Abstract: A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.

Abstract: An electromechanical linear actuator includes a pneumomechanical back-up system to ensure extension of retractable landing gear for landing an aircraft. Structurally, the linear actuator includes a stator forming a channel for receiving a ball screw. Further, the actuator includes a ball screw housing forming a chamber for receiving the ball screw. Specifically, the ball screw and the housing are in threaded engagement to translate rotation of the ball screw into axial extension of the housing. To power electromechanical extension of the actuator, the ball screw is selectively engaged to a motor with a gear train. Importantly, fluid communication between the ball screw housing and a pressurized fluid is selectively provided by a valve. If electromechanical extension of the actuator fails, the gear train is disconnected from the ball screw and the pressurized fluid is introduced into the chamber to drive pneumomechanical extension.

Abstract: A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.

Abstract: A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.

Abstract: A trim tab is disclosed for use on an aerodynamic foil that has first and second surfaces which extend between a leading edge and a trailing edge. Structurally, the trim tab includes a tab member that is bounded by slits formed through each surface to extend from the trailing edge toward the leading edge. Also, the tab member is bounded by a slot formed between the slits on the second surface to establish a flange between the slot and the trailing edge. Further, the trim tab includes an actuator that is mounted on the foil between the slot and the leading edge. The actuator includes an actuator arm that is connected to the flange. As a result, extension and retraction of the actuator moves the tab member about a hinge-less tab that is created on the first surface.

Abstract: A reinforced panel, made of a composite material, includes a single base layer. A first plurality of mutually parallel ridges is affixed to the surface of the base layer. A second plurality of mutually parallel ridges is also affixed to the surface of the base layer, but oriented transverse to the first plurality. Structurally, the ridges and the base layer are co-cured to create an integral, continuous structure that provides stiffness and rigidity to the panel.

Abstract: A cabin door assembly is provided for use with a pressurized aircraft. The assembly includes two door halves for engaging the fuselage of the aircraft. Structurally, each door half includes a waist section integral with an adjoining tapered section. Further, the assembly includes an activator that is mounted on the fuselage and attached to the door halves. Specifically, the activator is attached to each door half to concertedly move each door half between a closed configuration and an open configuration. In the closed configuration, the door halves are sealed to the fuselage and to each other for pressurization of the aircraft. In the open configuration, the door halves extend outwardly from the fuselage to allow for aircraft ingress and egress.

Abstract: A method and device are provided for manufacturing a unitary caul sheet to be used in creating a composite material fuselage for an airplane. Specifically, a generally tubular shaped tool having a hollow interior cavity defining a fuselage IML surface is provided. In the method, a caul sheet material such as polyurea is applied to the IML surface before an armature is inserted into the interior cavity of the tool. Then, a filler material is introduced between the armature and the caul sheet material. Further, steam is injected to form the filler material into an infrastructure. Then, the caul sheet material is cured before the tool is removed from the caul sheet material to expose the caul sheet to receive composite material.

Abstract: An aircraft wing made of a composite material, and its method of manufacture, require a plurality of kabobs (i.e. substantially rectangular shaped hollow tubes having an open end and a closed end). Of these kabobs, several are aligned end-to-end, to create a section. Several sections are then positioned side-by-side and covered by a layer of composite material to define an aerodynamic surface for the wing. The juxtaposed sections also establish spar webs for the wing, and the closed ends of the juxtaposed sections establish transverse ribs for the wing. Thus, the kabobs form the main load-bearing member of the wing. The sections of composite material are co-cured with the composite material of the aerodynamic surface.

Abstract: A method of indicating the presence of mechanical impact is used with a low-ductility material, such as a composite material, having a tensile elongation to failure of less than about 2 percent. The method includes preparing an indicator paint having an impact-sensitive component that produces a visible change when subjected to a mechanical impact, applying the indicator paint to the surface of the low-ductility material, placing the low-ductility material having the indicator paint thereon into circumstances where it may be subject to the mechanical impact, and thereafter inspecting the low-ductility material having the indicator paint thereon for the presence of the visible change. The method may be used to establish design criteria for the low-ductility material by establishing an impact-effect threshold value from the step of inspecting, and determining a design limit for the low-ductility material responsive to the impact-effect threshold value.