Patents Assigned to Hexcel Corporation
  • Method of molding complex composite parts using pre-plied multi-directional continuous fiber laminate
    Patent number: 8263205
    Abstract: Layers of unidirectional (UD) fiber prepreg are formed into a pre-plied, multi-directional, continuous fiber laminate that is used as a molding compound to form three dimensional structures. Cut-outs from the laminate are slotted and folded along fold lines to provide near-net-shaped preforms that may be compression molded to form fiber-reinforced composite structures having complex shapes.
    Type: Grant
    Filed: September 17, 2009
    Date of Patent: September 11, 2012
    Assignee: Hexcel Corporation
    Inventor: Matthew Kweder
  • AEROSPACE ARTICLES MADE FROM QUASI-ISOTROPIC CHOPPED PREPREG
    Publication number: 20120223183
    Abstract: Quasi-isotropic chopped prepreg is used to make parts found in aerospace vehicles. Exemplary aerospace parts that are made using quasi-isotropic chopped prepreg include aircraft window frames, wing fairing supports, flange supports, frame gussets, rudder actuator brackets, shear ties, seat pedestals, cargo floor flange supports, storage bin fittings, antenna supports, torque tube pans, handle boxes, side guide fittings, wing box covers and intercostals.
    Type: Application
    Filed: April 12, 2012
    Publication date: September 6, 2012
    Applicant: HEXCEL CORPORATION
    Inventors: Bruno S. Boursier, Jack D. Fudge
  • Mold for use in making composite structures
    Patent number: 8257631
    Abstract: Machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.
    Type: Grant
    Filed: May 30, 2011
    Date of Patent: September 4, 2012
    Assignee: Hexcel Corporation
    Inventor: Richard A. Callis
  • Aerospace articles made from quasi-isotropic chopped prepreg
    Patent number: 8212194
    Abstract: Quasi-isotropic chopped prepreg is used to make parts found in aerospace vehicles. Exemplary aerospace parts that are made using quasi-isotropic chopped prepreg include aircraft window frames, wing fairing supports, flange supports, frame gussets, rudder actuator brackets, shear ties, seat pedestals, cargo floor flange supports, storage bin fittings, antenna supports, torque tube pans, handle boxes, side guide fittings, wing box covers and intercostals.
    Type: Grant
    Filed: July 24, 2009
    Date of Patent: July 3, 2012
    Assignee: Hexcel Corporation
    Inventors: Bruno S. Boursier, Jack D. Fudge
  • Aerospace articles made from quasi-isotropic chopped prepreg
    Patent number: 8177168
    Abstract: Quasi-isotropic chopped prepreg is used to make parts found in aerospace vehicles. Exemplary aerospace parts that are made using quasi-isotropic chopped prepreg include aircraft window frames, wing fairing supports, flange supports, frame gussets, rudder actuator brackets, shear ties, seat pedestals, cargo floor flange supports, storage bin fittings, antenna supports, torque tube pans, handle boxes, side guide fittings, wing box covers and intercostals.
    Type: Grant
    Filed: November 16, 2011
    Date of Patent: May 15, 2012
    Assignee: Hexcel Corporation
    Inventors: Bruno S. Boursier, Jack D. Fudge
  • Helicopter blade mandrel
    Patent number: 8163219
    Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.
    Type: Grant
    Filed: May 26, 2010
    Date of Patent: April 24, 2012
    Assignee: Hexcel Corporation
    Inventors: Richard A. Callis, Joe White, Jane White, legal representative, Scott Newkirk
  • SOLVENT RESISTANT THERMOPLASTIC TOUGHENED EPOXY
    Publication number: 20120088863
    Abstract: Thermoplastic toughened epoxy resin for use in making prepreg for aerospace applications. The resin includes an epoxy resin component comprising a tri functional epoxy resin and/or tetra functional epoxy, a thermoplastic component and 4,4?-Bis(p-aminophenoxy)biphenyl (BAPB) as the curing agent. The use of BAPB as a curative was found to increase the resistance of the cured resin to attack by solvents.
