Sundstrand Corporation

Auto Air Composites, Inc.

John F Scanlon

David W Okey

Gary W Wigell

Hossein Saatchi

William D Sherman

John S Church

Jeffrey D Nelson

Gary A Wigell

Joel E Oman

Thomas A Bolgert

David M Moorehouse

James L Kasarsky

Shawn A Warner

Alan D Bengtson

An integrated structural composite panel and ceramic flame barrier which is a structural load bearing support member while exhibiting superior flame resistant characteristics. There is a first layer which is a structural polymer composite which defines the form of the finished supporting member. A second layer is a fiber reinforced film adhesive which binds the third layer to the first layer. The third layer is a polymer precursor of a ceramic matrix which exhibits polymeric properties at a lower temperature and ceramic matrix properties at a higher temperature. The three layers are co-cured in a one step process.

Integrated structural composite and ceramic flame barrier

A thrust vectoring panel which is a hybrid ceramic/ceramic composite consisting of three layers of lightweight materials, the anisotropic properties of which are manipulated such that the properties of the materials, i.e., the coefficient of thermal expansion, the strain energy release rate, and the tensile and flexure modules, either match or gradually transition from material to material. The three layers include a face layer which is of a high temperature capable material that can withstand temperatures within a range of 2300.degree.-25000.degree. F. for an extended period of time and a temperature as high as 28000.degree. F. for a short period of time. The middle layer simply is an insulating layer for providing adequate thermal insulation for the activator mechanism for the thrust panel. The third layer is a skeletal structure or layer which is of a lightweight material having sufficient strength to support all the integral interfaces, such as the activator mounts and the like.

Lightweight thrust vectoring panel

A hybrid metal/composite spinner cone used in aircraft applications and a method of manufacturing the same. The spinner cone has a metal outer shell which is bonded during the molding process to an inner structural member of thermoplastic composite. The metal shell imparts several desirable characteristics to the spinner cone such as impact resistance, erosion resistance, appearance, and supplying a lightning strike material to protect the composite structure. The thermoplastic composite has significant property advantages over metal or thermoset systems. The hybrid metal/composite spinner cone is manufactured using a ceramic mold which is less expensive and more readily available than a steel mold. The metal shell provides a barrier between the thermoplastic composite and the ceramic mold and allows the finished spinner cone to be easily released from the mold.

Method of manufacturing a metal/composite spinner cone

A continuous fiber reinforced composite panel and a one-step method of molding it using a high viscosity, thermoplastic matrix. The high viscosity, thermoplastic material is in the form of fibers and the fibers are commingled with reinforcing fibers producing a dry woven matte. The dry woven matte is placed in a mold and heated under pressure around a pin mandrel forming part of the mold. The method of forming the panels is a one-step method using a two-piece mold, one-half of which includes a pin mandrel having formed thereon a plurality of permanent die pins corresponding in number to the number of holes to be formed in the perforated composite panel. The other half of the mold has holes or cavities formed therein corresponding in number to the number of pins and into which these die pins are received when the mold is closed. The method simply is to place the dry woven matte over the die pins in the mold and to then close the mold. The mold is placed in a press and heat and pressure is applied to the mold. The mold then is allowed to cool and the pressure released. The perforated composite panel then is removed from the mold. Tougher perforated composite panels can be formed by interleaving in the mold the dry woven matte with film versions, or powder versions, of the same high viscosity thermoplastic material used in the matte.

One step molded continuous fiber reinforced perforated composite panels

A hybrid metal/composite spinner cone used in aircraft applications. The spinner cone has a metal outer shell which is bonded during the molding process to an inner structural member of thermoplastic composite. The metal shell imparts several desirable characteristics to the spinner cone such as impact resistance, erosion resistance, appearance, and supplying a lightning strike material to protect the composite structure. The thermoplastic composite has significant property advantages over metal or thermoset systems. The hybrid metal/composite spinner cone is manufactured using a ceramic mold which is less expensive and more readily available than a steel mold. The metal shell provides a barrier between the thermoplastic composite and the ceramic mold and allows the finished spinner cone to be easily released from the mold.

Metal/composite spinner cone

A method of fabricating a composite structure having at least one skin molecularly bonded to a core. A skin is provided of reinforcing fibrous material and a thermoplastic matrix. The skin is thermoformed to the general exterior shape of the composite structure. A core having a thermoplastic matrix complementary to the matrix of the skin is molded into the general shape of the composite structure. The skin and the core are placed in juxtaposition in a final forming mold. A thermoplastic material is injected into the final forming mold under isostatic conditions. The thermoplastic material is complementary to the thermoplastic matrices of the skin and the core.

Method of fabricating composite structures

A method of fabricating a composite structure having at least one skin molecularly bonded to a core. A skin is provided of reinforcing fibrous material and a thermoplastic matrix. The skin is thermoformed to the general exterior shape of the composite strucutre. The skin is placed in a mold, and a core material is injected into the mold against the skin under isostatic conditions. The core material includes a thermoplastic matrix compatible to the thermoplastic matrix of the skin to form a molecular bond therewith.

