64F 5/00 - Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided forHandling, transporting, testing or inspecting aircraft components, not otherwise provided for
B64F 5/10 - Manufacturing or assembling aircraft, e.g. jigs therefor
B29B 11/06 - Making preforms by moulding the material
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
76.
System and method for drilling holes and installing fasteners in vehicle structures
A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.
A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. An injection device may also move behind the plate and reciprocally inject a polymer between the first and second faying surfaces to provide toughness and crack arresting properties.
B29C 65/20 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool with direct contact, e.g. using "mirror"
B29C 65/00 - Joining of preformed partsApparatus therefor
Methods for in-situ solution heat treating an additively manufactured metallic component in order to increase the mechanical properties thereof and systems to perform the same. The method can include depositing filler material on a substrate forming a deposition layer, measuring the temperature of a heat affected zone corresponding to the deposition layer, and solution heat treating the deposition layer subsequent to the depositing and proximate to the deposition head. The solution heat treating can include heating the deposition layer to a solution temperature so as to achieve solution heat treatment and controlling the cooling rate of the deposition layer to at or above the critical cooling rate of the filler material until a target temperature is reached. Optionally, the method can include inducing an electron flow in the deposition layer to electromagnetically stir molten filler material in the heat affected zone.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
Methods for in-situ solution heat treating an additively manufactured metallic component in order to increase the mechanical properties thereof and systems to perform the same. The method can include depositing filler material on a substrate forming a deposition layer, measuring the temperature of a heat affected zone corresponding to the deposition layer, and solution heat treating the deposition layer subsequent to the depositing and proximate to the deposition head. The solution heat treating can include heating the deposition layer to a solution temperature so as to achieve solution heat treatment and controlling the cooling rate of the deposition layer to at or above the critical cooling rate of the filler material until a target temperature is reached. Optionally, the method can include inducing an electron flow in the deposition layer to electromagnetically stir molten filler material in the heat affected zone.
A composite aircraft engine pylon comprising a frame, an aircraft attachment component, and an engine support. The frame includes an outer structural section and an inner structural section configured to at least partially nest with the outer structural section. The outer structural section and the inner structural section sandwich the airframe attachment component and the engine support to form double shear connections between the frame and the aircraft attachment component and between the frame and the engine support.
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.
A system including mold pieces coupled together with breakaway bolts or other fasteners for facilitating the fabrication of composite parts for, e.g., aerospace vehicles. First and second mold pieces are coupled together to form a mold within which the composite part is fabricated from a composite material. A coefficient of thermal expansion of the mold pieces is higher than a coefficient of thermal expansion of the composite part. One or more breakaway fasteners couple together the mold pieces while the mold pieces and the composite material are heated, and then purposefully break and thereby decouple the mold pieces and release the composite part when the mold pieces are cooled. The fasteners may be constructed from polytetrafluoroethylene, may include a structural weakness to ensure breakage, may break into two or more pieces when under a tension or a sheering force, or may include threads that sheer when under a tension force.
A method of manufacturing a multi-sided or otherwise relatively three-dimensional formed structure for, e.g., an aerospace vehicle. A relatively planar base structure is constructed using a first construction technique. Features (e.g., ribs) are incorporated into the base structure using a second construction technique (e.g., additive or subtractive manufacturing) to create an intermediate structure. The intermediate structure is folded along fold-lines or otherwise physically formed to create the formed structure, such that some of the features are located within an internal space defined by the formed structure. Joints between the sides of the formed structure are welded, fastened, or otherwise secured. Separately constructed additional elements (e.g., bulkheads) may be incorporated into the structure. A closeout element may be added to the formed structure to further define and close the internal space. Throughout the process, the structures, features, and elements may be refined to desired tolerances.
