Abstract: An efficient and cost-effective method of manufacturing a kink-resistant tube, wherein a coated wire is wound around a mandrel while simultaneously being heated to melt the coating, is provided.

Abstract: A method of forming a homogenous composite pipe of unspecified length from strips of fiber reinforced thermoplastic material is disclosed. A mandrel is arranged stationary in a process direction to extend freely from a first supported end to a second end. A slip-sheath is applied about the mandrel. The thermoplastic material strips are wound about the slip-sheath. A section of the thermoplastic material strip winding is consolidated. The slip-sheath is formed from tape material which is applied longitudinally onto the mandrel surface. The slip-sheath is connected to a puller arranged downstream of the material in the process direction. Consolidated pipe sections are pulled off from the second end of the mandrel in synchronization with the winding and consolidation. An assembly for carrying out the method.

Abstract: A method of forming a composite layup on a substrate comprises: moving an automatic fiber placement head over the substrate; using the fiber placement head to lay down multiple, parallel strips of composite tape on the substrate, including staggering the start of at least certain of the tape strips so as to form a contour pattern; and, cutting the ends of all of the tape strips using a single cut.

Abstract: A composite reinforcing bar is formed by providing a reinforcing material supply of fiber strands ravings; a resin supply bath, and a puller for pulling the resin-impregnated reinforcing material through the resin bath. The material is wound on a helical holder, while the resin remains unset, rotated about its axis on a drive system so that the material is wrapped the holder which is indexed along it axis and removed when full for curing the resin on the holder while the body remains wrapped thereon. The bar is wrapped with the turns side by side and is then stretched out and held by longitudinal straight bars while the reinforcing structure so formed is embedded in a cast material.

Abstract: An efficient and cost-effective method of manufacturing a kink-resistant tube, wherein a coated wire is wound around a mandrel while simultaneously being heated to melt the coating, is provided.

Abstract: A mandrel for manufacturing a unitary seamless section of an aircraft fuselage comprises a thin lay-up mandrel element disposed onto the outer shell surface of an inner mandrel shell, forming a mandrel with a substantially continuous lay-up surface. A unitary pre-cured section of an aircraft fuselage is formed by laying up a plurality of resin impregnated skin fibers onto the mandrel's lay-up surface while the mandrel rotates.

Abstract: A system comprises an automated fiber placement (AFP) machine and a layup mandrel tool supported by the AFP machine. The mandrel tool includes a truss core and a plurality of mandrel panels attached to the truss core to form a layup surface.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: A layup mandrel includes a shell having a tool surface on which plies may be laid up. The shape of the shell is changed by an actuator.

Abstract: A method for producing a central wing box having an upper panel, a lower panel, a front spar and a rear spar, the upper edges of said spars approximately parallel to an axis Y being connected by the upper panel, and the lower edges of said spars approximately parallel to the axis Y being connected by the lower panel. The method includes producing at least one panel and at least one spar from composite material in one piece.

Abstract: The invention relates to a rod-shaped base body with at least one bearing surface which can be brought to bear against at least one counter-bearing surface of a bearing device for fastening to a further rod-shaped base body and/or a functional component for forming a framework. The rod-shaped base body can be a fibre-composite material, particularly carbon-fibre-reinforced plastic, and the rod-shaped base body has a recess as positioning mark determining the position of the further base body and/or the functional component in relation to the rod-shaped base body in the framework by the positive engagement due to the at least one bearing surface and at least one counter-bearing surface bearing against one another. The invention also includes a framework system having a rod-shaped base body of this type. The object of the invention is additionally achieved by a method for producing a rod-shaped base body of this type.

Abstract: The present invention describes composite rods keeping two elements apart a determined distance carrying the loads between them, such as railways, industrial premises, etc. Besides, the manufacturing method thereof and the tool involved in this process are also described.

Abstract: A fiber placement tool comprising a plurality of tool segments, each tool segment having an outer surface defining a predetermined profile, each tool segment being removably mounted on at least one elongate shaft.

