Sikorsky Aircraft Corporation

United Technologies Corporation

Edward Joseph Fabian

Darryl Mark Toni

Jonathan Bremmer

Jeffrey George Sauer

William E Hovan, Iii

Paul H Denavit

Philip J Ramey

Alexander C Dublinski

Robert A Lacko

Gary J Jacaruso

Christian A Rogg

Bruce Fredric Kay

Neil W Cawthra

Kenneth M Furnes

James S Giampapa

Ronald J Cooper

Gregory A Davidson

Matthew T Turner

Alan Lee Dobyns

Joaquin Terceno

Lauren Robert Napier

Bruce Henry Barr

Jeffrey G Sauer

A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

Composite structure and core positioning ply

A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.

Composite structure core crush prevention

A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.

Lattice grid caul for honeycomb composite structure

A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Co-curing reusable elastomeric caul plate

A method of fabricating a conformal deltoid noodle includes providing a composite prepreg material having a predetermined length and a width, the predetermined length being aligned along a longitudinal axis; subjecting the composite prepreg material to a cutting process to form a notched section coextensive along the predetermined length; and rolling the composite prepreg material along its width to create the conformal deltoid noodle.

Conformal deltoid noodle for a composite structure

A helicopter with one or more components formed from a self extinguishing composite primary structure material to provide increased passenger safety. The self extinguishing composite primary structure material has a core formed from a fire retardant material, which core has a first surface and a second surface, and at least one ply of a structural graphite prepreg material bonded to each of the first surface and the second surface.

Self extinguishing composite primary structure

A pressure tolerant composite panel has an inner fiber reinforced layer, an outer fiber reinforced layer and an core disposed therebetween. In one embodiment of the invention, the inner layer has weakening structures incorporated at the peripheral edges thereof, and has an outer layer of a different and lower modulus of elasticity than the inner layer to provide some degree of elongation. When high internal forces are encountered, the weakening structures allow the inner layer to separate, with the outer layers stretching to absorb the forces without failure. Optionally, strengthening straps are position about the panel such that it is compartmentalized into discrete sections to contain damage in localized areas. In an alternative embodiment of the invention, the inner core is produced of a crushable material which has a yield strength sufficient to provide structural support under normal operating conditions. When a high pressure is encountered which exceeds the yield limit, the core is crushed to prevent force transmission to the outer layer. Such a composite panel assures survivability of the panel when subject to impact damage.

Pressure tolerant fuel tank panels

A method of fabricating a structural member having a stiffener bead therein. Prepreg plies or layers of high tensile strength fabric are laid up on a conformable caul plate. A rubber-like plug is prefabricated to the shape of the stiffener bead and is urged into a stiffener bead cavity of the caul plate by a metal tool to sandwich the prepreg plies between the caul and the plug. The caul and the plug cooperate to cause the prepreg plies to conform to the desired shape of the stiffener bead.

Method of fabricating a structural member having a stiffener bead therein

The method of fabricating a complex part made of composite material and having a plurality of panels oriented in diverse angular relationship, and utilizing a plurality of conformable cauls upon which the composite material is individually laid up and which cauls cooperate to form one of the molds used in the co-curing of the individually laid-up composite materials.

Method of fabricating a complex part made of composite material

A structural member made up of a plurality of bonded plies of high tensile strength woven fabric and molded to include at least one stiffener bead having elliptically shaped ends, and a structural part so fabricated.

Growing community of inventors

Oxford, CT, United States of America

Edward Joseph Fabian