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
F02C 7/20 - Mounting or supporting of plantAccommodating heat expansion or creep
F16B 5/00 - Joining sheets or plates to one another or to strips or bars parallel to them
B21D 39/02 - Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by platingTube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
A ducted fan housing for directing a duct flow includes an annular cowling and an adjustable fan duct nozzle. The nozzle includes a flexible sleeve having rigid areas arranged circumferentially around the nozzle orifice and connected by flexible areas so as to form a unitary sleeve structure. The rigid areas are radially moveable between a normal configuration in which the orifice is smaller and a dilated configuration in which the orifice is larger. A drive mechanism uses drive elements to move at least some of the rigid areas between the configurations to adjust the size of the orifice. The rigid areas may be constructed from laminated graphite and epoxy, and the flexible areas may be constructed from laminated graphite and soft resin. If the housing includes a thrust reverser, then a flexible joint area extends circumferentially around the housing and connects the flexible sleeve to a thrust reverser cowl.
F02K 1/72 - Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
F02K 1/34 - Plants characterised by the form or arrangement of the jet pipe or nozzleJet pipes or nozzles peculiar thereto using fluid jets to influence the jet flow for attenuating noise
F02K 1/09 - Varying effective area of jet pipe or nozzle by axially moving an external member, e.g. a shroud
87.
Lightning strike protection surfacer and method of manufacturing the same
A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having an amorphous thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the amorphous thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.
B29C 70/02 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements and fillers incorporated in matrix material, forming one or more layers, with or without non-reinforced or non-filled layers
B29C 70/68 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers
B32B 15/02 - Layered products essentially comprising metal in a form other than a sheet, e.g. wire, particles
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
88.
System and method for thermoplastic welding using an induced thermal gradient
A system and method for thermoplastic composite welding comprising a cooling means and a heat source. The cooling means cools a heat-side laminate so as to create a thermal gradient in the heat-side laminate. The heat source heats the heat-side laminate after the cooling step is initiated but before the thermal gradient dissipates so that a first side of the heat-side laminate closer to the heat source does not deform as faying surfaces of the heat-side laminate and another laminate farther away from the heat source are welded together.
B29C 65/00 - Joining of preformed partsApparatus therefor
B29C 65/36 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
A method for manufacturing a composite part by laying up courses of composite tape using an automated tape layup (ATL) machine onto a conductive flexible facesheet laid flat on a flat surface, and then transferring the facesheet with the composite material thereon to a curved tooling surface for attachment of substructures and curing into the composite part. The method may also include applying insulation below the facesheet and above the composite material, then heating the conductive facesheet to cure the composite tape and fuse the composite tape to the substructures without heating the tooling surface or any other items used to compress and cure the composite material into the composite part. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to a plurality of conductive wires attached at opposing ends to the facesheet.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 65/02 - Joining of preformed partsApparatus therefor by heating, with or without pressure
B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B29C 70/42 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
90.
System and apparatus for manufacturing simple curvature thermoplastic composite parts
A system for manufacturing a composite part including a conductive flexible facesheet and an automated tape layup (ATL) machine for laying up composite tape onto the facesheet that is laid flat on a flat surface. The system also includes a curved tooling surface for transferring the facesheet with the composite material thereon to the curved tooling surface for attachment of substructures and curing into the composite part. System may also include insulation placed below the facesheet and insulation placed above the composite material, as well as a source of electricity and heat for heating the conductive facesheet to cure, melt, or fuse the composite tape and substructures without heating the tooling surface and other tooling used in the composite curing process. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to conductive wires attached at opposing ends to the facesheet.
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B29C 33/02 - Moulds or coresDetails thereof or accessories therefor with incorporated heating or cooling means
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
A system and method for forming an integral flange in an end portion of a composite laminate structure, such as an aerospace or other vehicle structure. First and second tool components cooperate to support the structure during a layup process, with the second tool component imparting an initial angle to the end portion. A third tool component includes a male radius positioned at an apex of the initial angle. A heater heats a succession of localized areas along the end portion to lower a viscosity of the resin. A roller applies pressure to the succession of localized areas after each is heated so as to push them around and against the third tool component to form a flange angle and the integral flange. The heater and the roller may make multiple passes along the end portion, with the roller angle increasing with each pass until the flange angle is achieved.
