Sundstrand Corporation

John S Church

John F Scanlon

David W Okey

Hossein Saatchi

Gary W Wigell

Gary A Wigell

James L Kasarsky

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 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.

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Wilmington, DE, United States of America

John S Church