Sikorsky Aircraft Corporation

United Technologies Corporation

William V Forster

Kenneth M Nowak

Darryl Mark Toni

Larry J Osiecki

Thomas Arthur Carstensen

Christian A Rogg

Alan R Goodworth

Peter L Grant

James A Anthony

Patrick L Riley

Steven R Hayse

Craig F Johnson

A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

Composite thermoplastic matrix airframe structure and method of manufacture therefore

A composite panel and method of manufacture includes a support structure and a tape skin wound about the support structure. A mandrel assembly with extractable longitudinal mandrels facilitates winding of the tape skin onto the support structure. The composite panel is suitable for use in an aircraft floor system.

Method of forming panels using an in-situ tape placement process and panels formed therefrom

Method for making honeycomb core composite articles

A method for fabricating a composite article having a composite stiffening member co-cure bonded in integral combination therewith wherein the composite article comprises outer mold line (OML) and inner mold line (IML) composite skins and a modified honeycomb core interposed therebetween. The method includes a first set of steps for modifying the honeycomb core of the composite article and includes the steps of providing a detail mold that defines a detail cavity and a core engagement surface, aligning the honeycomb core with the detail mold by abuttingly engaging a first surface of the honeycomb core with the core engagement surface wherein a base segment of the honeycomb core is aligned with the detail cavity, to injecting a RIM foam to fill the detail cavity and the honeycomb cells of the base segment, and curing the injected RIM foam to form the modified honeycomb core that includes a densified base segment and a detail mandrel integral with the densified base segment. The detail mandrel is operative to define the configuration of the composite stiffening member to be co-cure bonded in integral combination with the composite article. A second set of steps includes laying up a first set of prepreg composite plies that define the OML composite skin in combination with a fabrication mold, laying up the modified honeycomb core in combination with the layed-up first prepreg composite plies, mold, laying up additional prepreg composite plies that define the IML composite skin and the composite stiffening member in combination with the modified honeycomb core and co-curing the layed-up prepreg plies to form the composite article having the composite stiffening member co-cure bonded in integral combination therewith.

Method of fabricating a composite article having an integral, co-cured

A duct cover for use with a duct within a vehicle, the duct cover operative for directing a fluid flow. The duct cover being further operative for minimizing the entrance of foreign object debris into the duct. The duct cover has a flow directing honeycomb portion for conducting the passing fluid flow in a preferred direction. The flow directing honeycomb comprises an array of continuous, polygon shaped open cells which are biased with respect to the initial fluid flow direction. The periphery of the flow directing honeycomb is rigidized to stiffen the same for minimizing the displacements thereof. The rigidity is provided by a framing member comprising upper and lower skin structures affixed to a core material. The framing member is preferably adhesively bonded to the flow directing honeycomb by means of a foaming adhesive and a barrier member. The barrier member is operative for minimizing the expansion of the foaming adhesive into the open cells of the honeycomb. In order to improve the low observability characteristics of the structure, the cells of the flow directing honeycomb are preferably coated with a radar absorbent material, such as carbon, which acts to minimize the amount of electromagnetic energy that is reflected therefrom.

Duct cover for directing a fluid therethrough

A composite sandwich structure which includes upper and lower skin structures, first and second honeycomb core structures, and an intermediate portion disposed between the first and second honeycomb core structures. The intermediate portion comprises a composite laminate, a barrier member and a foaming adhesive layer disposed between the composite laminate and the barrier member. The foaming adhesive layer is of a type designed to expand when exposed to an elevated temperature. The composite laminate and the barrier member operate to limit the expansion of the foaming adhesive layer into the open cells of the first and second honeycomb core structures. The foaming adhesive layer, upon expansion, applies pressure against the composite laminate. This pressure, acting concomitantly with the applied curing pressure and the elevated temperature, cures the laminate. Furthermore, the expansion of the foaming adhesive urges the composite laminate and the barrier member apart so as to fill any core discrepancies, i.e., mistrimmed or damaged core, that may exist in the honeycomb core structures.

Complex composite sandwich structure having a laminate and a foaming

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Seymour, CT, United States of America

William V Forster