Abstract: A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

Abstract: A composite panel and method of manufacture includes a support structure and a tape skin wound about the support structure. A mandrel assembly with extractable longitudinal mandrels facilitates winding of the tape skin onto the support structure. The composite panel is suitable for use in an aircraft floor system.

Abstract: A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

Abstract: A composite panel and method of manufacture includes a support structure and a tape skin wound about the support structure. A mandrel assembly with extractable longitudinal mandrels facilitates winding of the tape skin onto the support structure. The composite panel is suitable for use in an aircraft floor system.

Abstract: A method for making a honeycomb core composite article includes forming a honeycomb core (24) and a precured composite skin (20) having a core edge (32) and a restraint edge (30), respectively. The precured composite skin (20) is placed in combination with a rigid mold member having a mold surface (12s) and the honeycomb core (24) is mated with the precured composite skin (20) to form a mated subassembly (36). An uncured composite skin (22) is laid over the mated subassembly (36) such that a peripheral portion (44) of the uncured composite skin (22) extends beyond the restraint edge (30) by a distance X and such that the peripheral portion (44) is in superposed abutting engagement with the mold surface (12s). The honeycomb core (24), the precured composite skin (20) and the uncured composite skin (22) define a composite lay-up (10) over which a vacuum bag (14) is disposed.

Abstract: A method for fabricating a composite article having a composite stiffening member co-cure bonded in integral combination therewith wherein the composite article comprises outer mold line (OML) and inner mold line (IML) composite skins and a modified honeycomb core interposed therebetween. The method includes a first set of steps for modifying the honeycomb core of the composite article and includes the steps of providing a detail mold that defines a detail cavity and a core engagement surface, aligning the honeycomb core with the detail mold by abuttingly engaging a first surface of the honeycomb core with the core engagement surface wherein a base segment of the honeycomb core is aligned with the detail cavity, to injecting a RIM foam to fill the detail cavity and the honeycomb cells of the base segment, and curing the injected RIM foam to form the modified honeycomb core that includes a densified base segment and a detail mandrel integral with the densified base segment.

Abstract: A duct cover for use with a duct within a vehicle, the duct cover operative for directing a fluid flow. The duct cover being further operative for minimizing the entrance of foreign object debris into the duct. The duct cover has a flow directing honeycomb portion for conducting the passing fluid flow in a preferred direction. The flow directing honeycomb comprises an array of continuous, polygon shaped open cells which are biased with respect to the initial fluid flow direction. The periphery of the flow directing honeycomb is rigidized to stiffen the same for minimizing the displacements thereof. The rigidity is provided by a framing member comprising upper and lower skin structures affixed to a core material. The framing member is preferably adhesively bonded to the flow directing honeycomb by means of a foaming adhesive and a barrier member. The barrier member is operative for minimizing the expansion of the foaming adhesive into the open cells of the honeycomb.

Abstract: A composite sandwich structure which includes upper and lower skin structures, first and second honeycomb core structures, and an intermediate portion disposed between the first and second honeycomb core structures. The intermediate portion comprises a composite laminate, a barrier member and a foaming adhesive layer disposed between the composite laminate and the barrier member. The foaming adhesive layer is of a type designed to expand when exposed to an elevated temperature. The composite laminate and the barrier member operate to limit the expansion of the foaming adhesive layer into the open cells of the first and second honeycomb core structures. The foaming adhesive layer, upon expansion, applies pressure against the composite laminate. This pressure, acting concomitantly with the applied curing pressure and the elevated temperature, cures the laminate. Furthermore, the expansion of the foaming adhesive urges the composite laminate and the barrier member apart so as to fill any core discrepancies, i.e.