    Type: Application
    Filed: October 12, 2010
    Publication date: April 12, 2012
    Applicant: Hexcel Corporation
    Inventor: Yen-Seine Wang
  • SOLVENT RESISTANCE OF EPOXY RESINS TOUGHENED WITH POLYETHERSULFONE
    Publication number: 20120088864
    Abstract: The solvent resistance of epoxy resins toughened with polyethersulfone is improved by using low molecular weight polyethersulfone. The resulting thermoplastic toughened epoxy resins are useful for making prepreg for aerospace applications.
    Type: Application
    Filed: October 12, 2010
    Publication date: April 12, 2012
    Applicant: Hexcel Corporation
    Inventor: Yen-Seine Wang
  • AEROSPACE ARTICLES MADE FROM QUASI-ISOTROPIC CHOPPED PREPREG
    Publication number: 20120055006
    Abstract: Quasi-isotropic chopped prepreg is used to make parts found in aerospace vehicles. Exemplary aerospace parts that are made using quasi-isotropic chopped prepreg include aircraft window frames, wing fairing supports, flange supports, frame gussets, rudder actuator brackets, shear ties, seat pedestals, cargo floor flange supports, storage bin fittings, antenna supports, torque tube pans, handle boxes, side guide fittings, wing box covers and intercostals.
    Type: Application
    Filed: November 16, 2011
    Publication date: March 8, 2012
    Applicant: Hexcel Corporation
    Inventors: Bruno S. Boursier, Jack D. Fudge
  • ACOUSTIC HONEYCOMB WITH PERFORATED SEPTUM CAPS
    Publication number: 20120037449
    Abstract: An acoustic structure that includes a honeycomb having cells in which septum caps are located. The septum caps are formed from sheets of flexible material that may be perforated before or after the material is inserted into the honeycomb. The flexible material is sufficiently flexible to allow folding into the shape of a septum cap. The flexible material is also sufficiently stiff to provide frictional engagement and locking of the septum cap to the honeycomb cell when the cap is inserted into the honeycomb during fabrication of the acoustic structure. An adhesive is applied to the septum caps after the caps have been inserted into the honeycomb cells to provide a permanent bond.
    Type: Application
    Filed: October 24, 2011
    Publication date: February 16, 2012
    Applicant: Hexcel Corporation
    Inventor: Earl Ayle
  • MACHINABLE COMPOSITE MATERIAL
    Publication number: 20120040169
    Abstract: An assembly that includes a first part composed of a fibrous structure that includes fibers and a cured resin matrix. The fibrous structure has at least one surface and a layer that is located on the surface. The layer includes a discontinuous fiber composite that is composed of randomly oriented short fibers and a cured resin matrix wherein the layer has been machined to provide a machined surface. The assembly also includes a second part that is attached to the first part. The second part includes at least one surface that fits against the machined surface on the first part.
    Type: Application
    Filed: August 31, 2011
    Publication date: February 16, 2012
    Applicant: Hexcel Corporation
    Inventor: Bruno Boursier
  • Helicopter Blade Mandrel With Roller Assembly
    Publication number: 20120034090
    Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.
    Type: Application
    Filed: October 19, 2011
    Publication date: February 9, 2012
    Applicant: Hexcel Corporation
    Inventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
  • Composite materials with blend of thermoplastic particles
    Patent number: 8097333
    Abstract: Pre-impregnated composite material (prepreg) is provided that can be cured to form composite parts that have high levels of damage tolerance. The matrix resin includes a thermoplastic particle component that is a blend of particles that have a melting point above the curing temperature and particles that have a melting point at or below the curing temperature.
    Type: Grant
    Filed: March 7, 2011
    Date of Patent: January 17, 2012
    Assignees: Hexcel Corporation, Hexcel Composites, Ltd.
    Inventors: David Tilbrook, Dana Blair, Maureen Boyle, Paul Mackenzie
  • Helicopter blade mandrel with roller assembly
    Patent number: 8066504
    Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.
