Abstract: An apparatus (10) that houses functional components of a mechanical assembly includes a frame component (12) formed of a first material, the frame component (12) bearing primary load, torque or pressure applied to the apparatus (10) during operation of said mechanical assembly. The housing apparatus (10) further includes a composite reinforcement component (130) for resisting forces applied to the apparatus during operation of the mechanical assembly and an enclosure component (80) formed of a second material of lower density than the first material of the frame component (12), the enclosure component (80) covering and sealing at least the functional components of the mechanical assembly from external conditions during operation of the mechanical assembly.

Abstract: Ballistic materials for enhanced energy absorption and fan casings for turbine engines including the same are provided. A hybrid ballistic material comprises a first ballistic fabric and at least one individual member woven through at least a portion of the first ballistic fabric. The fan casing comprises at least one layer of a first crushable material circumscribing a fan containment case. A ballistic material comprising a net-like ballistic material or the hybrid ballistic material circumscribes the at least one layer of the first crushable material. At least one layer of a second crushable material may circumscribe the ballistic material with the ballistic material disposed between the at least one layer of the first and second crushable materials. A containment covering is an outermost layer of the fan casing.

Abstract: Housings for electrical or electronic components made using braid or woven fabric sheets having multiple sections treated with different materials as well as processes and materials for making such housings are disclosed.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

Abstract: An aircraft wheel (14) comprises a metal support structure (30) having a first annular ring (31) and a second annular ring (32) connected via at least one connecting element (37); and a fiber-enforced, molded-composite body. The metal support structure (30) is at least partially embedded in the composite body to form a first aircraft wheel section (20, 22) having a rim flange (16a, 16b) for forming a seal with a tire.

Abstract: The inventive subject matter provides methods of manufacturing bulk absorbers and noise suppression panels.

Abstract: A fiber-based acoustic treatment material is provided. The material includes between about 3% and about 25% by weight of fibrillated microfibers, between about 20% and about 75% by weight of reinforcement microfibers, and between about 15% and about 60% by weight of a binder. Methods of making the material are also provided.

Abstract: An apparatus (10) that houses functional components of a mechanical assembly includes a frame component (12) formed of a first material, the frame component (12) bearing primary load, torque or pressure applied to the apparatus (10) during operation of said mechanical assembly. The housing apparatus (10) further includes a composite reinforcement component (130) for resisting forces applied to the apparatus during operation of the mechanical assembly and an enclosure component (80) formed of a second material of lower density than the first material of the frame component (12), the enclosure component (80) covering and sealing at least the functional components of the mechanical assembly from external conditions during operation of the mechanical assembly.

Abstract: Methods and apparatus are provided for making a fireproof panel. The fireproof panel includes a first ply of material and a ceramic material impregnating at least a portion of the first ply of material, the ceramic material formulated to resist loss of physical properties when exposed to temperatures of at least 1090° C.

Abstract: An avionics chassis for protecting against damage, dust, dirt and incidental moisture over an extended temperature range, EMI shielding to prevent radiation of internal circuit energy and preventing the entrance of external EMI. The chassis provides lower weight, lower levels of radiated emissions and improved resistance to incident external radiation. Electric and magnetic shielding is also provided.

Abstract: Noise suppression materials and methods of manufacturing noise suppression materials are provided. In an embodiment, by way of example only, a fibrous material includes a network of a plurality of fibers selected from a group consisting of glass fibers and ceramic fibers, the plurality of fibers including a first fiber and a second fiber, the first fiber having a first low melt component and a first high melt component, the first low melt component of the first fiber having a first melting point, the first high melt component of the first fiber having a second melting point that is higher than the first melting point, wherein the first low melt component of the first fiber extends alongside and is adjacent to at least a segment of the first high melt component of the first fiber and is bonded to the second fiber at a contact point.

Abstract: A fiber-based acoustic treatment material is provided. The material includes between about 3% and about 25% by weight of fibrillated microfibers, between about 20% and about 75% by weight of reinforcement microfibers, and between about 15% and about 60% by weight of a binder.

Abstract: Methods of forming flowbodies and flowbodies are provided. In an embodiment, by way of example only, a method includes providing a first sheet of a first material comprising a metal, providing a second sheet of a second material comprising a composite, attaching a portion of the first sheet to a first position on a preform, securing a portion of the second sheet to a second position on the preform, and winding the first sheet and the second sheet around the preform to form the first flowbody, the first flowbody including a laminate comprising alternating layers of the first sheet and the second sheet.

Abstract: An avionics chassis for protecting against damage, dust, dirt and incidental moisture over an extended temperature range, EMI shielding to prevent radiation of internal circuit energy and preventing the entrance of external EMI. The chassis provides lower weight, lower levels of radiated emissions and improved resistance to incident external radiation. Electric and magnetic shielding is also provided.

Abstract: Methods and apparatus are provided for making a fireproof panel. The fireproof panel includes a first ply of material and a ceramic material impregnating at least a portion of the first ply of material, the ceramic material formulated to resist loss of physical properties when exposed to temperatures of at least 1090° C.

Abstract: An aircraft wheel (14) comprises a metal support structure (30) having a first annular ring (31) and a second annular ring (32) connected via at least one connecting element (37); and a fiber-enforced, molded-composite body. The metal support structure (30) is at least partially embedded in the composite body to form a first aircraft wheel section (20, 22) having a rim flange (16a, 16b) for forming a seal with a tire.

Abstract: Methods are provided for repairing a defect in a noise suppression panel. In an embodiment, by way of example only, a method includes the steps of removing a section of the noise suppression panel that includes the defect to thereby create a cavity, forming an insert configured to mate with the cavity, the insert comprising an acoustic damping material comprising a plurality of fibers and a binder, and placing the insert within the cavity.

Abstract: Housings for electrical or electronic components made using braid or woven fabric sheets having multiple sections treated with different materials as well as processes and materials for making such housings are disclosed.

Abstract: Components made from solid fiber inorganic-organic-polymer matrix composites and methods of making the components and composites are provided. In one embodiment, and by way of example only, the method includes the steps of impregnating a fiber preform with a liquid resin comprising at least one compound selected from the group consisting of silsesquioxane and polysilazane, and heating the resin-impregnated preform at a temperature below the resin pyrolysis temperature to form the solid fiber inorganic-organic-polymer matrix composite. In other embodiments, a component, such as a mechanical or an aircraft component is provided that includes a solid fiber inorganic-organic-polymer matrix composite. The solid fiber inorganic-organic-polymer matrix composite may include a fiber preform impregnated with a resin comprising at least one silsesquioxane or a fiber preform impregnated with a resin comprising at least one polysilazane.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.