| SPIRIT AEROSYSTEMS, INC. Patent applications |
| Patent application number | Title | Published |
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| 20120123060 | HIGH TEMPERATURE SHAPE MEMORY POLYMER VIA REACTIVE EXTRUSION - Shape memory polymer compositions and methods of using those compositions to make products are provided. The compositions include a thermoplastic polymer and a high thermal stability free radical source, and they are extruded together to form the final shape memory product. | 05-17-2012 |
| 20120119417 | RECONFIGURABLE SHAPE MEMORY POLYMER TOOLING SUPPORTS - A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part. | 05-17-2012 |
| 20120119416 | RECONFIGURABLE SHAPE MEMORY POLYMER TOOLING SUPPORTS - A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part. | 05-17-2012 |
| 20120119412 | METHOD FOR REMOVING A SMP APPARATUS FROM A CURED COMPOSITE PART - A method and apparatus for removing a SMP apparatus from within a cured composite part. The method may comprise the steps of triggering the SMP apparatus from a rigid state to a malleable state, inducing a pressure differential that drives the SMP apparatus, in the malleable state, away from the cured composite part and toward an inner mandrel tool, and removing the inner mandrel tool with the SMP apparatus resting thereon out of the cured composite part. The inner mandrel tool may comprise an outer surface having varying contours such that a surface area of the outer surface is great enough to prevent the SMP apparatus from folding over onto itself or creasing when driven toward the inner mandrel tool. A maximum straight line distance between points on the outer surface may be small enough to allow the inner mandrel tool clearance for removal from the cured composite part. | 05-17-2012 |
| 20120119411 | RECONFIGURABLE SHAPE MEMORY POLYMER SUPPORT TOOLING - A support apparatus and method for providing structural support to a shape memory polymer (SMP) apparatus during fabrication of composite parts. The support apparatus may comprise an adjustable, rigid structural member and a plurality of SMP support components transitionable between a rigid and malleable state and fixed to an outer surface of the rigid structural member. The rigid structural member may extend in at least one cross-sectional dimension toward the SMP apparatus, pressing the SMP support components, in their malleable state, against the SMP apparatus. The SMP support components may thereby conform to a first surface of the SMP apparatus, then return to their rigid state while pressed against the SMP apparatus, thus providing a rigid load path between the SMP apparatus and the rigid structural member. Then composite material may be applied to a second surface of the SMP apparatus, opposite of the first surface. | 05-17-2012 |
| 20120118491 | RECONFIGURABLE SHAPE MEMORY POLYMER TOOLING SUPPORTS - A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part. | 05-17-2012 |
| 20120118487 | METHODS AND SYSTEMS FOR CO-BONDING OR CO-CURING COMPOSITE PARTS USING A RIGID/MALLEABLE SMP APPARATUS - A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. Next, composite material may be applied onto the SMP apparatus and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cured composite material and removed from within the composite part. | 05-17-2012 |
| 20120118486 | METHODS AND SYSTEMS FOR FORMING INTEGRAL COMPOSITE PARTS WITH A SMP APPARATUS - A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as a rigid lay-up tool. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material and/or nested components may be heated and compressed against the SMP apparatus. The SMP apparatus may be configured to remain rigid during the composite cure cycle. Once the composite material is cured, the SMP apparatus may be triggered to a malleable state and urged away from the cured composite material. | 05-17-2012 |
| 20120104162 | PYLON ARRANGEMENT FOR OPEN STRUCTURE - An aircraft pylon is disclosed, the pylon including a strut, a modular fluid containment structure and a modular firewall. The strut presents an open structure and connects an aircraft external element to the aircraft. The fluid containment structure is associated with a fluid transfer component, wherein the fluid containment structure contains escaped fluid from the fluid transfer component and channels the escaped fluid away from the aircraft. Both the fluid containment component and the firewall are modular and separable from the strut. | 05-03-2012 |
| 20120036716 | AERODYNAMIC DEVICE FOR THRUST REVERSER CASCADES - A method and aerodynamic device for modifying at least one vane of a cascade thrust reverser. One or more of the aerodynamic devices may be formed and attached to forward-facing surfaces of vanes of the thrust reverser. The aerodynamic device may include a first side shaped to rest flush against at least a portion of the forward-facing surface of the vane, a second side opposite of the first side, a ledge portion protruding from the first side and configured to rest flush against a blunt leading edge of the vane, a rounded first end portion extending from the ledge portion to the second side of the aerodynamic device, and a second end opposite of the first end portion at which the first side and the second side converge. The aerodynamic device changes the size and contour of airflow channels between the vanes, increase the efficiency of the thrust reverser. | 02-16-2012 |
| 20120012694 | FAIL-SAFE AIRCRAFT ENGINE MOUNTING APPARATUS - A mounting apparatus for an aircraft engine that provides load path redundancy includes a forward mount that attaches the aircraft engine to a pylon at a forward position of the aircraft engine, an aft mount that attaches the aircraft engine to the pylon at an aft position of the aircraft engine and a thrust assembly connected to the forward mount, and the aft mount. The forward mount includes an aircraft engine attachment assembly and a fail-safe assembly. The aft mount includes an aircraft engine attachment assembly and a fail-safe assembly. | 01-19-2012 |
| 20120012242 | METHOD AND SYSTEM FOR MATERIAL PLACEMENT OVER RADIUSED EDGES - A system and method for placement of a strip of material onto a three-dimensional surface having a first face and a second face, with a first radiused edge connecting the first face with the second face. The method may comprise placing one or more strips of material onto the three-dimensional surface along a predefined path requiring various amounts of steering of the strip of material. The method may specifically involve steering the strip of material by a first amount on the first face, steering the strip of material by a second amount on the first radiused edge, and steering the strip of material by a third amount on the second face. The first and/or third amounts may be greater than or equal to the second amount, limiting the amount of steering as the material transverses the first radiused edge. | 01-19-2012 |
