Christopher G Harris

US Patent:

6814916, Nov 9, 2004

Filed:

Aug 30, 2002

Appl. No.:

10/233270

Inventors:

Kurtis S. Willden - Kent WA
Christopher G. Harris - Auburn WA
Barry P. Van West - Bellevue WA

Assignee:

The Boeing Company - Seattle WA

International Classification:

B29C 4320

US Classification:

264257, 264258, 264292, 264324

Abstract:

A method for forming composite materials is presented, including providing a composite charge wider than a first surface of a mandrel, and positioning the composite charge across the first surface of the mandrel. The portion of the composite charge overhanging the first surface of the mandrel is supported and urged against the mandrel while supporting the unbent portion of the composite charge substantially parallel to the first surface of the mandrel. The invention also provides a system, using a compression mold of forming bladders and heater plates, to form a composite charge over a mandrel, while supporting the unbent portions of the composite charge during forming substantially parallel to the upper surface of the mandrel. The present invention minimizes the shear zone where plies in the composite laminate charge slide past one another during the forming process reducing or eliminating out-of-plane fiber buckling.

US Patent:

7118370, Oct 10, 2006

Filed:

Aug 30, 2002

Appl. No.:

10/233269

Inventors:

Kurtis S. Willden - Kent WA, US
Raymond N. Henderson - Federal Way WA, US
Gary E. Pfitzner - Issaquah WA, US
Surendra R. Parekh - Auburn WA, US
Christopher G. Harris - Auburn WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 70/44

US Classification:

425504, 425389, 425414, 425294, 901 41, 901 30

Abstract:

A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.

US Patent:

7651650, Jan 26, 2010

Filed:

Aug 10, 2006

Appl. No.:

11/463784

Inventors:

Kurtis S. Willden - Kent WA, US
Raymond N. Henderson - Federal Way WA, US
Gary E. Pfitzner - Issaquah WA, US
Surendra R. Parekh - Auburn WA, US
Christopher G. Harris - Auburn WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 70/02
B29C 53/02
B29C 53/80
B29C 33/00

US Classification:

264258, 264292, 4254031, 425403

Abstract:

A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.

US Patent:

8142181, Mar 27, 2012

Filed:

Sep 16, 2004

Appl. No.:

10/942501

Inventors:

Kurtis S. Willden - Kent WA, US
Barry P. Van West - Bellevue WA, US
Christopher G. Harris - Auburn WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 70/28
B29C 51/08

US Classification:

425416, 264292

Abstract:

A method for forming composite materials is presented, including providing a composite charge wider than a first surface of a mandrel, and positioning the composite charge across the first surface of the mandrel. The portion of the composite charge overhanging the first surface of the mandrel is supported and urged against the mandrel while supporting the unbent portion of the composite charge substantially parallel to the first surface of the mandrel. The invention also provides a system, using a compression mold of forming bladders and heater plates, to form a composite charge over a mandrel, while supporting the unbent portions of the composite charge during forming substantially parallel to the upper surface of the mandrel. The present invention minimizes the shear zone where plies in the composite laminate charge slide past one another during the forming process reducing or eliminating out-of-plane fiber buckling.

US Patent:

8236222, Aug 7, 2012

Filed:

Nov 3, 2009

Appl. No.:

12/611599

Inventors:

Raymond N. Henderson - Federal Way WA, US
Gary E. Pfitzner - Issaquah WA, US
Surendra R. Parekh - Auburn WA, US
Christopher G. Harris - Auburn WA, US
Kurtis S. Willden - Kent WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B28B 11/08

US Classification:

264292, 264257, 264258

Abstract:

A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.

US Patent:

8491743, Jul 23, 2013

Filed:

Dec 15, 2009

Appl. No.:

12/638947

Inventors:

Doan D. Pham - Tacoma WA, US
Mark W. Tollan - Puyallup WA, US
Richard M. Outzen - Snohomish WA, US
John C. Lockleer - Everett WA, US
Christopher G. Harris - Auburn WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B32B 27/00
B64C 3/20

US Classification:

156242, 156229, 156299, 1563069, 24412313

Abstract:

A stabilizing mechanism for resisting relative movement of upper and lower laminates of a composite structure having a core comprises a lower grip strip and at least one upper grip strip. The lower grip strip may be mounted to a tool upon which the composite structure may be processed. The lower grip strip may include an outer surface having at least one engagement feature for engaging at least one of the upper and lower laminates which make up the composite structure. The upper grip strip may have opposing outer surfaces which may include at least one engagement feature for engaging the lower strip and at least one of the upper and lower laminates.

US Patent:

8540833, Sep 24, 2013

Filed:

May 16, 2008

Appl. No.:

12/122124

Inventors:

Lyle R. Deobald - Shoreline WA, US
John D. Morris - Seattle WA, US
Karl B. Lee - Kirkland WA, US
Jeffery L. Marcoe - Bellevue WA, US
Mark C. Iden - Burien WA, US
Christopher G. Harris - Auburn WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

D04H 3/00
B29B 11/16

US Classification:

156180, 156181, 156245, 156292, 156293, 264241, 2642711, 428 61

Abstract:

A composite stiffener is fabricated using preforms of laminated, unidirectional composite tape. The stiffener includes a void that is reinforced by a filler wrapped with a structural adhesive. The surfaces of the preforms surrounding the void include a layer of composite fabric which is bonded to the filler by the adhesive, thereby increasing the toughness of stiffeners around the void and improving pull-off strength of the stiffener.

US Patent:

8632653, Jan 21, 2014

Filed:

May 3, 2005

Appl. No.:

11/119756

Inventors:

Todd A. Brown - Olympia WA, US
Stephen Douglas Friddell - Issaquah WA, US
Christopher G. Harris - Auburn WA, US
Andrew E. Modin - Enumclaw WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 65/00
B27N 3/10
B32B 9/04

US Classification:

1563041, 156196, 156264, 264235, 264236, 264257, 264258

Abstract:

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