Northrop Grumman Systems Corporation

Other

Carl Andrew Reis

Doris Andren Reis

Nicholas T Castellucci

Chandrakant Himatlal Shah

Robert W Koon

Christopher H Husmann

Benjamin S Wong

Douglas Dean Decker

Thomas J Ambrose

Tod Palm

John C Del Ferraro

Timothy Alan Dyer

Chi Hsien Sheu

George V Case

Richard A Osterman

A sandwich panel includes a honeycomb core of a plurality of cells. A first skin is adhered to a first surface of the honeycomb core with an adhesive. A second skin is adhered to a second surface of the honeycomb core with the adhesive. The plurality of cells extend longitudinally between the first and second skins. The first and second skins adhere to the honeycomb core to form a sandwich panel having a surface area of at least 2.25 square feet. A foam fill is disposed within the cells of the honeycomb core. The foam fill and the honeycomb core define a first gap region proximate to the first skin and a second gap region proximate to the second skin.

End gaps of filled honeycomb

A technique and tool are provided for repairing damaged areas of honeycomb structures. The tool includes a plurality of rods axially translatable into the damaged area. Foam material is inserted about the rods and allowed to cure. The rods are later withdrawn leaving a porous core of material. Sleeves may be provided to receive and support the rods as they translate into the damaged area. The sleeves may remain in the damaged area after the rods are withdrawn into the sleeves.

Syntactic tunnel core

The invention is a process for forming a preform for use in a structure having at least one curved portion of a specific length, including the steps of: 1) providing a preform having cable of expanding in length threads in rows parallel to the direction of curvature over a length equal to the length requiring curvature, such that the gaps between each thread row are spaced from the gaps in the adjacent tread rows; and 2) stretching the portions of the preform requiring curvature in a sine-wave pattern.

Process for making a curved preform made from woven composite materials

The invention is a process for forming a 3D woven PI shaped cross-section preform having a first and second bottom foot portions and first and second upstanding leg portions for use in a structure having at least one curved portion of a specific length. In detail, the process includes the steps of: 1) cutting the treads parallel to the direction of curvature into over a length equal to the length, such that the cuts in each thread are spaced from the cuts in the adjacent treads; 2) stretching the portions of the preform requiring curvature; and 3) forming the curvature in the preform.

Process for making a curved PI shaped preform made from woven composite materials

There is provided a pressure bonding system for applying pressure onto at least one tile of a workpiece. This system comprises upper and lower gripper members each having first and second gripper ends. The second gripper ends are connected to each other. The first gripper ends are movable relative to each other to receive the workpiece therebetween. Moreover, an upper pressure applicator assembly is slidably engaged to the upper gripper member. The upper pressure applicator assembly is slidable along the upper gripper member between the first and second ends along a length of the workpiece. The workpiece is placed between the upper and lower gripper members with an edge thereof being adjacent the second gripper ends. The upper pressure applicator applies pressure to the tile(s) upon relative movement of the first ends towards the workpiece to a position adjacent the tile(s).

Positive pressure hot bonder

A pressure regulated structure includes a first layer, a second layer, a non-metallic honeycomb assembly, and a vent. The honeycomb assembly is between the first layer and the second layer and includes a plurality of walls forming cells, at least some of the walls including laser-formed apertures to allow fluid communication between cells. The vent is fluidly coupled to the honeycomb assembly, wherein fluid in the cells of the honeycomb assembly may be removed through the vent to decrease pressure in the structure.

Pressure regulated structure

A drying tool for drying moisture present in cells of a honeycomb core. The tool includes an inflatable bladder compartment having a bendable exterior surface and a plurality of open-ended nozzles protruding from this exterior surface, with each nozzle having a passage in fluid communication with the bladder compartment. A connector element is connectible with a hot air source for delivering hot air into the bladder compartment for subsequent dispatch through the plurality of nozzles. Preferably, the nozzles are situated in a grid formation and are of a generally conical configuration. In use, the bendable exterior surface with the protruding nozzles is bowed or curved to generally configure to the exterior shape of the honeycomb core such that hot air is pinpointed in a grid pattern to drive heated air into the core and thereby cause circulation through the core cells for moisture evaporation.