| 20110308711 | METHOD AND SYSTEM FOR FORMING A COMPLEX MONOLITHIC THERMOSET PART - A system and method for forming a hollow, complex, monolithic composite part. Composite material may be placed around the mandrel, then an internal impermeable membrane may be placed into and/or through tunnels formed in the mandrel. Next, an external impermeable membrane may be placed around the composite material and sealed against itself and the internal impermeable membrane such that the mandrel and the composite material are both contained in an airtight manner between the internal and external impermeable membranes. Air may then be removed from within the sealed impermeable membranes, compressing the impermeable membranes against the mandrel and/or the composite material. The consolidated composite material may be hardened to form the composite part. Finally, the impermeable membrane may be removed from around the hollow composite part and from within the mandrel, followed by removal of the mandrel from within the composite part by breaking it up into smaller pieces. | 12-22-2011 |
| 20110272091 | METHOD OF MANUFACTURING COMPLEX COMPOSITE PARTS - A system for manufacturing a composite part from composite material comprises a bag and a tool. The bag may retain a first portion of the composite material and may include a chamber and a sheet, to which the chamber is coupled. The chamber may be positioned adjacent a rigidized support configured to maintain the chamber in the shape of a non-planar feature of the composite part. The tool may include an upper surface configured to retain a second portion of the composite material and shaped to correspond to an outer mold line of the composite part. The bag may be placed upon the upper surface of the tool such that the composite material is fully enclosed by the combination of the bag and the upper surface of the tool. A heating element may provide a high temperature to cure the composite material. | 11-10-2011 |
| 20110271685 | VARIABLE FAN DUCT NOZZLE - An aircraft nacelle comprising an outer cowl and an inner cowl located inward of the outer cowl with an air flow path formed therebetween. The inner cowl may comprise a forward portion and an aft portion slidable in a forward-to-aft direction via one or more actuators. When translated aftward, the aft portion may decrease the area of the nacelle's fan duct nozzle. The greatest radial distance between the inner cowl and a center axis of the nacelle may occur at or forward of a location in which the forward and aft portions overlap each other. The forward portion may be comprised of a different material than the aft portion. | 11-10-2011 |
| 20110265327 | APPARATUS AND METHOD FOR AIRCRAFT ENGINE CORE EXCHANGE - A method and ground support equipment (GSE) for attaching an engine core to an engine fan module on an aircraft pylon. The GSE may comprise GSE supports and lifting components attached to the pylon, two suspension rails attached to the lifting components, two translating rails translatably attached to the two suspensions rails and fixedly attached to opposite sides of the engine core, and two alignment fittings fixed to the engine fan module. The method of using the GSE may comprise lifting the engine core vertically using the lifting components and anchoring the suspension rails to the alignment fittings. The translating rails and engine core may then be translated in an aft-to-forward direction such that portions of the translating rails engage portions of the alignment fittings to cooperatively guide the translating rails into a final forward position in which the engine core is aligned relative to the engine fan module. | 11-03-2011 |
| 20110240214 | SYSTEM FOR PROCESSING COMPOSITE MATERIALS - A system for processing a composite material may comprise a chamber, a mandrel, an upper ramp, and an upper diaphragm. The chamber generally provides structural support while a vacuum is applied to the system and may have a six-sided generally rectangular box shape. The mandrel generally provides support for the composite material, and may be located within the chamber. The upper ramp generally provides a path for the upper diaphragm to follow under vacuum, and may be located adjacent to the mandrel and tilted at approximately 45 degrees downward thereto. The upper diaphragm may be placed over an opening along one side of the chamber. During processing, a vacuum may be applied to chamber and the upper diaphragm may be pulled inward through the opening to press the composite material against the mandrel. | 10-06-2011 |
| 20110232991 | METHOD FOR BONDING HONEYCOMB CORES - A method for splicing honeycomb core together to form a core structure, such as an acoustic panel for an aircraft. The core structure may comprise a first honeycomb core, a second honeycomb core, and an intermediate bonding part disposed between the first and second honeycomb cores. The intermediate bonding part may comprise a syntactic core wrapped with or sandwiched between a non-foaming film adhesive. The syntactic core sandwiched between a first and second layer of film adhesive and a first and second honeycomb core is then compressed by vacuum and cured to bond the honeycomb cores together, forming the core structure. | 09-29-2011 |
| 20110215193 | HYBRID TORQUE BOX FOR A THRUST REVERSER - A hybrid torque box comprising a plurality of composite tubes and metal fittings attached together in alternating succession and configured to attach a thrust reverser to an engine fan case of an aircraft. The hybrid torque box may be substantially hollow and may comprise two V-blades for attaching the torque box to the engine fan case. The hybrid torque box may also be attached to or integral with a bull nose fairing configured for attachment with a cascade of the thrust reverser. Furthermore, the hybrid torque box may comprise and/or attach to a cowl interface flange configured for interfacing with an outer cowl of the thrust reverser. | 09-08-2011 |
