Abstract: A method is disclosed for repairing a worn helicopter rotor blade made of composite materials by adhesively securing a supplemental leading edge abrasion wear strip made of nickel to the leading edge of the rotor blade. The periphery of the bonding surface of the leading edge of the rotor blade is masked. The bonding surfaces of the supplemental leading edge strip and the rotor blade are cleaned with a medium-grit scrubbing pad, grit-blasted with aluminum oxide and then rinsed with DI water. A strip of a structural adhesive film is hot bonded to the bonding surface of the supplemental leading edge strip using vacuum and a high temperature oven cure. The side of the structural adhesive film bonding surface which will be secured directly to the rotor blade bonding surface is first abraded and then wiped with a solvent. An epoxy adhesive mix is applied to the bonding surfaces of the rotor blade and the structural adhesive film of the supplemental leading edge strip.

Abstract: A corrugated composite panel has improved strength and load carrying abilities. Two layers of transverse unidirectional filaments sandwich a layer of unidirectional filaments which are parallel with the corrugations. The layers are impregnated with resin. Also, one or more layers of chopped randomly oriented filaments are included.

Abstract: A composite member is formed having improved strength and load carrying abilities by drawing a web of backing material toward a pair of primary rollers. A layer of transverse unidirectional filaments is laid down onto the backing web and a web of unidirectional filaments is drawn through the primary rollers simultaneously with the transverse layer and web of backing material. A resin is applied to the web of materials exiting the primary rollers and a second transverse layer of unidirectional filaments is laid onto the top of these materials to form a composite web. The composite web of materials is drawn to an oven where it is shaped and cured to produce the finished composite member. The finished member has a center ply of unidirectional filaments which is encapsulated by upper and lower transverse layers of unidirectional filaments. The transverse layers retain the shape of the unidirectional filaments, adding to the strength of the finished member.

Abstract: A method of constructing a fiberglass structure features that enable a gelcoat protective layer to be applied to an article formed in an automatic process. In the process, a web of fiberglass is drawn through a bath of structural resin to impregnate the fiberglass with the structural resin. A web of organic, porous veil material is drawn through a bath of gelcoat resin simultaneously with the structural resin impregnated web of fiberglass. The two webs are squeezed together, and the resin metered to provide a composite web having a layer of resin and a layer of gelcoat. A mold draws the composite web off of the rollers. Once a section has been drawn onto the mold, the web is sheared. Then the mold is moved into an oven for heating and curing the article.

Abstract: A fiberglass footbridge comprising a floor, handrails, and a web between the floor and the handrails, all of fiberglass. A continuous layer of fiberglass filaments that extend parallel with the bridge are formed in the handrails and the corners of the floor. U-shaped supporting members are attached around the web and the floor, and are spaced between the ends of the bridge. A subfloor or torque box is formed between the supporting members below the floor.

Abstract: A fiberglass ladder comprising a pair of rails and a plurality of rungs interposed at selected intervals. Each rung and each rail has a continuous layer of fiberglass filaments extending parallel to its respective length. At the intersection of the rails with the rungs, the filaments bend with a portion of the filaments in the rung extendingin one direction along the rail, and a portion of the filaments in the rung extending in the other direction along the rail. The ladder is cast in a mold in a solid integral piece. Woven fiberglass is placed in the channels of the mold over a coating of resin. The fiberglass filaments are placed over the fabric in the bottoms of the channels. The channels are then filled wth a rigid plastic foam and the ladder is allowed to cure.