Rohr, Inc.

Jennifer Davis

Nathaniel M Gray

Raphael Medina

Karl Potier

Jerome Socheleau

Jose S Alonso-Miralles

Steven M Kestler

Gerald S Abille

Paul Dsouza

Alan K Cheung

A method is provided for manufacturing. During this method, a woven fiber sleeve is disposed over a mandrel to provide an overbraided mandrel. The woven fiber sleeve includes a base section and a mount section. The base section is wrapped circumferentially around the mandrel and extends longitudinally along the mandrel between a first end and a second end. The mount section is disposed longitudinally at an intermediate location between the first end and the second end. The mount section projects out from the base section. The overbraided mandrel is arranged with tooling. A polymer material is disposed with the woven fiber sleeve to provide a duct structure. The duct structure includes a tubular duct and an annular flange. The tubular duct is formed by the base section. The annular flange is formed by the mount section.

Forming duct structure with overbraided woven fiber sleeve

A method is provided for manufacturing. During this method, a first woven fiber sleeve is disposed over a first mandrel to provide a first overbraided mandrel. The first woven fiber sleeve is wrapped circumferentially around the first mandrel. An opening is formed through a side of the first woven fiber sleeve. A second woven fiber sleeve is disposed over a second mandrel to provide a second overbraided mandrel. The second woven fiber sleeve is wrapped circumferentially around the second mandrel. The second overbraided mandrel is arranged with the first overbraided mandrel. The second woven fiber sleeve engages the side of the first woven fiber sleeve. A second overbraid first end is disposed at and extends circumferentially around the opening. A polymer material is disposed with the first woven fiber sleeve and the second woven fiber sleeve to provide a duct structure.

An assembly is provided for an aircraft. This aircraft assembly includes an aircraft control surface and a hydraulic actuator. The hydraulic actuator includes a housing and a piston within the housing. The housing is formed integral with the aircraft control surface.

Aircraft control surface with integrated hydraulic actuator

A tool for fabricating a control surface is disclosed. In various embodiments, the tool includes a first block defining a longitudinal direction running between a leading edge end and a trailing edge end; a first sidewall spaced a first lateral distance from the first block to form a first closeout channel running in the longitudinal direction between the first block and the first sidewall; and a second sidewall configured to form a second closeout channel running in the longitudinal direction, the second closeout channel disposed laterally opposite the tool from the first closeout channel.

Method for fabricating an aircraft control surface

A method is provided for manufacturing during which a first duct section is formed with a tubular first sidewall. A first opening extends through the tubular first sidewall. The forming of the first duct section includes disposing a first woven fiber sleeve over a first mandrel and disposing a polymer material with the first woven fiber sleeve. A second duct section is disposed with a tubular second sidewall. The forming of the second duct section includes disposing a second woven fiber sleeve over a second mandrel and disposing the polymer material with the second woven fiber sleeve. The second duct section is arranged with the first duct section. The second duct section engages the tubular first sidewall. The tubular second sidewall is located at and extends circumferentially around the first opening. A duct structure is formed by attaching the second duct section to the first duct section.

An apparatus is provided for an aircraft propulsion system. This apparatus includes a duct structure, and the duct structure includes a transition duct, an inlet duct and a bypass duct. The duct structure is configured as a monolithic body. The transition duct includes an inlet, a first outlet and a second outlet. The transition duct extends longitudinally along a longitudinal centerline from the inlet to the second outlet. The first outlet is arranged longitudinally along the longitudinal centerline between the inlet and the second outlet. A centerline axis of the first outlet is angularly offset from the longitudinal centerline. The inlet duct extends longitudinally along the longitudinal centerline to the inlet. The bypass duct extends longitudinally along the longitudinal centerline from the second outlet.

Duct structure for aircraft propulsion system

A control surface for an aircraft may comprise an outer skin and a core coupled to the outer skin. The core may include a plurality of corrugations. A height of the core may decrease in a direction extending from a leading edge of the control surface to a trailing edge of the control surface.