| 20110176149 | APPARATUS AND METHOD FOR THICKNESS DETECTION - An apparatus and method for detecting an increase in thickness of a strip of material from a desired thickness. The apparatus may comprise a light source, a light detector, an indicator, a first fiber optic cable coupled with the light source, a second fiber optic cable coupled with the light detector, and a housing. The housing may comprise a material slot for passing the strip of material therethrough and fixing optical fibers of the first fiber optic cables to reflect light off of a first and second face of the strip of material into optical fibers of the second fiber optic cable. The amount of light detected by the light detector depends on the proximity of each of the faces of the strip of material to ends of the optical fibers. The thicker the strip of material, the less light received by the light detector, which may actuate the indicator. | 07-21-2011 |
| 20110151184 | APPARATUS FOR INSULATING EXPOSED FASTENERS - A removable fastener insulating device comprising a heat resistant cover configured for insulating a fastener. The heat resistant cover may comprise a first portion with a hole formed therein for the fastener to be inserted through and a second portion with a cavity formed therein. The cavity may be lined with an insulating portion made of material resistant to heat transfer. In use, a portion of the fastener may be inserted into the hole of the heat resistant cover and the second portion may be actuated into the closed position. In the closed position, an end portion of the fastener may reside within the cavity between the first portion and the second portion. The heat resistant cover may also comprise attachment elements for holding the second portion in the closed position against the first portion. | 06-23-2011 |
| 20110146854 | SYSTEM AND METHOD FOR FORMING CONTOURED NEW AND NEAR-NET SHAPE TITANIUM PARTS - A system and method for shaping a net or near-net titanium part, the method comprising machining a piece of titanium into a titanium part having non-uniform thickness, heating the titanium part to a target temperature within a target temperature range between an auto-relief temperature of the titanium part and a minimum temperature required for super plastic forming of the titanium part, and lowering a die into the titanium part with sufficient force to shape the titanium part. The system for shaping the titanium part may comprise a multiple-axis machine, a die, electrical clamps, sensors, and a control system for adjusting heating temperatures based on information received from the sensors regarding the titanium part. | 06-23-2011 |
| 20110121132 | TRUSS-SHAPED ENGINE PYLON AND METHOD OF MAKING SAME - An aircraft engine pylon comprises a top wall, a bottom wall, a left side wall, and a right side wall. The left side wall includes a left truss structure along with a left upper ledge and a left lower ledge. The right side wall includes a right truss structure along with a right upper ledge and a right lower ledge. The top wall is joined with the left upper ledge and the right upper ledge and an upper truss structure is formed in the left upper ledge, the right upper ledge, and the top wall. The bottom wall is joined with the left lower ledge and the right lower ledge and a lower truss structure is formed in the left lower ledge, the right lower ledge, and the bottom wall. | 05-26-2011 |
| 20110084428 | APPARATUS AND METHOD FOR MANUFACTURING AN AIRCRAFT STRINGER - An apparatus and method of forming a stringer or an integral stringer and fuselage skin. The apparatus may be a solid bladder made of silicone, urethane, or any similar material or combination thereof. The method may comprise placing composite material onto a surface of a tooling having a channel sized and shaped to correspond to a desired stringer size and shape. Then the solid bladder may be placed onto the composite material relative the channel. The shape of the solid bladder may correspond to the shape of the channel. Composite material may then be placed over the solid bladder, vacuum-sealed against the bladder and the tooling, and cured to harden the composite material, thereby forming a stringer or an integral stringer and fuselage skin. | 04-14-2011 |
| 20110062279 | HYBRID BEAM FOR A THRUST REVERSER UNIT - Latch beams and hinge beams of an aircraft thrust reverser and a method for manufacturing the beams. The latch and hinge beams may comprise a plurality of hollow composite tubes joined with a plurality of machined metal fittings in alternating succession. The metal fittings may comprise at least one of hinge fittings and latching fittings. The latch and hinge beams may further comprise slider tracks configured to slidably attach to a translating sleeve of the thrust reverser. The hinge beams may each be rotatably attached to an engine strut or pylon of the aircraft, and the latch beams may each be mechanically latched with each other. Each of the latch and hinge beams may also be fixedly attached to an inner engine cowling of the thrust reverser. | 03-17-2011 |
| 20110060949 | VIRTUAL PRODUCTION TESTING OF LARGE INTEGRATED PRODUCTS - A communications system and method for testing components of an aircraft via Ethernet. The communications system may comprise one or more Ethernet links having software and hardware controls for timing, buffering, and messaging, and a dedicated Ethernet line. The Ethernet links may be configured to communicably link sections of a central communication system of the aircraft, each section being part of a separate aircraft component. The Ethernet links may also communicably link the sections with various databases over the Ethernet line. The databases may comprise loadable software, archived testing data, configuration data, and/or diagnostic data. Any of the central communication system sections and the databases may be located at geographically distant locations from each other, such as at separate production sites. The communications system may allow the aircraft components to test each other, or essentially for the aircraft to test itself prior to its components being physically joined together. | 03-10-2011 |
| 20110012290 | METHOD FOR SEPTUMIZING INJECTION MOLDED THERMOPLASTIC CORE - A method of fabricating and using a honeycomb core structure for aircrafts. The honeycomb core structure may comprise a septum positioned within and integral to a honeycomb core. The method may comprise sandwiching the septum between two sections of a die. Each section of the die may comprise a plurality of spaced apart columns, each having a hexagonal cross-section. The method may further comprise injecting melted thermoplastic throughout both sections of the die between the columns and cooling the thermoplastic, thereby hardening and integrating the thermoplastic and the septum together to form the honeycomb core structure. The method may also comprise affixing the honeycomb core structure within an aircraft structure to provide a structural load path for a primary component of the aircraft. | 01-20-2011 |
