Abstract: A conformal, load bearing, phased array antenna system having a plurality of adjacently positioned antenna aperture sections that collectively form a single, enlarged antenna aperture. The aperture sections are each formed by intersecting wall panels that form a honeycomb-like core having a plurality of electromagnetic radiating elements embedded in the wall panels that form the core. The aperture wall panels are assembled onto a single, multi-faceted back skin, bonded thereto, and then machined to produce a desired surface contour. A radome formed by a single piece of composite material is then bonded to the contoured surface. Antenna electronics printed wiring boards are also bonded to an opposite side of the back skin. The contour is selected to match a mold line of a surface into which the antenna system is installed. The antenna is able to form an integral, load bearing portion of the structure into which it is installed.

Abstract: An antenna aperture and method of assembling same. The antenna aperture forms a honeycomb-like core structure with dipole radiating elements integrally formed into structural wall portions of the honeycomb-like core. The antenna aperture has sufficient structural strength to form a structural portion of a mobile platform, while still being sufficiently light in weight for weight-critical applications such as with airborne mobile platforms.

Abstract: A phased array antenna aperture able to form a structural, load bearing portion of another structure, for example, a portion of a mobile platform. The antenna aperture is formed with a plurality of radiating elements sandwiched between prepreg fabric plies to form independent wall sections having a plurality of electromagnetic radiating elements embedded therein. The wall sections are secured in a honeycomb arrangement to form an array of cells of radiating elements. The manufacturing methods described herein enable arrays of widely varying sizes and shapes to be created and used as structural, load bearing portions of a wing, fuselage, door panel or other area of a mobile platform. The antenna aperture is lightweight because it does not include the weight of parasitic support components typically required in the construction of phased array antenna apertures.

Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.

Abstract: A antenna aperture having electromagnetic radiating elements embedded in structural wall portions of a honeycomb-like core. Independent wall sections each having a plurality electromagnetic radiating elements are formed into the honeycomb-like core. Feed portions of each radiating element form teeth that are copper plated before being assembled onto a back skin panel. Each of the teeth are then generally machined flush with a surface of the back skin to present electrical contact pads which enable electrical coupling to each of the radiating elements by an external antenna electronics board.

Abstract: An antenna aperture and method of assembling same. The antenna aperture forms a honeycomb-like core structure with dipole radiating elements integrally formed into structural wall portions of the honeycomb-like core. The antenna aperture has sufficient structural strength to form a structural portion of a mobile platform, while still being sufficiently light in weight for weight-critical applications such as with airborne mobile platforms.

Abstract: A phased array antenna aperture able to form a structural, load bearing portion of another structure, for example, a portion of a mobile platform. The antenna aperture is formed with a plurality of radiating elements sandwiched between prepreg fabric plies to form independent wall sections having a plurality of electromagnetic radiating elements embedded therein. The wall sections are secured in a honeycomb arrangement to form an array of cells of radiating elements. The manufacturing methods described herein enable arrays of widely varying sizes and shapes to be created and used as structural, load bearing portions of a wing, fuselage, door panel or other area of a mobile platform. The antenna aperture is lightweight because it does not include the weight of parasitic support components typically required in the construction of phased array antenna apertures.

Abstract: A antenna aperture having electromagnetic radiating elements embedded in structural wall portions of a honeycomb-like core. Independent wall sections each having a plurality electromagnetic radiating elements are formed into the honeycomb-like core. Feed portions of each radiating element form teeth that are copper plated before being assembled onto a back skin panel. Each of the teeth are then generally machined flush with a surface of the back skin to present electrical contact pads which enable electrical coupling to each of the radiating elements by an external antenna electronics board.

Abstract: A conformal, load bearing, phased array antenna system having a plurality of adjacently positioned antenna aperture sections that collectively form a single, enlarged antenna aperture. The aperture sections are each formed by intersecting wall panels that form a honeycomb-like core having a plurality of electromagnetic radiating elements embedded in the wall panels that form the core. The aperture wall panels are assembled onto a single, multi-faceted back skin, bonded thereto, and then machined to produce a desired surface contour. A radome formed by a single piece of composite material is then bonded to the contoured surface. Antenna electronics printed wiring boards are also bonded to an opposite side of the back skin. The contour is selected to match a mold line of a surface into which the antenna system is installed. The antenna is able to form an integral, load bearing portion of the structure into which it is installed.

Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.

Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.

Abstract: A method and apparatus for curing composite materials that emit large volumes of volatiles during processing. The apparatus includes tooling having a rigid forming surface contoured to the shape of the formed composite part. A plurality of passages extend from the forming surface through the tooling. The passages are in fluid contact with an exhaust port. A composite workpiece is laid up and placed adjacent the forming surface. The apparatus includes a heater that heats the composite workpiece to temperatures at which volatiles are emitted. An evacuation system draws the volatiles away from the composite workpiece through the passages in the tooling and out of the exhaust port. One embodiment of tooling according to the invention is used to form a sine wave spar. The tooling includes upper and lower tool inserts upon which U-shaped composite channels are formed. The upper and lower tools are placed adjacent to each other to form the web of the spar.

Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: The processing time and energy efficiency of metal or composite bonding operations is improved by heating the lay-up preform of the structure in an induction heating press where energy goes primarily to heating the workpieces rather than to heating the tooling or being lost to the environment. The bonding process is especially beneficial for joining thermoplastic composites, but it also can be used with metals or thermosets. Preferential heating at the bondline is achieved by using shims to define the bondline and to define bead regions that have relief from contact with the susceptor envelope because of the thickness of the shims in the bondline regions.

Abstract: The present invention discloses a structural panel sequentially comprising a first face sheet having an outward facing thermoplastic surface and an inward facing bonding surface, a first thermoplastic bonding layer, a titanium honeycomb core, a second thermoplastic bonding layer, and a second face sheet having an outward facing thermoplastic surface and an inward facing bonding surface. The face sheet is formed by thermally consolidating a thermoplastic laminate composite and a bonding layer. The face sheet bonding surface and intermediate bonding layer are made from thermoplastic resinous materials having comparable melt temperatures that are lower than that of the thermoplastic materials of the laminate composite.

Abstract: A method and apparatus for curing large composite parts. The method utilizes a fiber metal mesh sheet (40) situated against a composite material(34) during a curing process. The fiber metal mesh sheet (40) provides a porous network for flow of the reaction by-products during a curing and vacuuming process, yet gives adequate structure to prevent both mark-off by vacuum ports (52, 70) and crushing of the porous network as a result of autoclave and vacuum pressure. External vacuum ports (52) are located in a bagging film (50) surrounding the composite material (34). Alternatively, vacuum ports (70) are located below the composite material (34). The use of the external vacuum ports (52), vacuum ports (70) located beneath the composite material (34), or both, shortens by-product flow path and provides adequate vacuum pressure over all areas of the composite material (34) to remove reaction by-products.