Aircraft control surface having variable height corrugated core

A method for forming a fiber-reinforced thermoplastic acoustic panel may comprise: stacking plies of thermoplastic composite sheets to a first thickness to form a top sheet; stacking plies of thermoplastic composite sheets to a second thickness to form a backskin; staking plies of thermoplastic composite sheets to a third thickness to form a stiffening member; forming the top sheet in a first contour; forming the backskin in a second contour, the second contour being different from the first contour; forming the stiffening member comprising a shape having a plurality of peaks and troughs; bonding the stiffening member to the top sheet and the backskin; and perforating the top sheet.

Corrugated acoustic stiffening devices and methods

A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.

Corrugated stiffening devices utilizing peaks and valleys and methods of manufacture

An acoustic panel system is provided that includes a perforated first skin, a second skin and a core. The core is connected to the perforated first skin and the second skin. The core includes a plurality of chambers and a first constriction. Each of the chambers extends vertically through the core between the perforated first skin and the second skin. The chambers include a first chamber. The first constriction is configured to divide the first chamber into a plurality of fluidly coupled sub-chambers. The first constriction is configured from or otherwise includes a shape memory material.

Acoustic panel with reconfigurable chamber constrictions

An assembly is provided for an aircraft. This aircraft assembly includes an aircraft control surface. The aircraft control surface includes a first skin, a second skin and a support structure laterally between and connected to the first skin and the second skin. The support structure includes a spar, a first stiffener and a second stiffener. The spar extends spanwise within the aircraft control surface. The first stiffener extends longitudinally within the aircraft control surface to the spar. The second stiffener extends longitudinally within the aircraft control surface to the spar. An actuator receptacle projects longitudinally into the aircraft control surface from a base of the aircraft control surface to the spar. The actuator receptacle extends spanwise within the aircraft control surface between the first stiffener and the second stiffener.

Aircraft control surface with linear actuator

A method for forming a fiber-reinforced thermoplastic control surface may comprise: stacking plies of thermoplastic composite sheets to a first desired thickness to form a first skin; stacking plies of thermoplastic composite sheets to a second desired thickness to form a second skin; forming the first skin in a first contour; forming the second skin in a second contour; forming a stiffening member including a thermoplastic resin, the stiffening member including a shape having a plurality of peaks and troughs; assembling the stiffening member between the first skin and the second skin; and joining the stiffening member to the first skin and the second skin.

Thermoplastic composite panel with corrugated peaks and troughs stiffening systems and methods

An airfoil body is provided for an aircraft which includes a first skin, a second skin, a plurality of first stiffeners and a plurality of second stiffeners. The first stiffeners are configured from or otherwise include first stiffener composite material. The first stiffeners extends widthwise between and are connected to the first skin and the second skin. Each of the first stiffeners has a first stiffener longitudinal centerline that extends spanwise along the first skin and the second skin. The second stiffeners are configured from or otherwise include second stiffener composite material. The second stiffeners extend widthwise between and are connected to the first skin and the second skin. Each of the second stiffeners has a second stiffener longitudinal centerline that extends lengthwise along the first skin and the second skin.

Composite airfoil for an aircraft

A method of producing a cascade array and a cascade array is provided. The method includes: forming a plurality of strongbacks from a first thermoplastic material; forming a plurality of comb subassemblies, each said comb subassembly including one of the plurality of strongbacks and a plurality of vanes comprising a second thermoplastic material extending outwardly from the respective one of the plurality strongbacks; and attaching the plurality of comb subassemblies into a unitary structure to produce the cascade array.

Thrust reverser cascade array and method for producing the same

A thrust reverser door includes a backskin including an interior surface and an exterior loft surface. The thrust reverser door further includes a cover plate including a cover plate body having a first side and a second side opposite the first side. The thrust reverser door further includes a grid structure mounted to the second side of the cover plate body and the interior surface of the backskin.

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La Jolla, CA, United States of America

Jennifer Davis