Abstract: Continuous filament rope and method of making same whereby high strength continuous synthetic filaments may be used to provide a rope which in use will have a strength approaching the theoretical strength of the fibers therein. The rope is made by combining a plurality of filaments and twisting the filament group into a light twine in comparison to the rope ultimately desired. The twine is then impregnated with a suitable flexible resin system and wound in a loop having at least a substantial number of turns of the twine. Thereafter the loop is allowed to twist back on itself in response to the twist initially set in the twine so as to form a rope-like center section with loops at each end thereof. Curing of the flexible resin system results in a suitable flexibility of the rope while providing for abrasion and fraying resistance. The loops at the end of the rope may be looped over hooks or pins when in use, with the resulting strength of the rope approaching that of the combined fiber strength.

Abstract: Continuous filament apex fittings and methods of manufacture thereof to provide high-strength, low-weight fittings for use on cargo lifts and the like, and as replacements for metal clevises. The fittings are made by wet-winding one or more strands of continuous filaments into a loop, forming the loop into a basic clevis-like shape and curing the resin. The use of a flexible resin allows spreading of the clevis eyes for entry and removal of the item to be retained by the clevis without a separate clevis pin. Twisting of the loop one or more times along the major length of the loop prior to bending in the basic clevis shape creates an integrated clevis body having better load distribution across the cross-section thereof. Alternate methods of manufacture are disclosed.

Abstract: A fiber-reinforced plastic article of manufacture having a multi-chambered, cellular structure with an outer shell and an inner shell for use as part of a fluid foil structure, said inner shell extending between at least two generally opposite interior walls of said outer shell and being coupled thereto, thereby defining at least two chambers within said article, the wall of each of said shells being composed of a plastic having embedded therein at least one layer of continuous roving of a fibrous reinforcement material, said at least one layer in each of said shells being continuous and unbroken around each of said shells.

Abstract: Contoured load carrying filament reinforced matrix structure which may be in the form of an airfoil or hydrofoil and comprising a plurality of elongated coextensive tubes disposed in side-by-side relationship to form a tube assembly and individually of sufficient cross section to project substantially from one side to the other of the cross sectional contour of the foil with the opposite cross sectional extremities of such tubes cooperating to form a composite cross sectional contour defining the contour of such foil. A skin is wrapped around the composite tube assembly and is bonded thereto to secure such filament wound tubes in position and provide for good load distribution when such foil is loaded.

Abstract: A tubular member which is ideally suited as a drive shaft for transmitting power from an engine to a remote station such as the drive shaft for a helicopter tail rotor or a remotely mounted propeller or rotor and a method of fabricating said member. The tubular member has a cylindrical body portion and at least one conical end portion with an integral, radial flange upstanding therefrom. The wall of the tubular member is composed of a plastic having embedded therein at least one layer of continuous filaments of fibrous reinforcing material with each layer of such material comprising two adjacent thicknesses of filaments. The filaments are in parallel alignment in each thickness and in diagonal orientation between thicknesses at a first helix angle in the cylindrical body portion and at a second, greater helix angle, in the conical end portion.

Abstract: A fiber-reinforced plastic article of manufacture having a multi-chambered, cellular structure with an outer shell having a fluid foil shape with a leading edge having a smooth radius of curvature and a trailing edge [noncircular]cross section over a substantial portion of its length and containing therein an inner shell which extends between at least two opposite interior walls of said outer shell thereby defining at least two chambers within said article, the walls of said shells being composed of a plastic having embedded therein at least on layer of a continuous roving of a fibrous reinforcement material, said at least one layer comprising two adjacent thicknesses of said roving with the rovings being in parallel alignment in each thickness and the rovings being in parallel alignment in each thickness and in diagonal orientation between thicknesses and with the rovings in the outer shell being continuous and unbroken over the leading edge of said foil shape.

Abstract: There is disclosed a method of manufacturing a filament wound blade including the steps of forming a spar by winding a plurality of resin impregnated filaments in side-by-side relationship between a pair of spaced apart spools. The spools are held in their spaced apart orientation to maintain the filaments in their unidirectional orientation and a flexible bondable bag fitted over the spar filaments and inflated to assume a generally cylindrical configuration. Resin impregnated shell filaments are wound in a helical pattern about such bag to form a shell and the bag then deflated and placed in a female mold defining the desired contour of such blade, and such bag then re-inflated to thereby cause the shell to assume such desired contour.