F16L 23/024 - Flanged joints the flanges being connected by members tensioned axially characterised by how the flanges are joined to, or form an extension of, the pipes
B64G 1/22 - Parts of, or equipment specially adapted for fitting in or to, cosmonautic vehicles
A system and method for forming an integral flange in an end portion of a composite laminate structure, such as an aerospace or other vehicle structure. First and second tool components cooperate to support the structure during a layup process, with the second tool component imparting an initial angle to the end portion. A third tool component includes a male radius positioned at an apex of the initial angle. A heater heats a succession of localized areas along the end portion to lower a viscosity of the resin. A roller applies pressure to the succession of localized areas after each is heated so as to push them around and against the third tool component to form a flange angle and the integral flange. The heater and the roller may make multiple passes along the end portion, with the roller angle increasing with each pass until the flange angle is achieved.
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 53/04 - Bending or folding of plates or sheets
93.
System and method for welding thermoplastic components to create composite structure
A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.
B32B 37/00 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
B29C 65/20 - Joining of preformed partsApparatus therefor by heating, with or without pressure using heated tool with direct contact, e.g. using "mirror"
An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.
B65G 47/91 - Devices for picking-up and depositing articles or materials incorporating pneumatic, e.g. suction, grippers
B29C 70/54 - Component parts, details or accessoriesAuxiliary operations
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B25J 15/06 - Gripping heads with vacuum or magnetic holding means
A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.
B64C 1/00 - FuselagesConstructional features common to fuselages, wings, stabilising surfaces or the like
B64F 5/00 - Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided forHandling, transporting, testing or inspecting aircraft components, not otherwise provided for
B64F 5/10 - Manufacturing or assembling aircraft, e.g. jigs therefor
B29B 11/06 - Making preforms by moulding the material
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
A cap for a temporary fastener comprises a hollow, cup-shaped body and an inwardly tapered neck. The hollow body fits over a workpiece-engaging portion of the temporary fastener, and the neck extends from the hollow body. The tapered neck terminates in a hollow tip that is sized and configured to fit over aligned holes in the joined workpieces and to contact a minimal surface area of the outermost workpiece to reduce surface damage to the workpieces such that any damage will be removed when the holes are countersunk in the normal course of assembly.
F16B 37/12 - Nuts or like thread-engaging members with thread-engaging surfaces formed by inserted coil-springs, discs, or the likeIndependent pieces of wound wire used as nutsThreaded inserts for holes
F16B 19/10 - Hollow rivetsMulti-part rivets fastened by expanding mechanically
B21J 15/42 - Special clamping devices for workpieces to be riveted together, e.g. operating through the rivet holes
F16B 5/04 - Joining sheets or plates to one another or to strips or bars parallel to them by means of riveting
B33Y 80/00 - Products made by additive manufacturing
97.
SYSTEM AND METHOD FOR DRILLING HOLES AND INSTALLING FASTENERS IN VEHICLE STRUCTURES
A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.
B23P 23/00 - Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
B23P 19/06 - Screw or nut setting or loosening machines
B23B 45/02 - Hand-held or like portable drilling machines, e.g. drill gunsEquipment therefor driven by electric power
98.
System and method for drilling holes and installing fasteners in vehicle structures
A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.
B23P 23/04 - Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass for both machining and other metal-working operations
B23P 19/04 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformationTools or devices therefor so far as not provided for in other classes for assembling or disassembling parts
B62D 65/02 - Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
B21J 15/14 - Riveting machines specially adapted for riveting specific articles, e.g. brake lining machines
99.
Fastener insertion gun for installing fasteners in vehicle structures
A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.
An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.
B64F 5/10 - Manufacturing or assembling aircraft, e.g. jigs therefor
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