| 20110008530 | SYSTEM AND METHOD TO FORM AND HEAT-TREAT A METAL PART - A system and method for direct manufacturing and stress relieving a metal part without removing the metal part from a vacuumed chamber. The system may comprise the chamber, a wire feeder for depositing a metal wire onto a metal plate, an electron beam (EB) source for providing an electron beam to melt the metal wire during deposition, and a current-providing apparatus for joule heating the metal plate to provide heat treatment to the metal part. The method may comprise depositing the metal wire onto the metal plate within the vacuumed chamber, then providing intermediate stress relief after a portion of the metal wire is deposited onto the metal plate by applying an electrical current to the metal part. The electron beam may also be set at a temperature below a melting point of a particular metal of the metal part for relieving stress in the metal part. | 01-13-2011 |
| 20100288050 | MECHANISM FOR ADAPTIVE CONTOUR COMPLIANCE - An apparatus for inspecting samples that may include a curvature that varies from sample to sample comprises a scanning element, a feed mechanism, and a pivot mechanism. The scanning element transmits and receives a signal to and from the sample as the sample passes by, thereby building an image or profile of the sample. The feed mechanism includes a drive motor coupled to a series of pulleys and belts that form an open-ended chain. The pulleys rotate when driven by the drive motor and are coupled to an array of rollers that rotate as well to propel a inspection sample past the scanning element. The pivot mechanism includes a series of primary and secondary links that also form an open-ended chain. The primary links are coupled to the rollers and the combination pivots in unison to form an arc that matches the curvature of the sample in order to maintain a fixed distance between the sample and the scanning element. | 11-18-2010 |
| 20100269979 | BLADDER PRESSURE BONDING APPARATUS - An apparatus and method for providing pressure for bonding parts together. The apparatus may comprise a plurality of bladders independently actuatable to apply pressure for pushing a second part toward a first part having adhesive thereon. The apparatus may further comprise a frame supporting a plurality of reconfigurable bladder retainer devices positioned and angled such that the configuration of the bladders matches the contour of the second part. The bladders may expand and contract according to a sequence dictated by a control device, such that excess air and adhesive between the first and second part may be substantially squeegeed toward outer edges of the parts. | 10-28-2010 |
| 20100264676 | TERTIARY LOCK FOR PIVOT DOOR THRUST REVERSER - A locking assembly partially housed between a forward bulkhead and an aft bulkhead of an aircraft's fan duct for preventing a pivot door of a thrust reverser from inadvertently opening during flight and providing over-stow assistance during opening and closing of the pivot door. The locking assembly may comprise a lock arm configured to mate with a lock arm receiver fixed to the pivot door. The lock arm may have a first portion pivotally attached to a locking assembly housing mounted between the bulkheads, and a second portion extending aftward through an opening in the aft bulkhead. When the lock arm is pivoted away from the pivot door, the second portion may be configured to push inward against the lock arm receiver, urging the pivot door inward while simultaneously moving the lock arm away from the lock arm receiver to allow the pivot door to open outward. | 10-21-2010 |
| 20100236862 | ENGINE INLET DEEP ACOUSTIC LINER SECTION - An inlet of an aircraft nacelle having an acoustic barrel configured to reduce engine fan flutter by attenuating various frequencies. The acoustic barrel may comprise an acoustic panel of a honeycomb configuration sandwiched between a first back sheet and a face sheet and extending from a forward bulkhead to an aft bulkhead of the inlet. The acoustic barrel may further comprise a deep liner section bonded to and sandwiched between the first back sheet and a second back sheet. The deep liner section may have a narrower width than the acoustic panel and may be located proximate the aft bulkhead. The sections of the first back sheet, the face sheet, and a septum of the acoustic panel may be perforated and may contain additional holes formed in portions aligned radially inward of the deep liner section. | 09-23-2010 |
| 20100212286 | THRUST REVERSER CONFIGURATION FOR A SHORT FAN DUCT - A thrust reverser comprises a translating sleeve, a torque beam, a plurality of cascades, a plurality of blocker doors, and a plurality of actuators. The translating sleeve is positioned at the rear of an aircraft nacelle and is translated rearward during thrust reverser deployment. The torque beam is positioned within the nacelle and configured to prevent airflow into the nacelle during thrust reverser deployment. The plurality of cascades are positioned around the circumference of the torque beam during thrust reverser stowage and are translated rearward during thrust reverser deployment. The plurality of blocker doors are positioned in alignment with the plurality of cascades and direct airflow through the plurality of cascades during thrust reverser deployment. The plurality of actuators are coupled to the forward edge of the sleeve and configured to translate the sleeve rearward during thrust reverser deployment. | 08-26-2010 |
| 20100193632 | INTEGRAL COMPOSITE SLIDER FOR AIRCRAFTS - A slider apparatus integral with a slidable member and a method for integrating the slider apparatus with the slidable member. The slider apparatus integrated with the slidable member may be configured to slidably couple with and be structurally supported by a fixed structure. The slider apparatus may comprise a primary slider component made of composite material and at least one chamfered element bonded to the primary slider component. The slidable member may comprise the slider apparatus, a core assembly, a plurality of composite material plies wrapped around the slider apparatus and core assembly and cured therewith, and at least one low-friction slider shoe removably attached to the primary slider component outward of the plurality of composite material plies. | 08-05-2010 |
