Abstract:
Acoustic structures in which acoustic septa are located in the cells of a honeycomb for reducing the noise generated from a source. The honeycomb used to form the acoustic structure has walls that contain convex and concave contours which make the honeycomb flexible. The acoustic septa are formed by inserting planar acoustic inserts into the honeycomb cells to form a septum cap which is friction-locked within the cell and then permanently bonded in place. The planar acoustic septum is configured to match the unique shape of the cell contours to provide desired friction-locking when inserted into the cells and desired acoustic properties after being permanently bonded in place.
Abstract:
Light weight fibrous veils are incorporated into the uncured composite iace sheets of a tioiieycomb sandwich structure in order to reduce the la teral crushing of the honeycomb (core crush) that occurs during curing of the uncured structure in an autoclave or vacuum bag system. The light weight fibrous veils act as friction-promoting layers to reduce the relative movement of the uncured face sheets that leads to core crush during the curing process.
Abstract:
A stepped acoustic structure having multiple degrees of acoustic freedom for reducing noise generated from a source. Acoustic septum caps are anchored at the same depth within the cells of the stepped acoustic structure. The multiple degrees of acoustic freedom that is usually provided by locating the septum portions of the septum caps at different depths within the cells is obtained by placing steps within the cells which reduce the cross-sectional area of the cell. Depth control portions are optionally included in the septum caps so that the septum portions of different septum caps are located at different depths within the stepped acoustic structure. Various combinations of steps and depth control portions are used to provide an acoustic structure having multiple degrees of acoustic freedom even though the acoustic septum caps are anchored at the same depth within the structure.
Abstract:
An alternate resin-coated paper material for use in making honeycomb. The alternate resin-coated paper material is made from a paper that contains from 30 to 50 weight percent aramid fibers and from 50 to 70 weight percent of non-aramid fibers. A fire retarded phenolic resin is incorporated into the paper to make it self-extinguishing in less than 10 seconds with a self-extinguishing burn length of less than 12 inches when exposed to a 12-second vertical flame in accordance with the vertical bum test requirements set forth in 14 C.F.R. Part 25.583. The fire retarded phenolic resin includes a phenol formaldehyde resin and a phosphorous-containing fire retardant.
Abstract:
A multi-sectional composite tooling (10) for use in molding large composite structures. The tooling includes at least two tooling sections (12, 14) that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug (42) at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.
Abstract:
The bandwidth or acoustical range of an acoustic structure is increased by locating a sound wave guide (30) within the acoustic cell (22). The wave guide divides the cell into two acoustical chambers (42,44). The two chambers provide an effective increase in resonator length of the cell.
Abstract:
A composite material that can be machined to provide a composite part for structural applications that has at least one machined surface. The composite material includes a fibrous structure containing fibers and a resin matrix. The fibrous structure has at least one surface. A machinable layer of discontinuous fiber composite material is located on the surface(s) of the fibrous structure. A portion of the machinable layer(s) is removed to provide a composite part having the desired final machined dimension without penetrating into the fibrous structure.
Abstract:
Composite material that contain epoxy resin which is toughened and strengthened with thermoplastic materials and a blend insoluble particles. The uncured matrix resins include an epoxy resin component, a soluble thermoplastic component, a curing agent and an insoluble particulate component composed of elastic particles and rigid particles. The uncured resin matrix is combined with a fibrous reinforcement and cured molded to form composite materials that may be used for structural applications, such as primary structures in aircraft.
Abstract:
Layers of unidirectional (UD) fiber prepreg (12,14) are formed into a pre -plied, multi-directional, continuous fiber laminate (10) that is used as a molding compound to form three dimensional structures (40). Cut-outs from the laminate are slotted and folded along fold lines to provide near- net-shaped preforms that may be compression molded to form fiber-reinforced composite structures having complex shapes.
Abstract:
Composite prepreg including a gas venting network that allows multi-dimensional escape of gas from the prepreg during the curing process. Penetrable barriers are also provided between the matrix precursor elements to promote long- term storability of the prepreg at ambient temperatures. All or a portion of the gas venting network may be integrated with the penetrable barriers.