Abstract: A method for manufacturing a composite ring (1) comprising the steps of: (a) providing band-shaped means (2) of reinforcement fibres (5, 5?) impregnated with a high temperature thermoplastic material and (b) wrapping the band-shaped means (2) around a mandrel (9) to form the ring (1) in such a way that a first group (5) of the embedded reinforcement fibres extends substantially continuously along a first direction (3) with respect to the circumferential direction (10) of the ring (1), characterised in that the band-shaped means (2) is wrapped in such a way that a second group (5?) of the embedded reinforcement fibres extends substantially continuously along a second direction (4) different from the first direction (3) with respect to the circumferential direction (10) of the ring (1).

Abstract: A bicycle assembly can include a main frame having a bottom bracket shell to receive a bottom bracket. The bottom bracket shell can be made of carbon fiber with one or more metal rings to serve as bearing surfaces within the bottom bracket shell. The metal rings may also be split metal rings with a gap between two spaced apart ends.

Abstract: A method for making large pressure vessels using a composite over-wrap process and a soluble mandrel structure that is scalable to a much larger vessel size than can normally be accommodated by the over-wrap process. The method allows the production of very large, lightweight vessels with no seams and no metal liners. Extensions of the method provide for the fabrication of fully embedded threaded or non-threaded bosses of composite materials, and fully embedded longitudinal and circumferential stringers or stiffeners.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: A strut comprises a substantially hollow composite tube. A fitting on each end of the tube adapts the strut for attachment to a structure. The tube is stiffened by at least one pair of opposing stiffeners.

Abstract: A stabilizer bar or stabilizer link in fiber composite construction is of a monolithic construction without fiber interruption. The cross section geometry, the wall thickness, and the fiber orientation vary in axial direction and radial direction such that the requirements defined by the available construction space and the expected loads are fulfilled. The fiber orientation is adjusted axially and radially load-appropriately. The middle section of the stabilizer bar that is primarily torsion-loaded is reinforced with fibers oriented between +/?35° and +/?55° relative to the longitudinal axis and the end members that are primarily bending-loaded are reinforced with fibers oriented between +/?20° and +/?40° relative to the longitudinal axis. In the transitional areas between the middle section and the end members there are transitions between these fiber orientations relatively to the longitudinal axis.

Abstract: A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. A skin is applied to a smooth, hard base tool. Ribs comprised of carbon-fiber tows are formed on the skin, and shallow cavities are formed between the ribs and the skin. An expansion block is placed in each of the cavities, and is held in place by an elastomeric contact adhesive having adhesive properties that are substantially diminished when the adhesive is heated to an elevated curing temperature. The assembly is then autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. A grid-stiffened sandwich structure is formed by applying an outer skin over the ribs and expansion blocks, before curing the assembly. After cooling, the outer skin is removed to allow extraction of the blocks, and subsequently bonded to the ribs.

Abstract: A collapsible mandrel comprises an inflatable bladder. The bladder includes a reinforcement sandwiched between inner and outer layers of a fluoroelastomeric rubber.

Abstract: A structural member such as a strut includes a composite material tube having metal end fittings that are attached to the tube by co-bonded, double shear joints. The double shear bond joint construction reduces the residual stress on the bonds that result from mismatch of the coefficients of thermal expansion of the composite tube and the metal end fittings. The ends of the fittings that are bonded to the tube may include a stepped profile that functions to limit the peak stresses in the bonds.

Abstract: A device for manufacturing an FC component with at least one distributing device for placing at least band-shaped material onto a surface of a tool mold or semi-finished product for manufacturing the FC component, wherein the device has at least one bogie truck that carries the distributing device and a guide way that runs around the surface at least partially in its circumferential direction, on which the bogie truck for traversing the distributing device can be moved relative to the surface, as well as a method for manufacturing a fiber composite component and a component fabricated according to such a method.

