Abstract: A hybrid ice protection system (HIPS) including both an electro-expulsive de-icing system (EEDS) and electrothermal heaters to first break ice away from an outer surface of an engine nacelle inlet lip and then melt remaining residual ice from the outer surface of the inlet lip. The EEDS may have a plurality of EEDS actuators positioned to provide striking force to inner surfaces of both outer and inner walls of the inlet lip. The electrothermal heaters may be positioned to heat the inlet lip at areas between locations where the EEDS actuators provide striking force. The HIPS may also include a control system for actuating the EEDS actuators to strike the inner surface of the inlet lip when the inlet lip is at or below a predetermined temperature and then activating the electrothermal heaters to remove residual ice left on the inlet lip after actuation of the EEDS actuators.

Abstract: A die for forming an elongated strand of continuous material includes a front surface, an opposing back surface, a peripheral surface positioned therebetween, a groove, and a pair of peaks. The groove may be located on the front surface and may originate near the center of the front surface and terminate at the edge of the front surface. The groove may revolve around the center, getting progressively farther away from the center as it revolves. The peaks may be located at opposing edges of the groove, wherein the peaks of one portion of the groove contact the peaks of neighboring portions of the groove to form a blade. The die is pressed against an adhesive charge, such that the blade cuts the material to form an elongated, continuous noodle.

Abstract: Methods and apparatus for filling form gaps are disclosed. In one embodiment, a method includes providing a heating and pressurizing dispenser for thermoplastic, heating and pressurizing a thermoplastic in the dispenser, discharging the thermoplastic through a nozzle attached to the dispenser and filling the gap in a form with the discharging thermoplastic from the nozzle. In other aspects of the invention, the thermoplastic includes polypropylene with talc. In another aspect of the invention, a composite product is produced by providing a form, and filling the gaps in the form with thermoplastic, and forming the composite product against the form. In yet another aspect to the invention, a high temperature and high pressure dispenser for filling gaps in forms is provided.

Abstract: Methods and systems are provided for protecting an acoustic liner having a perforated facesheet from water leakage during a through-transmission ultrasonic (TTU) inspection using an ultrasonic squirter system. The testing method utilizes a repositionable mask that covers the openings in the perforated facesheet. The repositionable mask utilizes a pressure sensitive adhesive that adheres to the surface of the perforated facesheet. The repositionable mask can be removed after completing a TTU inspection and can be reused for subsequent TTU tests with minimal adverse effects on the mask or on the facesheet. For ease in handling, the repositionable mask may be configured with a semi-rigid backing carrier.

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: Methods and apparatus are provided for protecting an acoustic liner having a perforated facesheet from water leakage during a through-transmission ultrasonic (TTU) inspection using an ultrasonic squirter system. The apparatus comprises a repositionable mask that covers the openings in the perforated facesheet. The repositionable mask is comprised of a pressure sensitive adhesive that adheres to the surface of the perforated facesheet. The repositionable mask can be removed after completing a TTU inspection and can be reused for subsequent TTU tests with minimal adverse effects on the mask or on the facesheet. For ease in handling, the repositionable mask may be configured with a semi-rigid backing carrier.

Abstract: A surface compensating shaving apparatus (24) has been provided for removing a plurality of pins (12) from a surface of a pinmat (14). The apparatus (24) includes a rotary member (28) and a surface compensating member (32) that is fixedly coupled to the rotary member (28) in a rotational direction and slidably coupled to the rotary member (28) in an axial direction. The surface compensating member (32) has a plurality of cutting members (34) extending therefrom for cutting the pins (12). The surface compensating member (32) and the cutting members (34) are intended to move in the axial direction in response to the contour of the surface (26) of the pinmat (14). In this regard, the cutting members (34) can shear the pins (12) at the surface (26) of the pinmat (14).

Abstract: A method and a gauge for measuring the sharpness of the tip of an object is provided. The method includes receiving the tip of the measured object in the end of a tube. The object deflects a plunger inside the tube a finite distance proportional to the sharpness of the object inserted in the tube. A measurement of sharpness of the tip of the object is derived by measuring the deflection distance of the plunger. The measuring method may be used to measure the sharpness of a number of objects in sequence by displaying the sharpness of the object, such as where the objects being measured are pins arranged in a matrix pattern.

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: A low penetration-force pinmat (20) has been provided for perforating an uncured laminate sheet (14). The pinmat (20) includes a mat portion (28) and a series of pins (26) extending from the mat portion (28). Each pin (26) includes a shank portion (38) and a tip portion (40) extending from the shank portion (38). The tip portion (40) has one or more facets (42) that are positioned adjacent to one or more edges (44). In one embodiment, three facets (42) are adjoined by three edges (44). These facets (42) are positioned at a predetermined facet angle (52) relative to a longitudinal axis (50) of the shank portion (38). Additionally, adjacent facets (42) are positioned at a predetermined blade angle (54) relative to each other so as to define a sufficiently sharp edge (44) for cutting and fracturing the fibers (32). The edges (44) are positioned at a predetermined edge angle (48) relative to the longitudinal axis (50) of the shank portion (38).

Abstract: A surface compensating shaving apparatus (24) has been provided for removing a plurality of pins (12) from a surface of a pinmat (14). The apparatus (24) includes a rotary member (28) and a surface compensating member (32) that is fixedly coupled to the rotary member (28) in a rotational direction and slidably coupled to the rotary member (28) in an axial direction. The surface compensating member (32) has a plurality of cutting members (34) extending therefrom for cutting the pins (12). The surface compensating member (32) and the cutting members (34) are intended to move in the axial direction in response to the contour of the surface (26) of the pinmat (14). In this regard, the cutting members (34) can shear the pins (12) at the surface (26) of the pinmat (14).

Abstract: A method and a gauge for measuring the sharpness of the tip of an object is provided. The method includes receiving the tip of the measured object in the end of a tube. The object deflects a plunger inside the tube a finite distance proportional to the sharpness of the object inserted in the tube. A measurement of sharpness of the tip of the object is derived by measuring the deflection distance of the plunger. The measuring method may be used to measure the sharpness of a number of objects in sequence by displaying the sharpness of the object, such as where the objects being measured are pins arranged in a matrix pattern.