US 12,240,188 B2
Apparatus and method for manufacturing thermoplastic wrinkle coupons
Greg M. Reyneke, Everett, WA (US); Aaron R. Cowin, Dardenne Prairie, MO (US); Michael H. Larson, Mercer Island, WA (US); Kenndy San, Wentzville, MO (US); Emma L. Morrissey, Saint Louis, MO (US); and Andrew D. Wilkerson, Wentzville, MO (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Oct. 2, 2022, as Appl. No. 17/937,456.
Claims priority of provisional application 63/364,018, filed on May 2, 2022.
Prior Publication US 2023/0347599 A1, Nov. 2, 2023
Int. Cl. B29C 70/34 (2006.01); B29C 70/54 (2006.01); B29K 71/00 (2006.01); B29K 307/04 (2006.01); B29K 309/08 (2006.01); B29L 9/00 (2006.01)
CPC B29C 70/345 (2013.01) [B29C 70/545 (2013.01); B29K 2071/00 (2013.01); B29K 2307/04 (2013.01); B29K 2309/08 (2013.01); B29L 2009/00 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A frame-laminate assembly for forming a wrinkle in a thermoplastic laminate, comprising:
a thermoplastic laminate having a laminate outer surface and opposing laminate side edges, and comprised of multiple plies, each ply comprised of reinforcing fibers pre-impregnated with thermoplastic resin;
a laminate support frame, having a frame panel configured to support the thermoplastic laminate, the frame panel extending between opposing frame side members respectively located adjacent to the laminate side edges;
at least one wrinkle-forming element configured to extend across the laminate surface between the laminate side edges;
a pair of wrinkle-forming-element attachment mechanisms respectively on the frame side members, and configured to secure opposing ends of the wrinkle-forming element to the laminate support frame while applying tension to the wrinkle-forming element; and
wherein the wrinkle-forming-element attachment mechanisms are configured to support the wrinkle-forming element over the laminate outer surface during the application of heat to the thermoplastic laminate, and the application of compaction pressure on the wrinkle-forming element against the laminate outer surface, for urging the wrinkle-forming element into the thermoplastic laminate, thereby causing the wrinkle-forming element to form a wrinkle as an out-of-plane deformation in one or more of the plies.