Abstract: A process and apparatus for producing perforated composite structures, such as acoustic skins suitable for aircraft engine nacelle and duct components. The process includes placing a mat member, a non-impregnated fabric member, and a resin film on a tool surface so that pins disposed on the mat member project through the fabric member and resin film to define holes therein. The fabric member is between the mat member and resin film, and the fabric member and resin film define a stack that conforms to the mat member and tool surface. A caul member is then placed on the stack so that apertures in the caul member are penetrated by the pins. The stack is heated to melt the resin film and cause molten resin to infuse the fabric member and yield a resin-infused fabric stack, after which the molten resin within the resin-infused fabric stack is at least partially cured.

Abstract: Method including: (a) forming a laminate structure including a plurality of uncured prepreg sheets, wherein the laminate structure comprises an initial substantially planar configuration; (b) subjecting the laminate structure to suitable first curing conditions to provide a partially cured laminate structure while maintaining the substantially planar configuration; (c) providing the partially cured laminate structure with a plurality of perforations to provide a partially cured and perforated laminate structure; (d) shaping the partially cured and perforated laminate structure; and (e) subjecting the partially cured and perforated laminate structure to second curing conditions at least partially simultaneously with or after step (d) to provide a shaped and finally cured laminate structure.

Abstract: A process for producing composite structures having a core between resin-impregnated composite layers, and composite structures formed by such a process. The process uses non-impregnated fabric layers and a core layer placed on a mold such that the core layer is between at least two fabric layers, a first of which is disposed between the mold surface and a first surface of the core layer, and a second of which is disposed at a second surface of the core layer. The second fabric layer is then infused with a resin, which flows through holes in the core layer into the first fabric layer, such that the first and second fabric layers are uniformly impregnated with the resin and the core layer is not. The resin is then cured to cause the impregnated first and second fabric layers to bond to the core layer.