Abstract: Processes for fabricating polymer composite materials that contain a polymer matrix, reinforcement fabrics, and particles of a filler material. The processes include spraying the particles of the filler material on at least two articles that each comprise at least one of the reinforcement fabrics to form particle-laden articles. The particle-laden articles are stacked to form a stacked structure, and a resin present within the stacked structure is then cured to form a laminate polymer composite material. The process can be employed in the fabrication of at least a portion of an aircraft engine nacelle, for example, the inlet lip of a fan nacelle.

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: An anti-icing system and method for an aircraft engine nacelle. The nacelle has an inlet lip that defines a leading edge of the nacelle and has a cross-sectional shape and oppositely-disposed exterior and interior surfaces. An anti-icing system contacts at least the inlet lip of the nacelle. The anti-icing system includes at least one heating element having a cross-sectional shape that conforms to the cross-sectional shape of the inlet lip and in which carbon nanotubes are oriented and arranged to conduct electrical current through the heating element. Passing an electrical current through the heating element causes Joule heating of the heating element and heating of the inlet lip by thermal conduction.

Abstract: A thermal insulation blanket for an aircraft engine, and processes for producing the thermal insulation blanket to have low thermal conductivity and high temperature capability. The thermal insulation blanket has a layered construction that includes an aerogel insulation material, a composite layer disposed at a first surface of the aerogel insulation material, and a backing layer disposed at an opposite surface of the aerogel insulation material so that the aerogel insulation material is encapsulated between the composite and backing layers. The composite layer contains a resin matrix material reinforced with a fiber reinforcement material.

Abstract: Processes for fabricating polymer composite materials that contain a polymer matrix, reinforcement fabrics, and particles of a filler material. The processes include spraying the particles of the filler material on at least two articles that each comprise at least one of the reinforcement fabrics to form particle-laden articles. The particle-laden articles are stacked to form a stacked structure, and a resin present within the stacked structure is then cured to form a laminate polymer composite material. The process can be employed in the fabrication of at least a portion of an aircraft engine nacelle, for example, the inlet lip of a fan nacelle.

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: 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: An anti-icing system and method for an aircraft engine nacelle. The nacelle has an inlet lip that defines a leading edge of the nacelle and has a cross-sectional shape and oppositely-disposed exterior and interior surfaces. An anti-icing system contacts at least the inlet lip of the nacelle. The anti-icing system includes at least one heating element having a cross-sectional shape that conforms to the cross-sectional shape of the inlet lip and in which carbon nanotubes are oriented and arranged to conduct electrical current through the heating element. Passing an electrical current through the heating element causes Joule heating of the heating element and heating of the inlet lip by thermal conduction.

Abstract: A process for producing resin-impregnated laminate composite structures that comprise a closed-cell core between resin-impregnated fabric layers, and preliminary and composite structures formed by such a process. The process includes stitching a roving in a preliminary structure that includes the core so as to structurally reinforce the core. The roving passes through through-holes in the core and traverses opposite outer surfaces of the preliminary structure. The outer surfaces of the preliminary structure traversed by the roving may be defined by outer surfaces of the core, or the preliminary structure may further include two or more fabric layers on outer surfaces of the core such that the core is between the fabric layers, the roving passes through one or more fabric layers, and at least one of the outer surfaces of the preliminary structure and traversed by the roving is defined by a fabric layer.

Abstract: An inflatable restraint, and method of using the same, is used to provide support and shock isolation for missiles, torpedoes, missile canisters or the like in naval vessels. The inflatable restraint features a structural collar, at least one inflatable bladder and at least one interference member. The interference member is attached to the inside of the structural collar and the interference member is fully adjustable to ensure a snug fit during the loading of the missile, torpedo or missile canister into the structural collar. Once the missile, torpedo, missile canister or the like is properly inserted into the structural collar, the at least one inflatable bladder, which is also attached to the inside of the structural collar, is inflated to restrain the object. The pressure of the inflatable bladder may be regulated to provide variable spring constants and stiffness.

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.

Abstract: An armor that is used, for example, in multi-cell missile launchers is disclosed. In some embodiments, the armor includes three layers. The inner-most layer undergoes explosive welding when exposed to a pressure wave from an explosion. An intermediate layer in-elastically deforms when exposed to the explosion. The third and outer-most layer includes a plurality of elongated, pressurized tubes that contain fire retardant, among other chemicals. Silicone gel is interposed between the tubes.

Abstract: An armor that is used, for example, in multi-cell missile launchers is disclosed. In some embodiments, the armor includes three layers. The inner-most layer undergoes explosive welding when exposed to a pressure wave from an explosion. An intermediate layer in-elastically deforms when exposed to the explosion. The third and outer-most layer includes a plurality of elongated, pressurized tubes that contain fire retardant, among other chemicals. Silicone gel is interposed between the tubes.

Abstract: A reconfigurable missile launcher that avoids some of the costs and disadvantages associated with missile launchers in the prior art. In particular, the illustrative embodiment of the present invention uses a variable-size receptacle for locating and holding a missile canister chosen from a set of missile canister types. The illustrative embodiment also includes a controller that includes data sets that are specific to each of a plurality of missile types.

Abstract: An inflatable restraint, and method of using the same, is used to provide support and shock isolation for missiles, torpedoes, missile canisters or the like in naval vessels. The inflatable restraint features a structural collar, at least one inflatable bladder and at least one interference member. The interference member is attached to the inside of the structural collar and the interference member is fully adjustable to ensure a snug fit during the loading of the missile, torpedo or missile canister into the structural collar. Once the missile, torpedo, missile canister or the like is properly inserted into the structural collar, the at least one inflatable bladder, which is also attached to the inside of the structural collar, is inflated to restrain the object. The pressure of the inflatable bladder may be regulated to provide variable spring constants and stiffness.

Abstract: A sheet of uncured polymer, which is preferably reinforced with multiple layers of fiber, is staged or partially cured to a state in which the sheet is rigid at room temperature. Multiple apertures are drilled into, and preferably through, the sheet. The apertures are for acoustic or laminar flow control, and include holes having diameters in the range of 0.025 to 0.120 inch. In the case in which the fabricated panels must conform to a particular shape, the perforated, partially cured panels are heated to a temperature at which the panel softens, and conformed to the desired surface. The partially cured, perforated sheets are then cured. In order to prevent closure of the drilled holes during the cure, the perforated panel is sandwiched between two layers of glass fabric and cured on an elastomeric tool surface which expands with increases in temperature, forcing the glass fabric to seal the holes during cure. Release coatings are used to aid panel/liner separation.

Abstract: In a laminated structure, such as a structural component of an aerospace vehicle or the like, which is fabricated of layers of filament composite material, means is provided for protection against lightning strike damage and electromagnetic interference. In particular, the outer surface layer of the filament composite material is fabricated of conductive metallic-coated filaments to provide a conductive barrier to disperse the current from lightning or other electromagnetic sources. The filaments may be fabricated of a composite material such as glass which has an aluminum coating. The structure may be woven or filament wound with intermixed resin, and the metallic-coated filaments are cured simultaneously with the entire laminated structure of filament composite material.