| 20100193628 | CONTINUOUS COMPOSITE FAN DUCT AND THRUST REVERSER - A duct having a continuous C-shaped cross section slidably attached to a strut supporting an aircraft engine. The duct may comprise an inner wall, an outer wall, a first end wall, a second end wall, at least one slider, a thrust reverser, and an outer cowl panel of a thrust reverser. The inner wall may comprise a forward section and an aft section. The aft section may be integral with the first end wall, the second end wall, the outer wall, and the at least one slider. The forward section may comprise a right half and a left half which may be pivotally attached to the strut and may pivot to an open position when the rest of the fan duct is slid aftward away from the engine. The duct, excluding the forward section of the inner wall, may slide aftward on its at least one slider, providing engine access. | 08-05-2010 |
| 20100181700 | METHOD AND APPARATUS FOR TENSIONING COMPOSITE MATERIAL - An apparatus and method for tensioning material ( | 07-22-2010 |
| 20100175383 | DILATING FAN DUCT NOZZLE - A turbofan engine includes an engine core and a ducted fan assembly, with the ducted fan assembly including an annular cowling and a dilating fan duct nozzle. The nozzle includes continuous nozzle sections with intermeshing tiles. The tiles include drive tiles that are pivotal between nominal and dilated positions and driven tiles that intermesh with the drive tiles and shift with the drive tiles between the positions. The intermeshing tiles cooperatively adjust an orifice size of the nozzle by shifting between the positions and thereby affect the thrust and noise developed by the ducted fan assembly. | 07-15-2010 |
| 20100155537 | ENERGY-ABSORBING STRUCTURAL COMPOSITE ELEMENT - A structural, energy absorbing composite element for aircraft structures includes a metallic or nonmetallic skin shell with a porous filler material insert positioned within the skin shell. The porous filler material is a material having ligaments that collapse resulting in a densification of the porous filler material in response to impact loading or a compression force sufficient to cause failure of the combined assembly. | 06-24-2010 |
| 20100155533 | COMPOSITE FORWARD PRESSURE BULKHEAD - A forward pressure bulkhead for aircraft includes an energy dissipating material layer, a metallic or nonmetallic inboard skin with a porous filler material positioned within said layers. The energy and load distribution layer redistributes and disperses energy of impacts and penetrations. The porous filler material is a material having ligaments that collapse resulting in a densification of the porous filler material in response to impact loading or a compression force sufficient to cause failure of the combined assembly. | 06-24-2010 |
| 20100146732 | HINGE LOCATOR DEVICE - A locator device for locating the centerline of a plurality of piano hinge segments without the use of hard tooling includes a target support element, a pair of targets supported on opposite ends of the target support element, and a locator element for locating the target support element relative to hinge pin holes so that the targets are equally spaced from the hinge pin holes. The targets may be reflective-type targets used in laser targeting systems, photogrammetry targets used in digital photogrammetry locating systems, or other known targets. | 06-17-2010 |
| 20100119822 | CARBON NANOTUBE COPOLYMERS AND COMPOSITIONS AND METHODS OF USING THE SAME - New carbon nanotube polymers and compositions are provided. The polymers comprise recurring blocks or units of carbon nanotubes and a compound other than a carbon nanotube. The compound is a polymeric or oligomeric block and is bonded to the carbon nanotube outer sidewall rather than to the carbon nanotube end, and is preferably a block copolymer of the compound and the carbon nanotube. The polymers can be used to prepare compositions that can be formed into products that are useful for building components present in airplanes. | 05-13-2010 |
| 20100112118 | REUSABLE SEALING DEVICE - A sealing device for forming an airtight seal between a first body, such as a cure tool, and a second body, such as a vacuum bag, without the use of adhesives. The sealing device may comprise an outer surface attached to the second body, an inner surface configured to face the first body, and two cusps located at opposite edges of the inner and outer surfaces. The sealing device may form a continuous boundary around an area of any shape or size. The sealing device may have a substantially crescent-shaped cross-section, allowing the sealing device to suction to the first body when compressed against the first body. The sealing device may also comprise a tab portion protruding from the inner surface between the first and second cusp for providing a more secure seal between the sealing device and the first body. | 05-06-2010 |
| 20100112117 | REUSABLE INFUSION BAG - A reusable apparatus and method for forming a composite part through vacuum assisted resin transfer molding (VARTM). The reusable apparatus may be configured to vacuum seal a curable material, such as composite material, against a tool and disperse a permeating substance such as liquid resin through the curable material. The reusable apparatus may comprise a sheet of material such as rubber having a plurality of surface deviations facing the curable material and the tool. The surface deviations may provide paths for evenly distributed air flow as air is evacuated from between the sheet of material and the tool. Additionally, the surface deviations may allow the permeating substance to be evenly dispersed throughout the curable material. A vacuum outlet of the tool may be positioned between two sealing apparatuses to provide continuous vacuum suction proximate a perimeter of the sheet of material to prevent air from leaking in. | 05-06-2010 |
| 20100079297 | APPARATUS AND METHOD FOR WIDTH DETECTION - An apparatus and method for detecting a difference in width of a strip of material from a desired width of material. The apparatus may comprise a light source, a light detector, an alarm, a first fiber optic cable coupled with the light source, a second fiber optic cable coupled with the light detector, and a housing. The housing may comprise a material slot for passing the strip of material therethrough such that edges of the strip of material may at least partially intersect a plurality of light fields directed from the first fiber optic cable to the second fiber optic cable. The amount of light detected by the light detector is dependant on the amount of light blocked by the strip of material. If the amount of light received is outside of a range of tolerance from the desired width of material, the alarm may be actuated. | 04-01-2010 |
| 20100063241 | HIGH PERFORMANCE POLYASPARTIMIDE RESIN - New polyaspartimide compositions and methods of forming and using those compositions arc provided. The compositions are formed by reacting a bismaleimide and diamine in a solvent-free environment. The resulting polyaspartimide comprising recurring monomers of | 03-11-2010 |
