Abstract:
Acoustic, structures in which acoustic septa are located in the angled cells of a honeycomb for reducing the noise generated from a source. The honeycomb used to form the acoustic structure has cell walls that extend at an angle relative to the honeycomb edges such that the depth of the honeycomb cells is greater than the honeycomb core thickness. The acoustic sepia are formed by inserting planar acoustic inserts into the angled honeycomb cells to form septum caps which are friction-locked within the angled cells and then permanently bonded in place.
Abstract:
Pre-impregnated composite material (prepreg) is provided that can be cured/molded to form composite parts having high, levels of compressive strength under dry conditions at room temperature and which retain their compressive strength when subjected to hot and wet conditions. The pre-impregnated composite materials are composed of reinforcing fibers and an uncured resin matrix. The uncured resin matrix includes a resin component made up of one or more difunctional epoxy resins and multifunctional epoxy resins. The uncured resin matrix further includes a thermoplastic particle component, a thermoplastic toughening agent and a curing agent. The thermoplastic particle component is composed of a mixture of a first group of polyamide particles that do not contain crosslinked polyamide and a second group of polyamide particles that contain crosslinked polyamide.
Abstract:
Preforms made by molding composite chips (16) that are composed of fibers and an uncured thermosetting resin. Cold composite chips are formed into a stream of non-agglomerating chips that is used to fill the cavity (26) of a preform tool (22). The non-agglomerating chips flow into the preform tool cavity (26) to form a population of non-cohesive composite chips. The non-cohesive composite chips are then heated to form a preform made up of a consolidated population of cohesive composite chips in which the non-sticky uncured thermosetting resin of the non-cohesive chips has been converted to a sticky uncured thermosetting resin.
Abstract:
A prepreg comprising a fibre reinforced curable resin, the curable resin being composed of 25 to 35 weight percent tetrafunctional epoxy resin based on the total weight of the curable resin; 18 to 28 weight percent difunctional epoxy resin; 4 to 18 weight percent polyether sulfone; 2 to 10 weight percent polyamide 12 particles; 2 to 10 weight percent polyamide 11 particles; 1 to 8 weight percent potato shaped graphite particles; and 17.4 to 27.4 weight percent of a curing agent for said curable resin.
Abstract:
A method for making a discontinuous fiber molding compound (28) from carbon fiber tow (12). The method involves using remnants of carbon fiber tows from spent carbon fiber spools. The remnants are chopped into pieces to form an assembly of chopped carbon fiber tows (18) that are from 1 cm to 10 cm long. The chopped carbon fiber tows (18) are then mixed with a powdered resin (24) to form a blend (22) of chopped carbon fiber tows and powdered resin (24). The blend (22) is heated to soften/melt the particles of resin (24) and then cooled to form a discontinuous fiber molding compound (28).
Abstract:
Thermally insulating septums are located internally within the cells of an acoustic honeycomb to regulate heat flow into the acoustic structure. The infernally located insulating septums protect the honeycomb and acoustic septums located within the honeycomb cells from heat damage that might otherwise be caused by a heat source, such as the hot section of a jet engine. The internal thermal regulators are useful in combination with heat blankets or other thermal insulating structures to provide a reduction in size and /or weight of the insulating structure while still providing the same overall degree of thermal insulation for the acoustic honeycomb.
Abstract:
Pre -impregnated composite material (prepreg) is provided that can be cured/molded to form composite parts having high compression strength under hot and wet conditions, as well as, high damage tolerance and interlaminar fracture toughness. The matrix resin includes a thermoplastic particle component that includes polyamide particles which are composed of the polymeric condensation product of a methyl derivative of bis(4-aminocyclohexyl)methane and an aliphatic 1, 10-decane dicarboxylic acid.
Abstract:
An acoustic structure that includes a. honeycomb having cells in which septum caps are located, The septum caps are formed from sheets of flexible material that may be perforated before or after the material is inserted into the honeycomb. The flexible material is sufficiently flexible to allow folding into the shape of a septum cap. The flexible material is also sufficiently stiff to provide frictional engagement and locking of the septum cap to the honeycomb cell when the cap is inserted into the honeycomb during fabrication of the acoustic structure. An adhesive is applied to the septum caps after the caps have been inserted into the honeycomb cells to provide a permanent bond.
Abstract:
Composite pre-forms are molded at high pressure to form composite parts that can be used in place of metal -based high performance parts, such as the outlet guide vanes found in turbofan jet engines, The composite pre-forms include two different fiber orientations that are co-molded in a resin matrix at high pressures to provide composite outlet guide vanes and other high performance parts. Chambers within the composite part are optionally formed during molding of the pre-form at high pressures.
Abstract:
Epoxy resins and composite materials that generate reduced levels of sulfur dioxide and which unexpectedly have reduced self-extinguishing times. The epoxy resins are composed of from 50 to 70 weight percent of an epoxy resin component. The epoxy resin composition also includes from 20 to 35 weight percent of a thermoplastic blend that is composed of polyetherimide and polyamideimide. The epoxy resin composition further includes from 5 to 25 weight percent of a curative agent. The composite materials may be used for primary structures in aircraft and other load-bearing structures.