    Type: Grant
    Filed: January 25, 2008
    Date of Patent: November 29, 2011
    Assignee: Hexcel Corporation
    Inventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
  • Acoustic septum cap honeycomb
    Patent number: 8066098
    Abstract: An acoustic structure that includes a honeycomb having cells in which septum caps are located. The septum caps are formed from sheets of acoustic material and include a resonator portion and a flange portion. The flange portion has an anchoring surface that provides frictional engagement of the septum caps to the honeycomb cells when the caps are inserted into the honeycomb during fabrication of the acoustic structure. An adhesive is applied to the anchoring surface of the septum caps after the caps have been inserted into the honeycomb cells to provide a permanent bond.
    Type: Grant
    Filed: December 6, 2010
    Date of Patent: November 29, 2011
    Assignee: Hexcel Corporation
    Inventor: Earl Ayle
  • Composite Materials With Improved Performance
    Publication number: 20110262630
    Abstract: A composite material comprising at least one polymeric resin and optionally at least one fibrous reinforcement where the polymeric resin comprises at least one difunctional epoxy resin and at least one epoxy resin with a functionality greater than two having at least one meta-substituted phenyl ring in its backbone.
    Type: Application
    Filed: July 1, 2011
    Publication date: October 27, 2011
    Applicants: Hexcel Corporation, Hexcel Composites Limited
    Inventors: David Tilbrook, Dana Blair, Paul Mackenzie, Maureen Boyle
  • Composite Material For Structural Applications
    Publication number: 20110259514
    Abstract: Composite material that contain epoxy resin which is toughened and strengthened with thermoplastic materials and a blend insoluble particles. The uncured matrix resins include an epoxy resin component, a soluble thermoplastic component, a curing agent and an insoluble particulate component composed of elastic particles and rigid particles. The uncured resin matrix is combined with a fibrous reinforcement and cured/molded to form composite materials that may be used for structural applications, such as primary structures in aircraft.
    Type: Application
    Filed: April 21, 2010
    Publication date: October 27, 2011
    Applicants: Hexcel Composites Ltd., Hexcel Corporation
    Inventors: Maureen Boyle, Dana Blair, Yi-Jui Wu, Yen-Seine Wang, Bryce Floryancic, Paul Mackenzie
  • Epoxy resins with improved burn properties
    Patent number: 8039109
    Abstract: Epoxy resin compositions that generate reduced levels of sulfur dioxide and which unexpectedly have reduced self-extinguishing times. The epoxy resins are composed of from 50 to 70 weight percent of an epoxy resin component. The epoxy resin composition also includes from 15 to 35 weight percent of a thermoplastic blend that is composed of polyetherimide and polyamideimide. The epoxy resin composition further includes from 5 to 25 weight percent of a curative agent.
    Type: Grant
    Filed: October 7, 2008
    Date of Patent: October 18, 2011
    Assignee: Hexcel Corporation
    Inventors: Yen-Seine Wang, Yi-Jui Wu
  • Pressurized molding of composite parts
    Patent number: 8034278
    Abstract: Apparatus and methods for molding composite bodies into composite parts using pressure. A lower inflexible mold is combined with an elastic upper mold layer to form a molding cavity in which the composite body to be molded is placed. An elastic pressure layer is used in combination with the upper mold layer to form a pressure chamber. A flexible expansion control layer is used to limit the increase in surface area of the pressure layer during pressurization. A perimeter retention lock is provided to prevent the perimeters of the elastic and flexible layers from moving inward or away from the lower mold during application of pressure to the pressure chamber.
    Type: Grant
    Filed: January 13, 2006
    Date of Patent: October 11, 2011
    Assignee: Hexcel Corporation
    Inventor: Alfonso Lopez
  • Composite materials with improved burn properties
    Patent number: 8034453
    Abstract: Epoxy resins and composite materials that generate reduced levels of sulfur dioxide and which unexpectedly have reduced self-extinguishing times. The epoxy resins are composed of from 50 to 70 weight percent of an epoxy resin component. The epoxy resin composition also includes from 20 to 35 weight percent of a thermoplastic blend that is composed of polyetherimide and polyamideimide. The epoxy resin composition further includes from 5 to 25 weight percent of a curative agent. The composite materials may be used for primary structures in aircraft and other load-bearing structures.
    Type: Grant
    Filed: September 29, 2009
    Date of Patent: October 11, 2011
    Assignee: Hexcel Corporation
    Inventors: Yen-Seine Wang, Yi-Jui Wu