Drying tool for honeycomb core

A cured composite material formed in accordance with the method of the present invention. The method initially providing for providing a peel-ply sheet which defines opposed planar faces. A multitude of elongate bond fibers are embedded into the peel-ply sheet in a manner wherein a majority of the bond fibers do not extend in co-planar relation to the planar faces of the peel-ply sheet. A resin composite material is provided. The peel-ply sheet is applied to the resin composite material such that the bond fibers are partially embedded therein. The resin composite material is cured. The peel-ply sheet is removed from the cured resin composite material such that the bond fibers remain implanted therein.

Cured composite material formed utilizing Z-peel sheets

In accordance with the present invention, there is provided a pressure applicator device for applying pressure to a repair patch of a repair surface. The pressure applicator device is provided with a generally annular suction member for providing suction attachment to the repair composite surface about the repair patch. The pressure applicator device is further provided with a cover member which is disposable above and across the suction member. The cover member is attached to the suction member. The pressure applicator device is further provided with a flexible pressure bladder formed of a generally fluid tight elastic material which is disposed beneath the cover member and interior to the suction member. The pressure bladder defines upper and lower chambers. The upper chamber is disposed between the cover member and the pressure bladder. The lower chamber is disposable between the pressure bladder and the repair surface. The pressure bladder is sized and configured to apply pressure to the repair patch upon fluid evacuation of the lower chamber.

Repair pressure applicator

A pressure application device for applying pressure to a repair patch of a variable contoured aircraft surface, the pressure applicator device is provided with an inflatable pressure bladder. The bladder is configured for applying pressure to the repair patch and is formed of a generally fluid tight elastic material. The pressure applicator device is further provided with at least one variable direction adjustable arm. The arm is disposed in mechanical communication with the bladder for facilitating the application of pressure by the bladder to the repair path upon inflation of the bladder. The bladder is further provided with at least one suction device for providing suction attachment to the aircraft surface. The bladder is attachable to a respective one of the at least one variable direction adjustable arm. The arm facilitates selective attachment of the respective suction device to the variable contoured aircraft surface while maintaining the position of the bladder with respect to the repair path.

Repair pressure applicator for in the field damaged aircraft

A system is provided for filling a gap between adjoining coplanar first and second sheet members mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces. A permanent gap filler member of predetermined shape and size intended for eventual permanent reception in the gap is employed for partially filling the gap. A temporary gap filler tool which includes a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, has an abutting surface for contiguous engagement with the first edge surface of the first sheet member when advanced to an attached position before the permanent gap filler member is mounted in the gap, a minor gap surface facing opposite said abutting surface, and means for releasably attaching the temporary gap filler tool to the first sheet member. A minor gap is thereby defined between the temporary gap filler element and the second edge surface of the second sheet member. Fairing material is initially laid down as an epoxy resin slurry in a minor gap resulting between the substitute gap filler element and the second edge surface of the second sheet member, then cured to hardened form having a substitute second edge surface contiguous with the minor gap surface of the substitute gap filler element. Thereafter, the temporary gap filler is removed from the gap and the permanent gap filler member is inserted and bonded to the common substrate resulting in the entire gap being filled.

Gap standardization technique for specialized fillers

A method for repairing a multi-layered damage area in a multi-layered composite structure. The method first includes obtaining depth measurement data, and obtaining topographical measurement data by laser scanning the surface of the damage area. This depth measurement data and topographical measurement data are inputted into a microprocessor along with thickness data of each layer. All inputted information is correlated among itself to thereby internally produce a three-dimensional damage area display-replica and interpolate a two-dimensional pattern of each layer of the damage area and of the surface of the damage area. The damage area is removed by first projecting a two-dimensional laser pattern of the damage area thereat on the surface of the structure, and thereafter manually removing the area to produce a void. Repair is accomplished by projecting onto respective replacement material a two-dimensional laser image pattern of each layer and manually cutting that layer according to the appropriate pattern. The cut layers then are arranged in accord with construction of the removed damage area to form a plug that is placed within the void.

Growing community of inventors

Torrance, CA, United States of America

Carl Andrew Reis