| 20100024952 | MATERIAL PLACEMENT METHOD AND APPARATUS - A material placement head for dispensing and compacting a plurality of strips of a material onto a surface with a plurality of independently movable roller assemblies. Each roller assembly of the placement head comprises a compacting roller and may be rotatably and linearly moved in six-degrees of freedom independent of the other roller assemblies of the placement head. The roller assemblies may be arranged in a staggered configuration and substantially simultaneously apply the plurality of strips of the material to the surface, such that the strips of the material are applied to adjacent paths on the surface. Each compacting roller may be malleable and substantially crowned around its outer circumferential surface to provide even compaction to the strips of the material. | 02-04-2010 |
| 20100018212 | DILATING FAN DUCT NOZZLE - A turbofan engine includes an engine core and a ducted fan assembly, with the ducted fan assembly including an annular cowling and a dilating fan duct nozzle. The nozzle includes continuous nozzle sections with intermeshing tiles. The tiles include drive tiles that are pivotal between nominal and dilated positions and driven tiles that intermesh with the drive tiles and shift with the drive tiles between the positions. The intermeshing tiles cooperatively adjust an orifice size of the nozzle by shifting between the positions and thereby affect the thrust and noise developed by the ducted fan assembly. | 01-28-2010 |
| 20090278319 | VACUUM TRANSFER SEAL - An intermediate sealing element and method for unsealing a vacuum membrane from one tool surface and transferring it to another tool surface without damaging the vacuum membrane. The intermediate sealing element forms a continuous path around the periphery of a vacuum membrane and is sealed directly to one or more vacuum membranes and a tool surface using any means known in the art to create an airtight seal between two surfaces. The intermediate sealing element is able to withstand high temperatures and high pressure without altering its structural characteristics. Because of its durability, the intermediate sealing element can be removed from the tool surface without tearing or elongating, subsequently allowing the vacuum membranes to be detached from the tool surface without tearing or elongating. | 11-12-2009 |
| 20090271016 | RECONFIGURABLE NUMERICAL CONTROL FOR MULTI LEVEL MODULAR MACHINE - A control system for a modular reconfigurable numerically controlled machine comprising at least one memory storage device associated with each of a plurality of detachable modular components to store kinematic and connection information about the modular component. The information in the memory storage devices is read and processed by a main processing unit when the modular component is attached to a primary structure of the numerically controlled machine. The control system further comprises a plurality of component actuators, which receive control signals from the main processing unit, to actuate the modular components attached to the numerically controlled machine. A hardware component connector may provide at least one of a physical, electrical, communications, and pneumatic connection between the primary structure of the numerically controlled machine and the modular components. | 10-29-2009 |
| 20090259411 | SYSTEM AND METHOD FOR SELF-CONTAINED STRUCTURAL HEALTH MONITORING FOR COMPOSITE STRUCTURES - A system and method for structural health monitoring (SHM) of a physical structure, such as an aircraft component. The system may comprise a central data acquisition module and a plurality of wireless, self-contained sensor wafers bonded to a surface of the physical structure. The central data acquisition module and the sensor wafers may be communicably coupled in a hierarchical order. If any of the sensor wafers detects a structural fault, it may be stored in a memory of the central data acquisition module for retrieval by maintenance personnel. If one or more of the sensor wafers malfunctions, the central data acquisition module may reconfigure the hierarchical order in which the sensor wafers communicate to exclude the malfunctioning sensor wafer or wafers. The sensor wafers may include a sensor, circuitry, a wireless antenna, and a power source. | 10-15-2009 |
| 20090255321 | DYNAMIC CALIBRATION ASSEMBLY FOR A FRICTION STIR WELDING MACHINE - A calibration assembly for a friction stir welding machine having a rotatable pin tool with upper and lower shoulders. The calibration assembly includes: a force measuring component for placement between the upper and lower shoulders of the pin tool; an upper bearing for placement between the upper shoulder of the pin tool and the force measuring component for permitting relative rotation therebetween; and a lower bearing for placement between the lower shoulder of the pin tool and the force measuring component for permitting relative rotation therebetween. The upper and lower bearings permit the pin tool to be rotated relative to the force measuring component during a calibration procedure. This permits the force measuring component to measure the forces directly applied by the pin tool while the upper and lower shoulders are either stationary or rotated relative to the force measuring component. | 10-15-2009 |
| 20090212155 | ENGINE PYLON MADE FROM COMPOSITE MATERIAL - A load-bearing structure, such as a pylon or strut, comprising a monolithic tubular-shaped first central structure composed of composite material and a plurality of metal fittings for supporting an engine on an airframe structure of an aircraft, such as a wing. Most of the fittings are integrated into the load-bearing structure through bonding. The metal fittings carry the high bearing loads that are transmitted into the pylon at the engine-pylon and wing-pylon interfaces. The load-bearing structure may also comprise a second central structure of a tubular shape composed of composite material and integrated with one end portion of the first central structure by bonding and/or mechanical fastening means. | 08-27-2009 |