Abstract: A fiberglass-binder insert is made by fabricating a shape-constant, cured fiberglass-binder mixture, into a shape-constant insert core, and shrink-wrapping the core while leaving exposed any bore which extends into the core. The core is fabricated by mixing fiberglass and uncured binder in a mixer, dropping the mixture into a conforming guide such as a funnel, and moving the mixture through the conforming guide and into a mold. A tamper can tamp the mixture to move the mixture from the conforming guide into the mold, and to distribute portions of the mixture vertically in the mold. Rotation of the mold effects circumferential distribution of the mixture in the mold. The mixture in the mold is heated to cure the binder, thus to establish a fixed shape of the resultant core product. A shrink film is shrunk about the core, providing apertures in the shrunk film at bore openings in the core.

Abstract: A composite reinforcing bar is formed by providing a reinforcing material supply of fiber strands rovings; a resin supply bath, and a puller for pulling the resin-impregnated reinforcing material through the resin bath. The material is wound on a holder, while the resin remains unset, rotated about its axis on a drive system so that the material is wrapped around a plurality of bars at spaced positions around the axis such that the fed length of the body is wrapped from one bar to the next to form bent portions of the body wrapped partly around each bar and straight portions between the bars. Each bar has angularly grooves which are shaped to mold the bent portions to a required bent shape. The holder is indexed along it axis and removed when full for curing the resin on the holder while the body remains wrapped thereon.

Abstract: A method of making a corded surface flexible elastomer golf club grip. An underlist is extruded of seamless tubular uncured elastomer and a pattern of textile cords wound thereon. In one version of the method, an outer seamless tubular extruded uncured elastomer layer is assembled over the cord patterned underlist. A core rod is inserted in the underlist, an uncured elastomer cap assembled on the end and the assemblage cured in a heated compression mold. Upon removal from the mold, some material is removed from the outer surface to expose some of the cord. In another version, the uncured cord wound underlist with core rod is inserted in a mold cavity and a thin outer layer of elastomer injection molded thereover and the assemblage cured in the mold.

Abstract: A non-compliant fiber-reinforced medical balloon comprises a first fiber layer and a second fiber layer embedded in a continuous matrix of thermally-weldable polymer material defining a barrel wall, cone walls and neck walls. The fibers of the first fiber layer run substantially parallel to one another and substantially parallel to the longitudinal axis. The fibers of the first fiber layer have a pattern of different lengths and are divisible into a first group and a second group based on length. Each fiber of the first group begins in the neck wall at one end of the balloon, extends continuously in the longitudinal direction and terminates in the neck wall at the opposite end of the balloon. Substantially all of the fibers of the first group have a generally uniform length. Each fiber of the second group begins in the cone wall at one end of the balloon, extends continuously in the longitudinal direction and terminates in the cone wall at the opposite end of the balloon.

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.

Abstract: Methods for manufacturing composite sections for aircraft fuselages and other structures are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: A process for obtaining pipes and connections from a polymeric composite is provided. An internal pipe is formed using a fiberglass and epoxy resin matrix. Made in a mold by filament winding a roving wire, the internal pipe is impregnated with epoxy resin and catalyzed with a heat curing agent. The pipe extremities are formed through a mold using a composite of epoxy resin and carbon fiber base. The external face of the internal layer is sanded. A second layer is formed by filament winding a roving wire, impregnated with polyester resin with an added silica base, and catalyzed with cold-cured cobalt and polyester. Charge is added to the silica base. The polyester resin is deposited in an intercalated manner between the layers of winding filament. A third layer of polyurethane is deposited over the second layer and cold cured.

Abstract: A flexible muffler for use in an aircraft environmental system includes a flexible body having a porous inner layer and an air impervious outer layer both supported by a helically wound adhesively attached reinforcing cord. The flexible body includes a pair of connecting end caps at opposed ends thereof which are joined to the flexible body in an air tight attachment. The resulting muffler provides acoustic energy absorptive and is readily flexed and bent to accommodate space restrictions within the environmental control system of the aircraft.

Abstract: An automated in-line feed-through system integrating the delivery, application and infusion of a resin to one or more fiber tows and layup of the one or more infused fiber tows to form a composite structure. The system includes an automated resin delivery, deposition and infusion system configured to deposit the resin on one or more fiber tows and form the infused fiber tows. The system integrates an automated layup system including a compaction roller, a guide roller coupled to an extending cylinder, and an auxiliary roller configured to adhere the one or more infused fiber tows to a substrate. The system further includes a controller configured to control system parameters, including the control of tension of the one or more infused fiber tows within the automated layup system. Other aspects of the automated in-line manufacturing system are also provided.

Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on reinforcing fibres and on a cross-linkable resin, by continuously winding in superposition a predetermined number Nc of layers of a tape of the reinforcing fibres embedded in a matrix based on a composition comprising the cross-linkable resin, the method comprising, from the upstream end downstream, the steps of: forming a tape made of the reinforcing fibres, the thickness of the tape being between 0.1 mm and 0.5 mm; depositing the tape on a support that dictates the final shape of the composite block, and winding the tape onto the support, in a single direction, by superposing the number Nc of layers in order directly to form the continuous ring on the support, Nc being less than 15.

Abstract: Provided is a first reinforcing fiber layer (11) formed of reinforcing fibers which are wound around an outer periphery of a mandrel (20), aligned in parallel to a direction (+? direction) in which the reinforcing fibers intersect with an annular direction (0° direction) of the mandrel (20), and seamlessly continue in the annular direction of the mandrel (20) by an amount of at least one rotation.

Abstract: According to the present invention, a method for manufacturing a prepreg sheet includes steps of (A) forming a resin layer 61 on a surface of a supporter 3, (B) winding a reinforcing yarn 10 around the resin layer 61, and (C) embedding at least a part of the reinforcing yarn 10 in the resin layer 61. Preferably, in step (C), the surface of the supporter 3 is relatively moved towards the reinforcing yarn 10.

Abstract: Composite tubes may be fabricated by filament winding a layer of resin impregnated carbon fiber with a near-axial fiber orientation over a mandrel and over end-fittings. Bands of resin-impregnated fibers are then wound circumferentially around this near-axial layer in a position that coincides with a circumferential groove in the underlying end-fittings. The ends of the near-axial layer are folded back over the bands, resulting in a double layer of intact near-axial fibers locked into the groove on the end-fittings by the bands of intact circumferential fibers. Testing has shown this arrangement to be effective for introducing very high axial loads onto the composite tube.

Abstract: A method for producing a fibre-reinforced plastic component is specified. In a first step, a positive arrangement is produced by fixing at least one reinforcement ready to be used on a positive core. In a second step, fibres are wound around the positive arrangement, concave regions of the positive arrangement that are formed by the reinforcement being spanned by the fibres. In a third step, the entire area of the fibres is pressed onto the positive arrangement in a negative mould. Finally, the component is cured in the negative mould following the introduction of a cross-linking plastic.

Abstract: A composite reinforcing bar is formed by providing a reinforcing material supply of fiber strands rovings; a resin supply bath, and a puller for pulling the resin-impregnated reinforcing material through the resin bath. The material is wound on a holder, while the resin remains unset, rotated about its axis on a drive system so that the material is wrapped around a plurality of bars at spaced positions around the axis such that the fed length of the body is wrapped from one bar to the next to form bent portions of the body wrapped partly around each bar and straight portions between the bars. Each bar has angularly grooves which are shaped to mold the bent portions to a required bent shape. The holder is indexed along it axis and removed when full for curing the resin on the holder while the body remains wrapped thereon.

Abstract: A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. A skin is applied to a smooth, hard base tool. Ribs comprised of carbon-fiber tows are formed on the skin, and shallow cavities are formed between the ribs and the skin. An expansion block is placed in each of the cavities, and is held in place by an elastomeric contact adhesive having adhesive properties that are substantially diminished when the adhesive is heated to an elevated curing temperature. The assembly is then autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. A grid-stiffened sandwich structure is formed by applying an outer skin over the ribs and expansion blocks, before curing the assembly. After cooling, the outer skin is removed to allow extraction of the blocks, and subsequently bonded to the ribs.

Abstract: The invention provides a method of manufacturing a housingless hollow fiber filtration apparatus using batch, continuous, and semi-continuous processes. Also provided is manufacturing methods to increase rigidity of the apparatus.