A method is provided for improving the adhesion of a substrate material which does not form stable bonds to a bondable material by applying high energy bondable ions to the surface of the substrate to create an interface alloy layer and then adhering a bondable material to the surface of the substrate material. The high energy ions used may be meal ions. Before adhering, the thickness of the interface layer may be increased to form a layer utilizing conventional processes such as flame spray, plasma spray or D-gun spray. Additionally, the method may be used to join similar or dissimilar first and second substrate materials.

Enhanced adhesion of substrate materials using ion-beam implantation

A composition for a pressure molded core of a composite structure, including a thermal plastic resin. The composition also includes a component to reduce the coefficient of thermal expansion, a lightweight high compressive strength filler, and a blowing agent. The thermoplastic resin may be polyetheretherketone, the component may be carbon fibers, and the filler may be hollow glass microspheres.

Dimensionally-stable lightweight core for composite structures

A self-locking retention system is provided for a composite rotor blade supported on a rotor hub. A radially extending, stud-like retention member is provided on the rotor hub. A composite thickness projects radially inwardly from the rotor blade and substantially surrounds the retention member. The composite thickness is woven in a pattern which grips the retention member in response to outward forces applied to the rotor blade and the woven composite thickness.

Means and method for securing a composite rotor blade

A heat exchanger is illustrated in the form of a pair of juxtaposed chambers defining a first flow path for passing a heated fluid therethrough and a second flow path for passing a cooling medium therethrough. A heat exchanging structure extends between the first and second flow paths in communication therewith. The heat exchanging structure includes at least one composite of thermally conductive fibrous material laid up unidirectionally in a direction between the flow paths for transferring heat from the heated fluid in the first flow path for absorption by the cooling medium in the second flow path.

Heat exchanger

In order to accommodate post-manufacturing, or secondary operations in precision assemblies using composite materials, where the secondary operations consist of drilling, machining, grinding, lapping, or other material-removing processing, without the need to resort to expensive diamond tooling and while maintaining needed structural integrity, a composite formed of a base material, a matrix, and a machineable material is provided. The matrix is bonded to the base material and the machineable material is rendered integral with the matrix and sufficiently thick to accommodate subsequent material-removing processing to a precision dimension. By utilizing the composite, method of forming the composite, and article of manufacture, it is possible to take advantage of the characteristics of high strength and light weight even in precision assemblies due to the fact that the machineable surface is not required for structural integrity, and the machineable surface can be applied for initial machining or other material-removing processing and reapplied for subsequent machining or other material-removing processing to restore worn or damaged surfaces.

Composite, method of forming a composite, and article of manufacture

Ballscrew actuators are well known for use as a primary flight control actuator for operating a flight control surface. The operation of the ballscrew actuator is critical to the success of an aircraft mission; however, when the actuator is subject to ballistic fire, a projectile hit which is not totally destructive can still render the actuator inoperable. Increasing the potential for operability of the ballscrew actuator after a projectile hit which is not totally destructive will increase the number of successful returns from aircraft missions. The ballistic tolerant dual load path ballscrew actuator has a selectively-driven ballnut and a ballscrew drivingly connected to the ballnut. The ballscrew has an outer tubular member with an external helical ball groove providing a primary load path. An inner tubular member fits closely within and is fixed to the outer tubular member to provide a secondary load path upon cracking of the outer tubular member by a projectile passing through the outer tubular member. The inner tubular member is formed of ballistic tolerant composite material to maintain its structural integrity when contacted by a projectile which has passed through and cause cracking of the outer tubular member. In one embodiment, the inner tubular member has an outer energy absorbing layer of a ceramic material. In another embodiment, the inner tubular member is preloaded in tension to prevent propagation of a circumferential crack in the outer tubular member and is constructed of wound fibers providing ballistic tolerance and strength in torsion and tension.

Ballistic tolerant dual load path ballscrew and ballscrew actuator

Ballscrew actuators are well known for use as a primary flight control actuator for operating a flight control surface. The operation of the ballscrew actuator is critical to the success of an aircraft mission; however, when the actuator is subject to ballistic fire a projectile hit which is not totally destructive can still render the actuator inoperable. Increasing the potential for operability of the ballscrew actuator after a projectile hit which is not totally destructive will increase the number of successful returns from aircraft missions. The ballistic tolerant dual load path ballscrew actuator has a selectively driven ballnut and a ballscrew drivingly connected to the ballnut. The ballscrew has an outer tubular member with an external helical ball groove providing a primary load path. An inner tubular member fits closely within and is fixed to the outer tubular member to provide a secondary load path upon cracking of the outer tubular member by a projectile passing through the outer tubular member. The inner tubular member is formed of ballistic tolerant composite material to maintain its structural integrity when contacted by a projectile which has passed through and caused cracking of the outer tubular member.

To transfer a fluid at high service temperature and pressure without the limitations of rigid tubing, a flexible tube is provided with a plurality of generally concentric tubular layers for transferring fluids. The innermost layers define a fluid flow path and provide insulation without pressure containment whereas the outermost layers provide fluid containment and resist pressure exerted by the fluid flowing through the tube. By utilizing a plurality of layers of different materials selected to have specific characteristics, the flexible tube operates at a service temperature and pressure providing a high level of energy transfer.

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Roscoe, IL, United States of America

John F Scanlon