A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

An aircraft heat exchanger system according to an exemplary embodiment of this disclosure, among other possible things includes a first heat exchanger assembly that is disposed in an inlet duct assembly, and a skin heat exchanger assembly is in thermal communication with an outer surface of an aircraft structure. The skin heat exchanger is in fluid communication with the first heat exchanger such that a working fluid is communicated therebetween.

Multifunctional surfacing materials for use in composite structures are disclosed. According to one embodiment, the surfacing material includes (a) a stiffening layer, (b) a curable resin layer, (c) a conductive layer, and (d) a nonwoven layer, wherein the stiffening layer (a) and the nonwoven layer (d) are outermost layers, and the exposed surfaces of the outermost layers are substantially tack-free at room temperature (20° C. to 25° C.). The conductive layer may be interposed between the curable resin layer and the stiffening layer or embedded in the curable resin layer. According to another embodiment, the surfacing material includes a fluid barrier film between two curable resin layers. The surfacing materials may be in the form of a continuous or elongated tape that is suitable for automated placement.

Multifunctional surfacing materials for use in composite structures are disclosed. According to one embodiment, the surfacing material includes (a) a stiffening layer, (b) a curable resin layer, (c) a conductive layer, and (d) a nonwoven layer, wherein the stiffening layer (a) and the nonwoven layer (d) are outermost layers, and the exposed surfaces of the outermost layers are substantially tack-free at room temperature (20° C. to 25° C.). The conductive layer may be interposed between the curable resin layer and the stiffening layer or embedded in the curable resin layer. According to another embodiment, the surfacing material includes a fluid barrier film between two curable resin layers. The surfacing materials may be in the form of a continuous or elongated tape that is suitable for automated placement.

An aircraft fuselage includes an element forming a skin and a load-carrying structure supporting the element forming the skin. The load-carrying structure includes a plurality of elements forming a spar disposed parallel to an axial direction defined by the fuselage and a plurality of elements forming a frame disposed spaced apart along the axial direction. Each element forming a frame being arranged substantially perpendicularly to the elements forming a spar, where the element forming the skin is fastened on an external perimeter of each element forming a frame by means of fastening elements configured to keep the element forming the skin away from the external perimeter and where the element forming the skin is made of a transparent material.

An aircraft fuselage includes an element forming a skin and a load-carrying structure supporting the element forming the skin. The load-carrying structure includes a plurality of elements forming a spar disposed parallel to an axial direction defined by the fuselage and a plurality of elements forming a frame disposed spaced apart along the axial direction. Each element forming a frame being arranged substantially perpendicularly to the elements forming a spar, where the element forming the skin is fastened on an external perimeter of each element forming a frame by means of fastening elements configured to keep the element forming the skin away from the external perimeter and where the element forming the skin is made of a transparent material.

A side wall portion of an aircraft has an integrated structural battery and heating member. The side wall portion has a plurality of solar cells arranged on an inner circumferential surface of a window frame structure. The electrical energy produced by the solar cells is stored in the structural battery and output to the heating members, so as to heat the side wall portion. With this a thinner thermal insulation of the fuselage structure is possible in the vicinity of the seats so as to allow for an additional seat in the abreast direction.

A side wall portion of an aircraft has an integrated structural battery and heating member. The side wall portion has a plurality of solar cells arranged on an inner circumferential surface of a window frame structure. The electrical energy produced by the solar cells is stored in the structural battery and output to the heating members, so as to heat the side wall portion. With this a thinner thermal insulation of the fuselage structure is possible in the vicinity of the seats so as to allow for an additional seat in the abreast direction.

A method for manufacturing a structural element for a fuselage of an aircraft. To improve the manufacture of structural elements, a method includes laying up textile material members on a mandrel to form a plurality of structural element preforms that are space apart along an extended direction of the mandrel. The structural element preforms form closed loops and are subsequently cured to obtain annular structural elements. The annular structural elements are used as basic building blocks for stiffening panel members or are directly used as structural frame elements reinforcing cut-outs in a fuselage for windows and/or doors.

A method for manufacturing a structural element for a fuselage of an aircraft. To improve the manufacture of structural elements, a method includes laying up textile material members on a mandrel to form a plurality of structural element preforms that are space apart along an extended direction of the mandrel. The structural element preforms form closed loops and are subsequently cured to obtain annular structural elements. The annular structural elements are used as basic building blocks for stiffening panel members or are directly used as structural frame elements reinforcing cut-outs in a fuselage for windows and/or doors.