Abstract: A slider apparatus integral with a slidable member and a method for integrating the slider apparatus with the slidable member. The slider apparatus integrated with the slidable member may be configured to slidably couple with and be structurally supported by a fixed structure. The slider apparatus may comprise a primary slider component made of composite material and at least one chamfered element bonded to the primary slider component. The slidable member may comprise the slider apparatus, a core assembly, a plurality of composite material plies wrapped around the slider apparatus and core assembly and cured therewith, and at least one low-friction slider shoe removably attached to the primary slider component outward of the plurality of composite material plies.

Abstract: A method of constructing, assembling and disassembling a mandrel for fabricating a monolithic composite nacelle panel for use on an airplane comprises attaching a first fairing bar including an exposed ball roller assembly to a tilting plate; attaching a first outer section to said first fairing bar; attaching a second outer section to said first fairing bar; attaching a center section to said first outer section and said second outer section; attaching a nozzle section to said first fairing bar and positioned adjacent an inner wall of said first outer section, an inner wall of said center section, and an inner wall of said second outer section; attaching a second fairing bar to said first outer section, said center section, and said second outer section; and attaching a cavity section to said second fairing bar.

Abstract: Aircraft systems including thrust reversers with monolithic components are described herein. An aircraft system in accordance with one embodiment includes a thrust reverser having a fan duct inner wall section, a fan duct outer wall section radially outward of the fan duct inner wall section, and a connecting wall section extending between the fan duct inner wall section and the fan duct outer wall section. The fan duct inner wall section, the fan duct outer wall section, and the connecting wall section form a monolithic member.

Abstract: A slider apparatus integral with a slidable member and a method for integrating the slider apparatus with the slidable member. The slider apparatus integrated with the slidable member may be configured to slidably couple with and be structurally supported by a fixed structure. The slider apparatus may comprise a primary slider component made of composite material and at least one chamfered element bonded to the primary slider component. The slidable member may comprise the slider apparatus, a core assembly, a plurality of composite material plies wrapped around the slider apparatus and core assembly and cured therewith, and at least one low-friction slider shoe removably attached to the primary slider component outward of the plurality of composite material plies.

Abstract: A mandrel is disclosed for fabricating a monolithic composite nacelle panel for use on an airplane. Also disclosed is the method of constructing the mandrel, the method of assembling the mandrel, and the method of disassembling the mandrel.

Abstract: A method of constructing, assembling and disassembling a mandrel for fabricating a monolithic composite nacelle panel for use on an airplane comprises attaching a first fairing bar including an exposed ball roller assembly to a tilting plate; attaching a first outer section to said first fairing bar; attaching a second outer section to said first fairing bar; attaching a center section to said first outer section and said second outer section; attaching a nozzle section to said first fairing bar and positioned adjacent an inner wall of said first outer section, an inner wall of said center section, and an inner wall of said second outer section; attaching a second fairing bar to said first outer section, said center section, and said second outer section; and attaching a cavity section to said second fairing bar.

Abstract: A pinmat (12) for perforating a composite laminate sheet (20). The pinmat (12) includes a mat portion (22) and a series of pins (24) extending from the mat portion (22). Each pin (24) has a shank portion (30) extending from the mat portion (22) and a tip portion (32) extending from the shank portion (30). The tip portion (32)includes a base portion (34) extending from the shank portion (30), an accelerating portion (36) extending from the base portion (34), and a piercing portion (38) extending from the accelerating portion (36). The piercing portion (38) is utilized for penetrating the composite laminate sheet (20) within a substantially low range of applied pressure for forming a hole within the composite laminate sheet (20). Moreover, the accelerating portion (36) is utilized for penetrating the composite laminate sheet (20) at a substantially high speed for forcing the base portion (34) into the composite laminate sheet (20) within the substantially low range of applied pressure.

Abstract: A method of forming a composite acoustic panel (26). The method begins by arranging a perforated sheet (54) on a convex lay-up mandrel (70), arranging a core material (62, 74) on the perforated sheet (54), and curing the perforated sheet (54) and the core material (62, 74) to form a composite acoustic core (60) having a lay-up mandrel side and an opposite upper side. Composite sheets (96, 98) are then arranged on a concave lay-up mandrel. The composite acoustic core (60) is arranged on the composite sheets (96, 98) with the opposite upper side of the acoustic core (60) against the composite sheets (96, 98). The composite acoustic core (60) and the composite sheets (96, 98) are then cured so as to form the acoustic panel (26). A sacrificial sheet (76) can be added to upper side of the core material (62, 74) prior to curing the perforated sheet (54) and the core material (62, 74). The sacrificial sheet (76) preferably has a low coefficient of thermal expansion.

Abstract: An acoustic panel (26) for the nacelle (20) of a high bypass jet engine. The acoustic panel (26) has a perforated composite inner sheet (54), an outer composite sheet (96, 98), and a honeycomb-core material (74) sandwiched therebetween. The acoustic panel (26) includes an integral forward ring (36) and integral wedge fairings (44).

Abstract: An improved acoustic panel (26) for the nacelle (20) of a high bypass jet engine. The acoustic panel (26) has a perforated composite inner sheet (54), an outer composite sheet (96, 98), and a new reinforcement structure, or pre-cured doubler (62) therein. The pre-cured doubler (62) is arranged to receive a load applied to the acoustic panel (26), and includes a face sheet (64) connected to a structural attachment area (52) of the perforated composite inner sheet (54). A structurally-reinforced core (63) is connected the face sheet (64). Preferably, the width of the face sheet (64) in an air flow direction of the acoustic panel (26) is substantially equal to the width of the structurally reinforced core (63) in the air flow direction. The pre-cured doubler (62) provides increase acoustic area in parts of the acoustic panel adjacent to attachment fittings (46). Expanded epoxy (87a) is also used to reinforce side edges and selected areas of the acoustic core (60) for the acoustic panel (26).