| 20090208745 | COMPOSITE MATERIAL PLACEMENT - A method of applying a length of discontinuous fiber material to a surface comprises placing the material between a roller and the surface, urging the roller toward the surface such that the roller causes at least a portion of the length of discontinuous fiber material to engage the surface, and applying the length of discontinuous fiber material to the surface by moving one of said roller and said surface relative to the other such that the roller rolls along an application path of said surface. The application path may include one or more curves, wherein a first portion of the material lengthens relative to a second portion of the material, thereby allowing the material to lay evenly against the surface through the one or more curves without separating from the surface. | 08-20-2009 |
| 20090205312 | SWEPT FAN RAMP FOR PIVOT DOOR THRUST REVERSER - A swept fan ramp for a pivot door thrust reverser includes a cylindrical unit with an elliptical flared portion, a side portion, and a rectangular flared portion. The elliptical flared portion is operable to reduce drag on airflow in a reverse direction and is coupled to the top center and bottom center of the circumference of the cylindrical unit. The side portion is operable to reduce side spillage airflow and is coupled to the central left side and central right side of the aft circumference of the cylindrical unit. The rectangular flared portion is operable to promote separation of airflow into an upper airflow path and a lower airflow path, is coupled with the aft circumference of the cylindrical unit, and is connected to the elliptical flared portion and the side portion. | 08-20-2009 |
| 20090165562 | MECHANISM FOR ADAPTIVE CONTOUR COMPLIANCE - An apparatus for inspecting samples that may include a curvature that varies from sample to sample comprises a scanning element, a feed mechanism, and a pivot mechanism. The scanning element transmits and receives a signal to and from the sample as the sample passes by, thereby building an image or profile of the sample. The feed mechanism includes a drive motor coupled to a series of pulleys and belts that form an open-ended chain. The pulleys rotate when driven by the drive motor and are coupled to an array of rollers that rotate as well to propel a inspection sample past the scanning element. The pivot mechanism includes a series of primary and secondary links that also form an open-ended chain. The primary links are coupled to the rollers and the combination pivots in unison to form an arc that matches the curvature of the sample in order to maintain a fixed distance between the sample and the scanning element. | 07-02-2009 |
| 20090163115 | METHOD OF MAKING ACOUSTIC HOLES USING UV CURING MASKING MATERIAL - A method of forming acoustic holes in a composite sound-insulating material includes creating a image of at least a portion of an array of holes and transferring the image to an ultraviolet (UV) radiation transparent medium. The method continues with positioning the medium in contact with a UV-curable mask and exposing the medium-covered mask to UV radiation to cure the UV-exposed areas. The method further includes removing the uncured mask material to create an abrading mask that includes a plurality of holes in a desired pattern. The method also includes positioning the abrading mask in contact with the sound-insulating material and directing a stream of abrasive matter at the abrading mask to create perforations in the sound-insulating material that correspond to the pattern of holes in the abrading mask. | 06-25-2009 |
| 20090152401 | NACELLE INLET THERMAL ANTI-ICING SPRAY DUCT SUPPORT SYSTEM - An anti-icing system for an aircraft engine nacelle comprises a generally ring-shaped hollow spray tube for directing hot gasses toward a portion of the nacelle; a plurality of fasteners for attaching the spray tube to a support structure of the aircraft engine; and a supply duct for delivering the hot gasses from the aircraft engine to the spray tube. The spray tube includes two closed ends which define a thermal expansion gap therebetween to accommodate thermal expansions and contractions caused by the hot gasses. Each of the fasteners comprises a support bracket for attachment to the support structure of the aircraft and a guide assembly for supporting the spray tube to the support bracket. The guide assembly includes a generally ring-shaped block for encircling the spray tube, a bushing positioned within the block for contact with a bearing sleeve of the spray tube, and a pair of bushing retainers positioned on opposite sides of the block for retaining the bushing within the block. The bushings permit the spray tube to slip relative to the fasteners to further accommodate thermal expansions and contractions. | 06-18-2009 |
| 20090143207 | MODULAR NUMERICALLY CONTROLLED SYSTEM - A reconfigurable system having at least one detachable component and at least one detachable head assembly. The reconfigurable system may be a numerically controlled (NC) machine for manufacturing processes, such as milling or automatic fiber placement (AFP). The reconfigurable system may further comprise a gantry structure comprised of movably attached beams on which detachable components may be movably attached. The detachable components may include a concave component and a convex component. At least one detachable head assembly may be movably attached to at least one of the detachable components. The detachable components and head assemblies may be at least one of physically, electrically, and pneumatically connected to a connecting assembly attached to the gantry structure. | 06-04-2009 |
| 20090140451 | MATERIAL PLACEMENT METHOD AND APPARATUS - A roller assembly for bidirectionally dispensing and compacting a strip of a material onto a surface without requiring the roller assembly to rotate 180° to dispense the material in the reverse direction. The roller assembly comprises a first guide element, a second guide element, a third guide element, and a compacting roller. When the first guide element is in a first position, the strip of the material is fed to the second guide element. When the first guide element is in a second position, the strip of the material is fed to the third guide element. The compacting roller is malleable and substantially crowned around an outer circumferential surface of the compacting roller to provide even compaction to the strip of the material. | 06-04-2009 |
| 20090139654 | MATERIAL PLACEMENT METHOD AND APPARATUS - A material placement head for dispensing and compacting a plurality of strips of a material onto a surface with a plurality of independently movable roller assemblies. Each roller assembly of the placement head comprises a compacting roller and may be rotatably and linearly moved in six-degrees of freedom independent of the other roller assemblies of the placement head. The roller assemblies may be arranged in a staggered configuration and substantially simultaneously apply the plurality of strips of the material to the surface, such that the strips of the material are applied to adjacent paths on the surface. Each compacting roller may be malleable and substantially crowned around its outer circumferential surface to provide even compaction to the strips of the material. | 06-04-2009 |
