John David Spalding

US Patent:

7857925, Dec 28, 2010

Filed:

Jun 15, 2007

Appl. No.:

11/764078

Inventors:

Russell L. Keller - Maple Valley WA, US
John F. Spalding - Renton WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B32B 41/00

US Classification:

156 64, 156 94, 156 98, 264 361, 264 3622

Abstract:

A protocol for determining process parameters for debulking composite laminates is established using a standardized a double vacuum debulk (DVD) process. This allows for the development of a rapid fabrication process for thick laminates of toughened carbon/epoxy composite materials. For rework, a single piece multilayer patch is made available for bonding with an adhesive layer to a prepared structural area.

US Patent:

7935200, May 3, 2011

Filed:

Jun 10, 2010

Appl. No.:

12/797901

Inventors:

Russell L. Keller - Maple Valley WA, US
John F. Spalding - Renton WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B32B 41/00

US Classification:

156 64, 156 94, 156 98, 264 361, 264 3622

Abstract:

A protocol for determining process parameters for debulking composite laminates is established using a standardized double vacuum debulk (DVD) process. This allows for the development of a rapid fabrication process for thick laminates of toughened carbon/epoxy composite materials. The protocol provides for obtaining cure and current consolidation information of a composite material system as a preliminary baseline. A test matrix is prepared for varying time/temp profiles to pursue better results or find process limits and the testing defined by the matrix is run with variations of time/temp DVD profiles to confirm data values. Results for the process variations in the test matrix are then assessed. An optimum consolidation is determined and process points are defined at which quality drops off. The protocol results are then applied to part preparation for the material tested.

US Patent:

20060274812, Dec 7, 2006

Filed:

Jun 7, 2005

Appl. No.:

11/146785

Inventors:

Morteza Safai - Seattle WA, US
Gary Georgeson - Federal Way WA, US
John Spalding - Renton WA, US
Jeffrey Thompson - Kent WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

G01N 17/00
G01J 5/00

US Classification:

374005000, 374057000, 374121000

Abstract:

Systems and methods for thermographically inspecting a composite material or honeycombed type structures are disclosed. In one embodiment, a system includes a thermal heat source configured to be either removably coupled to or positioned proximate to the composite material to generate a localized thermal field in a selected area of the composite material. A thermal imaging device generates a visible image of the generated thermal field.

US Patent:

20070095457, May 3, 2007

Filed:

Nov 2, 2005

Appl. No.:

11/163872

Inventors:

Russell Keller - Maple Valley WA, US
John Spalding - Renton WA, US
Steven Blanchard - Issaquah WA, US

Assignee:

THE BOEING COMPANY - Chicago

International Classification:

B29C 73/00

US Classification:

156094000

Abstract:

A fast line maintenance repair process for damaged composite structures includes the application of a pre-cured patch that uses a quick curing paste adhesive to bond the patch to the structure. The adhesive is cured at relatively low elevated temperatures provided by a chemical heat pack. The low temperature cure eliminates the need to dry out the part and permits the application of the repair in a hazardous environment. In a typical commercial airline application, airline maintenance personnel can install the repair at the flight gate. The repair is intended to restore the structure to a desired load capability in approximately one hour. The repair can be removed if need be with less overall damage than would occur upon removal of typical mechanically fastened repairs. All or some of the repair materials and tools can be provided in a portable kit.

US Patent:

20100276064, Nov 4, 2010

Filed:

Sep 4, 2009

Appl. No.:

12/554554

Inventors:

STEVE BLANCHARD - Issaquah WA, US
Aydin Akdeniz - Langley WA, US
John Spalding - Renton WA, US
David M. Anderson - Sammamish WA, US

International Classification:

B29C 73/10
B29C 73/12
B32B 3/10

US Classification:

156 94, 428137, 425 14

Abstract:

A patch may be used to rework a composite structure in the filed. The patch is bonded to the structure by a layer of adhesive and includes perforations that allow the escape of air from the adhesive as the patch is compressed against the structure. A spacer may be introduced between the patch and the structure to control the thickness of the adhesive layer.

US Patent:

20100276065, Nov 4, 2010

Filed:

Nov 6, 2009

Appl. No.:

12/613810

Inventors:

Steve Blanchard - Issaquah WA, US
Aydin Akdeniz - Langley WA, US
John Spalding - Renton WA, US
David M. Anderson - Sammamish WA, US
Michael W. Evens - Burien WA, US

International Classification:

B32B 37/18
B32B 7/12

US Classification:

156 94, 428343

Abstract:

A patch is used to rework an area of a structure. The patch is bonded to the structure by a layer of adhesive. A spacer placed between the patch and the structure is used to control the thickness of the adhesive and/or a bondline.

US Patent:

20230088819, Mar 23, 2023

Filed:

Nov 21, 2022

Appl. No.:

18/057546

Inventors:

- Chicago IL, US
John F. Spalding - Tukwila WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 73/04

Abstract:

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

US Patent:

20210129463, May 6, 2021

Filed:

Oct 30, 2019

Appl. No.:

16/669247

Inventors:

- Chicago IL, US
John F. Spalding - Tukwila WA, US

Assignee:

The Boeing Company - Chicago IL

International Classification:

B29C 73/04

Abstract:

Described are methods and systems for repair of composite components without the use of vacuum bagging, The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.