Abstract: In a method and a tool for forming an elongate, hollow article of a fiber-reinforced composite material one end of an article laminate applied to a tool bar is placed in engagement with or is supported by an anvil of the tool so as to control the direction of longitudinal movement of the cured article relative to the tool bar during the cooling and dismantling phase.

Abstract: The object of the invention is a process for the production of a tube of high stiffness, characterized in that it comprises the following steps: producing a first internal tube (10) of a first material, placing intermediate members (12) on this first tube, regularly spaced, these intermediate members being made of a composite material producing at least one second tube (14) of a second material, about these intermediate members, at least one of the first or second tubes being made by filamentary winding. The invention also covers the obtained tube.

Abstract: The invention relates to a head for application of carbon-fibre strips that has at least two spools (1) conveying respective carbon-fibre strips for the selective feed of said strips and in order thus with said strips to make up the width of the stripping for application. These spools (1) are arranged on a master roller (5) formed by independent sections that are actuated individually by respective rotary transmissions.

Abstract: A method for fabricating a tower or component thereof for use with a wind turbine is disclosed. The method comprises weaving a fibrous tow in a shape corresponding to the shape of the tower or component to form a flexible textile preform; and laminating the flexible textile preform to form a composite shell. Also disclosed is a wind turbine assembly comprising a composite wind turbine tower and a wind turbine coupled to the tower.

Abstract: The present invention relates to a method for manufacturing a connecting rod including: a) manufacturing an inner body; b) adding one end of the inner body to the end of the reduced outer diameter of each end piece, said end of the inner body resting on the shoulder of the end piece; (c) inserting a first portion of a second mandrel in the hollow cylindrical portion of each end piece and placing a driving bit at the free end of a second portion of the second mandrel; d) winding said pre-impregnated fibres onto the outer surface of an assembly consisting of the inner body, the end piece(s) and the second part(s) of the second mandrel(s) which are free of bits, said fibres then forming an outer body; e) after removing the bit(s), polymerising the inner body and the outer body to form a polymerised integral body; f) removing the second mandrel(s) and cutting the polymerised integral body to the required length.

Abstract: Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are disclosed herein. A composite section configured in accordance with one embodiment of the invention includes a skin and at least first and second stiffeners. The skin can include a plurality of unidirectional fibers forming a continuous surface extending 360 degrees about an axis. The first stiffener can include a first flange portion bonded to an interior surface of the skin and a first raised portion projecting inwardly and away from the interior surface of the skin. The second stiffener can include a second flange portion bonded to the interior surface of the skin and a second raised portion projecting inwardly and away from the interior surface of the skin. A method for manufacturing a section of a fuselage in accordance with one embodiment of the invention includes positioning a plurality of uncured stiffeners on a mandrel assembly.

Abstract: A first insert (15) forming a ring is placed inside and in contact with a core (10) in degradable material. On the outer face of the core a plurality of inserts (20) is arranged each comprising a platform (21) applied against the outer face of the core and at least one blade (22) extending substantially radially outwards. A fibrous structure (56) is wound around the core passing over the platforms (21) and over the inner surface of the ring-shaped insert (15). Molding of the fibrous structure, impregnated with a composition containing a resin, is performed before polymerization of the resin and removal of the core.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: To fabricate a composite item, a first end effector is selected from a plurality of end effectors to apply tows to a form. The first end effector includes an integrated creel configured to store spools of the tow on an assembly of spindles. The assembly of spindles is substantially parallel to a longitudinal axis of the first integrated creel. The first end effector is secured to a positioning device. The tows are applied to the form and the tows are compacted on the form with a compaction device. The assembly of spindles are disposed circumferentially about the compaction device.

Abstract: A golf club shaft is provided that has a grip end opposite a head end and defining a length of the shaft extending between those two ends. The shaft has a tubular cross-section over at least one portion of the shaft length which cross-section has a substantially circular outer periphery and a polygon inner periphery formed of a plurality of between 4 and 24 flats, and preferably formed of 8-16 flats. A mandrel having the shape of the inner periphery of the shaft is also provided, as is a method of forming the shaft that uses the mandrel and composite matrix materials.