| 20090127806 | LOW-LEAKAGE SEAL SYSTEM FOR PIVOT DOOR TYPE THRUST REVERSER - A low-leakage seal system for a pivot door type thrust reverser comprises a forward seal, an aft seal, and a pair of seal stops. The forward seal is attached to a forward portion of a thrust reverser. The aft seal is attached to an aft portion of the pivot door. The seal stops are attached to opposing sides of the pivot door and each seal stop couples with a pivot door hinge pin. Each seal stop includes a forward tab and an aft tab. The forward tabs of the seal stops make flush contact with the forward seal and the aft tabs make flush contact with the aft seal such that a continuous seal is formed between the pivot door and the fixed structure of the thrust reverser when the pivot door is stowed. | 05-21-2009 |
| 20090126151 | SYSTEM FOR ADJUSTMENT OF THRUST REVERSER PIVOT DOOR - A system that allows for quick and easy adjustment of the position of a thrust reverser pivot door comprises an actuator rod end bolt and a pair of pivot door hinge pins, all of which have an eccentric element. The actuator rod end bolt includes a cylindrical portion along the center of the length of the bolt that has an eccentric element which protrudes beyond the outer surface of the cylinder. Each pivot door hinge pin includes a cylindrical portion along the center of the length of the pin that has an eccentric element which protrudes beyond the outer surface of the cylinder. Rotation of either the actuator rod end bolt or the pivot door hinge pins or both the actuator rod end bolt and the pivot door hinge pins adjusts the position of the pivot door. | 05-21-2009 |
| 20090120586 | METHOD AND APPARATUS FOR FORMING ADHESIVE STRIPS - A method and apparatus for forming adhesive strips from an adhesive sheet. The apparatus may generally comprise a first forming wheel, a second forming wheel, and a cutting wheel including a plurality of circumferential grooves. The cutting wheel can be positioned in proximity to the first and second forming wheels to define a first formation interface with the first forming wheel and a second formation interface with the second forming wheel. The cutting wheel can be operable to receive at least a portion of the adhesive sheet and rotate to force at least a portion of the adhesive sheet through the first formation interface and the second formation interface such that the adhesive sheet is at least partially cut by at least one of the circumferential grooves at both the first and second formation interfaces to at least partially form the adhesive strips. | 05-14-2009 |
| 20090084204 | MECHANISM FOR ADAPTIVE CONTOUR COMPLIANCE - An apparatus for inspecting samples that may include a curvature that varies from sample to sample comprises a scanning element, a feed mechanism, and a pivot mechanism. The scanning element transmits and receives a signal to and from the sample as the sample passes by, thereby building an image or profile of the sample. The feed mechanism includes a drive motor coupled to a series of pulleys and belts that form an open-ended chain. The pulleys rotate when driven by the drive motor and are coupled to an array of rollers that rotate as well to propel a inspection sample past the scanning element. The pivot mechanism includes a series of primary and secondary links that also form an open-ended chain. The primary links are coupled to the rollers and the combination pivots in unison to form an arc that matches the curvature of the sample in order to maintain a fixed distance between the sample and the scanning element. | 04-02-2009 |
| 20090065963 | METHOD AND APPARATUS FOR TENSIONING COMPOSITE MATERIAL - An apparatus and method for tensioning material ( | 03-12-2009 |
| 20090051069 | RAPID RECONFIGURABLE FUSELAGE MANDREL - A system and method for making and using a reconfigurable composite part mandrel operable in the manufacture of composite parts. The system may comprise an assembly fixture, a generic mandrel, a reconfigurable simulated skin, a reconfigurable frame portion, and state-changing material operable to harden into a desired configuration for forming a particular composite part. The method of forming and using the reconfigurable composite part mandrel may comprise: inserting the simulated skin within the assembly fixture, inserting or assembling the frame portion within the assembly fixture; inserting the generic mandrel into the assembly fixture; filling a cavity between the generic mandrel and the assembly fixture with the state-changing mixture to encapsulate the frame portion; hardening the state-changing mixture; and removing the assembly fixture and the simulated skin. | 02-26-2009 |
| 20090037022 | SYSTEM AND METHOD FOR ROBOTIC ACCURACY IMPROVEMENT - A system and method for sensing and compensating for unintended joint movement of a robotic arm caused by application of a load. The system may have a plurality of external encoders each in intimate contact with an external edge portion of one of a plurality of robotic arm joints to sense joint movement caused by application of the load, and a computing device configured for calculating a compensation amount based on the sensed joint movement and sending the calculated compensation amount to a corresponding robot motor encoder to correct the position of the joint by the compensation amount. The method may comprise applying the load one portion at a time, such that a portion of the load is applied, the compensation amount is calculated, the position of the joint is corrected, and then the process repeats, with another portion of the load applied to the robotic arm. | 02-05-2009 |
| 20080281554 | SYSTEM AND METHOD FOR REPAIRING COMPOSITE PARTS - A composite repair system and method for assisting in the repair of a cured composite part in which a damaged portion has been cut out and removed, exposing a plurality of composite plies and their corresponding composite ply edges. The composite repair system may comprise a light source to illuminate the ply edges, an image capturing device to obtain an image of the ply edges, and a computing device for processing the image of the ply edges and creating a map of the ply edges based on the image. The map may be used to manufacture filler plies having peripheral edges shaped to correspond with the composite ply edges for replacing the damaged portion of the composite part. | 11-13-2008 |
