Rohr, Inc.

Goodrich Corporation

Bryan Thai

Vijay V Pujar

Christopher Charles Koroly

Katherine E Waugh

Delphine Turpin

Patrick J Nolan

Joseph R Lemanski

A commingled fiber preform is provided. The commingled fiber preform includes a plurality of first fabric layers and a second fabric layer. The second fabric layer is positioned on top of the plurality of first fabric layers. The second fabric layer is joined to the plurality of first fabric layers via through thickness reinforcement (TTR) using a commingled thread. A transport depth of the TTR penetrates completely through a thickness of the second fabric layer and partially through a thickness of the plurality of first fabric layers. The commingled thread comprises carbon fibers commingled with fugitive fibers. The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids.

Commingled fiber preform architecture for high temperature composites

A commingled fiber preform is provided. The commingled fiber preform includes at least one first fabric layer and a second fabric layer. The second fabric layer is positioned on top of the at least one first fabric layer. The second fabric layer is joined to the at least one first fabric layer via through thickness reinforcement (TTR) using a commingled thread. A transport depth of the TTR penetrates completely through a thickness of the second fabric layer and an entirety of the at least one first fabric layer. The commingled thread comprises carbon fibers commingled with fugitive fibers. The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids.

A tooling element includes a flexible sleeve defining an interior cavity. The flexible sleeve includes a sealable access port extending through the flexible sleeve from the interior cavity to an exterior of the flexible sleeve. The tooling element further includes vacuum-packed tooling particulate disposed within and filling the interior cavity of the flexible sleeve.

Tooling element and methods for forming and using same

A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Method for fabricating composite structures using combined resin film and dry fabric

A system for forming a composite component includes a close mold tool defining a cavity that corresponds to a shape of the composite component and configured to receive a composite material. The system further includes a perforated release film defining a plurality of openings and configured to be positioned on a surface of the composite material within the cavity. The system further includes a breather configured to be positioned on the perforated release film, to allow a vacuum to be applied to the composite material through the breather and the plurality of openings, and to allow pressurized fluid to be applied to the perforated release film through the breather.

Vacuum pressurized molding

A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.

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Poway, CA, United States of America

Bryan Thai