Abstract: Reinforced structures of graphite, fiberglass, and the like, together with thermoplastic resinous fibers such as in ribbon, filament and monofilament form are produced. The graphite fiber is combined or blended with a resinous fiber to form a single yarn. The blended yarn is then woven into a soft, supple and flexible fabric having the appropriate concentration of graphite and resin, and with good uniform characteristics. Hybrid fabrics produced by interweaving graphite and the polymeric fibers, ribbon, etc., may be utilized instead of the blended yarn. The fabric is finally shaped to conform with a mold or substrate and heated to melt the resin and produce the resin-graphite laminate.

Abstract: An interwoven fabric having moveable layers of graphite, fiberglass, Kevlar, and similar materials are wrapped or conformed around shaped mold parts. These layered shape parts are subsequently impregnated with resin and cured to produce a reinforced product having a reasonably uniform fiber density. Typical shaped structures include boxes, hemispheres, ojives, etc. The process is particularly suitable for producing structures where the fabric distortion is severe at corners, angles, and so forth.

Abstract: Rocket exit cones, and similar components are produced by weaving graphite fibers into fabric and wrapping a continuous length of the woven fabric over a rotating wind up form having a non-linear shape as the fabric leaves the loom. A compensator system is provided to accommodate for the varying distances the fabric must travel from the loom to the non-linear wind up form. During wrapping, the wind up form may be traversed for a short distance across the weaving loom to produce a differential wall thickness between the cylinder portion and the conical portion of the cone. In addition, the traverse motion enables the proper curvature to be imparted to the interface between the cylinder and conical portions of the exit cone.The built fabric has a controlled shape, which is adapted for resin-impregnation and curing. The cured structure has sufficient integrity that permits machining of the conical portion to a uniform thickness or to a tapered thin wall.

Abstract: Misaligned strands in a graphite fiber on tape are aligned and wound up on reels with a minimum of degradation by the steps of: separating the individual strands, diverging the strands, aligning the strands and winding the individual strands onto separate take-up reels in one continuous operation.Graphite fabric woven from the strands exhibit little or no degradation and have a uniform density and excellent physical properties. The alignment apparatus is inexpensive, simple to operate and occupies a relatively small space.

Abstract: Weavable yarns whose fibers are metallic or have a heat conducting, metallized coating are woven together with a plurality of yarn layers using, say, an angle weave to produce an interlocked, multilayer fabric. The fabric provides heat conduction paths for the efficient transferring of heat from a substrate.Typical coated or metallic fibers which may be employed in the yarn include glass, graphite, ceramic, polyester, nylon, rayon, cotton, wool, acrylonitrile, etc.; metallic fibers such as copper, aluminum and steel are also suitable. A preferred heat conductive coating comprises an aluminum, aluminum alloy or other suitable metal which can be applied to a glass fiber.

Abstract: An apparatus and process for producing a unique, continuous and endless, bias cut fabric employing ceramic and synthetic fibers is disclosed. The apparatus comprises a take up roll system positioned at the output of a tubular weaving operation.The roll system takes up the tube evenly and ensures a uniform movement of the tube through the system to maintain a uniform weave oriented at 90.degree. to the fabric length.This permits the tube, as it leaves the system, to be cut diagonally and to be unwound as a lay flat fabric having a uniform weave pattern oriented at a bias to the fabric length.