Rohr, Inc.

Alan Richard Douglas

Ray Listak

Mark Alan Ramsey

Joseph Irrgang

Steve Holt

Gabriel Joseph Gutierrez

Steve Stubner

Steven Mark Ranum

An apparatus for forming a nacelle leading edge includes an actuation assembly, a punch, and a die. The punch is in communication with the actuation assembly and annularly disposed about a first axis. The punch is configured to mate with an interior surface of a preform. The die is in communication with the actuation assembly and disposed within the first axis. The die is configured to retain an exterior surface of the preform. The actuation assembly is configured to effect relative motion between the punch and the preform. The actuation assembly is configured to offset the punch so that the punch is annularly disposed about a second axis, different than the first axis.

Method and apparatus for forming a nacelle leading edge

Aspects of the disclosure are directed to a bonding of a first skin and a second skin to a core material, coupling a sheet to the first skin to form with the first skin an enclosure containing the second skin and the core material, exposing the first skin, the second skin, and the core material to heat, and based on the exposition of heat, applying pressure via the enclosure to the first skin to cause the first skin to deform and expand to a shape of a die.

Forming a complexly curved metallic sandwich panel

Adjoining edges of adjacent honeycomb core panel sections are mechanically interlocked. In one embodiment, the method includes forming a first edge along a first cellular core panel section. The first edge includes a first plurality of edge cell walls along the first edge. The method further includes forming a second edge along a second cellular core panel section, wherein the second edge includes a second plurality of edge cell walls along the second edge. The first edge is positioned proximate to the second edge. At least a portion of at least one of the first plurality of edge cell walls is mechanically interlocked with at least a portion of at least one of the second plurality of edge cell walls to form a joint therebetween. A composite structure may be at least partially produced by such a method.

Composite honeycomb structure

Adjoining edges of adjacent honeycomb core panel sections are mechanically interlocked. In one embodiment, the method includes forming a first edge along a first cellular core panel section. The first edge includes a first plurality of edge cell walls along the first edge. The method further includes forming a second edge along a second cellular core panel section, wherein the second edge includes a second plurality of edge cell walls along the second edge. The first edge is positioned proximate to the second edge. At least a portion of at least one of the first plurality of edge cell walls is mechanically interlocked with at least a portion of at least one of the second plurality of edge cell walls to form a joint therebetween. The invention also includes a composite structure at least partially produced by such a method.

Systems and methods for noise suppression are disclosed herein. In one embodiment, an acoustic structure has a core that includes a plurality of cells. Each of the plurality of cells includes one or more engaging structures for positioning a septum relative to the cell. The acoustic structure further includes a plurality of septums positioned relative to the plurality of cells.

System and method for noise suppression

The invention includes a joint assembly for connecting first and second longitudinal edges of portions of an acoustic barrel or panel having an open cell core, a perforated inner skin, and an outer skin. The joint assembly includes at least one strip covering a plurality of openings in walls of cells along the first and second longitudinal edges. The strip is separate from the inner and outer skins. A plate includes a first portion connected to the outer skin proximate to the first longitudinal edge, and a second portion connected to the outer skin proximate to the second longitudinal edge.

System for joining acoustic cellular panel sections in edge-to-edge relation

A 360&#xb0; tool for making a one-piece composite tubular structure, such as a skin of an acoustic liner, is adjustable between a molding position and a non-molding position. The tool includes a base, a fixed segment mounted to the base, first and second doors hingedly connected on either side of the fixed sector, and third door hingedly connected to the second door. The third door has a circumferential extent that is less than one-fourth that of either the first or second door. Sealing members are provided between the doors. Collectively, the fixed sector, and the first, second and third doors have a predetermined shaped surface that corresponds to a portion of the contour of the tubular structure to be formed. After composite material is applied on the outer surfaces of the fixed sector and the doors, a vacuum bag is formed to surround the composite material and also the joint areas on the inner surface of the tool. The entire tool may be placed in an autoclave for curing. The tool may also be used for the layup and bonding of an acoustic core sandwiched between pre-cured skins.

Apparatus and method for making a tubular composite barrel

The invention includes a method of joining edges of adjacent honeycomb core panel sections. In one embodiment, the method includes forming a first edge along a first cellular core panel section. The first edge includes a first plurality of edge cell walls along the first edge. The method further includes forming a second edge along a second cellular core panel section, wherein the second edge includes a second plurality of edge cell walls along the second edge. The first edge is positioned proximate to the second edge. At least a portion of at least one of the first plurality of edge cell walls is mechanically interlocked with at least a portion of at least one of the second plurality of edge cell walls to form a joint therebetween. The invention also includes a composite structure at least partially produced by such a method.

Method of joining composite honeycomb sections

A method for making a composite tubular structure, such as the inner skin of an acoustic liner, includes providing a tool that is adjustable between a molding position and a non-molding position. The tool has a base on which are mounted a plurality of sectors, each sector having an outer panel provided with a predetermined shaped surface. The predetermined shaped surface corresponds to a portion of the contour of the tubular structure to be formed. At least one of the sectors is fixed relative to the base while the remaining sectors are movable in a radial direction and separable from all the other sectors. The method includes adjusting the movable sectors until the tool is in the molding position, applying composite material on an outer surface of each sector, curing the composite material to form an inner skin, and removing the inner skin from the outer surface. The thus-formed composite tubular structure may be remounted on the tool for bonding to additional exterior layers.

Method for making a tubular composite structure

A tool for making a composite tubular structure, such as the inner skin of an acoustic liner, includes a base on which are mounted a plurality of sectors, each having an outer panel provided with a predetermined shaped surface. The predetermined shaped surface corresponds to a portion of the contour of the tubular structure to be formed. At least one of the sectors is fixed relative to the base while the remaining sectors are movable in a radial direction and separable from all the other sectors. The sectors are provided with air bearings to facilitate movement along a radial direction. Splice plates are used to form a joint between the outer panels of adjacent sectors. After composite material is applied on the outer panels, a vacuum bag is formed to surround the composite material and also the joint areas on the inner surface of the tool. The entire tool may be placed in an autoclave for curing. The thus-formed composite tubular structure may be remounted on the tool for bonding to additional exterior layers.

Growing community of inventors

Chula Vista, CA, United States of America

Alan Richard Douglas