Abstract: An improved reciprocating internal combustion engine has a plurality of engine pistons, which are fabricated from carbon-carbon composite materials, in operative association with an engine cylinder block, or an engine cylinder tube, or an engine cylinder jug, all of which are also fabricated from carbon-carbon composite materials.

Abstract: A three-dimensional piston molding is fabricated from a mixture of chopped, carbon tow filaments of variable length, which are prepregged with carbonaceous organic resins and/or pitches and molded by conventional molding processes into a near net shape, to form a carbon-fiber reinforced organic-matrix composite part. Continuous reinforcement in the form of carbon-carbon composite tapes or pieces of fabric can be also laid in the mold before or during the charging of the mold with the chopped-fiber mixture, to enhance the strength in the crown and wrist-pin areas. The molded chopped-fiber reinforced organic-matrix composite parts are then pyrolized in an inert atmosphere, to convert the organic matrix materials to carbon. These pyrolized parts are then densified by reimpregnation with resins or pitches, which are subsequently carbonized. Densification is also accomplished by direct infiltration with carbon by vapor deposition processes.

Abstract: A carbon fiber reinforced carbon composite valve for internal combustion engines and the like formed of continuous carbon fibers throughout the valve's stem and head is disclosed. The valve includes braided carbon fiber material over axially aligned unidirectional carbon fibers forming a valve stem; the braided and unidirectional carbon fibers being broomed out at one end of the valve stem forming the shape of the valve head; the valve-shaped structure being densified and rigidized with a matrix of carbon containing discontinuous carbon fibers; and the finished valve being treated to resist oxidation. Also disclosed is a carbon matrix plug containing continuous and discontinuous carbon fibers and forming a net-shape valve head acting as a mandrel over which the unidirectional and braided carbon fibers are formed according to textile processes. Also disclosed are various preform valves and processes for making finished and preform carbon fiber reinforced carbon composite valves.

Abstract: An improved exhaust system for an internal combustion gasoline-and/or diesel-fueled engine includes an engine exhaust manifold which has been fabricated from carbon-carbon composite materials in operative association with an exhaust pipe ducting which has been fabricated from carbon-carbon composite materials. When compared to conventional steel, cast iron, or ceramic-lined iron parts, the use of carbon-carbon composite exhaust-gas manifolds and exhaust pipe ducting reduces the overall weight of the engine, which allows for improved acceleration and fuel efficiency; permits operation at higher temperatures without a loss of strength; reduces the "through-the wall" heat loss, which increases engine cycle and turbocharger efficiency and ensures faster "light-off" of catalytic converters; and, with an optional thermal reactor, reduces emission of major pollutants, i.e. hydrocarbons and carbon monoxide.

Abstract: Carbon fiber reinforced carbon composite rotary, sleeve, and disc valves for internal combustion engines and the like are disclosed. The valves are formed from knitted or braided or warp-locked carbon fiber shapes. Also disclosed are valves fabricated from woven carbon fibers and from molded carbon matrix material. The valves of the present invention with their very low coefficient of thermal expansion and excellent thermal and self-lubrication properties, do not present the sealing and lubrication problems that have prevented rotary, sleeve, and disc valves from operating efficiently and reliably in the past. Also disclosed are a sealing tang to further improve sealing capabilities and anti-oxidation treatments.

Abstract: An improved, lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon--carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon--carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbocharging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Abstract: An improved structure for carbon-carbon composite piston architectures consists of replacing the knitted fiber, three-dimensional piston preform architecture described in U.S. Pat. No. 4,909,133 (Taylor et al.) with a two-dimensional lay-up or molding of carbon fiber fabric or tape. Initially, the carbon fabric or tape layers are prepregged with carbonaceous organic resins and/or pitches and are laid up or molded about a mandrel, to form a carbon-fiber reinforced organic-matrix composite part shaped like a "U" channel, a "T"-bar, or a combination of the two. The molded carbon-fiber reinforced organic-matrix composite part is then pyrolized in an inert atmosphere, to convert the organic matrix materials to carbon. At this point, cylindrical piston blanks are cored from the "U"-channel, "T"-bar, or combination part. These blanks are then densified by reimpregnation with resins or pitches which are subsequently carbonized.

Abstract: A device for attaching an experiment carrier to a space station handrail is provided. The device has two major components, a clamping mechanism for attachment to a space station handrail, and a pointing carrier on which an experiment package can be mounted and oriented. The handrail clamp uses an overcenter mechanism and the carrier mechanism uses an adjustable preload ball and socket for carrier positioning. The handrail clamp uses a stack of disk springs to provide a spring loaded button. This configuration provides consistent clamping force over a range of possible handrail thicknesses. Three load points are incorporated in the clamping mechanism thereby spreading the clamping load onto three separate points on the handrail. A four bar linkage is used to provide for a single actuation lever for all three load points. For additional safety, a secondary lock consisting of a capture plate and push lock keeps the clamp attached to the handrail in the event of main clamp failure.

Abstract: An improved structure for a reciprocating internal combustion engine or compressor piston fabricated from carbon-carbon composite materials is disclosed. An integral ring carbon-carbon composite piston, disclosed herein, reduces the need for piston rings and for small clearances by providing a small, flexible, integral component around the piston that allows for variation in clearance due to manufacturing tolerances, distortion due to pressure and thermal loads, and variation in thermal expansion differences between the piston and the cylinder liner.

Abstract: A garment for protecting a person against bites from insects uses a fabric of fine mesh for hindering the entry of small insects and an inner skeleton for supporting the fabric of fine mesh. The fine mesh includes a plurality of outer edges and elastic material. The elastic material connects to a different outer edge. The elastic material allows the fine mesh to fit snugly over the inner skeleton. The elastic material also constricts any openings around the neck, wrists, waist, and ankles of the wearer. The inner skeleton comprises a group of supporting bands, each band comprising a group of poly-filled spacers and a group of second spacers connected to the poly-filled spacers. Each band encircles and surrounds a particular area of the garment wearer's body. Each band also connects to a contiguous supporting band by stretchable material attached to the second spacers and by a poly-filled spacer on one side.