Abstract: A mold and a method for molding high strength, non-metallic fiber reinforced composite parts having a variety of (e.g., cylindrical) shapes that are lighter in weight than similar parts manufactured from metal. An unmolded non-metallic pre-form having long continuous fibers is placed around a mandrel, and a segmented, adjustable diameter compression ring is disposed in surrounding engagement with the pre-form at an upper position within an inwardly tapered compression ring support. The compression ring is formed from a plurality of loose compression ring segments that are initially spaced circumferentially from one another at the upper position of the compression ring support. The mandrel and the pre-form are first heated and then located in a press.

Abstract: A method for compression molding a composite, fiber reinforced wheel. The strength, stiffness and reliability of the wheel is maximized so as to resist failure under high shear and other mechanical loads by controlling the orientation of non-metallic fibers which run through the wheel. Substantially all of the fibers in an inner bearing housing of the wheel extend circumferentially therearound, substantially all of the fibers in a cylindrical outer attachment flange run in a radial direction with respect to the wheel, and substantially all of the fibers of an intermediate rim run in an axial direction. During compression molding, some of the axial running fibers of the rim are forced towards and interspersed among some of the fibers which run circumferentially around the bearing housing so as to establish a wave-shaped mechanical interlock at the interface therebetween.

Abstract: A method for making a non-metallic, fiber reinforced wheel for an in-line skate and similar rolling articles. Resin impregnated carbon fibers are compression molded to form a high strength and very stiff (i.e. rigid) annular hub having a central channel extending longitudinally therethrough to accommodate an axle. Bearing cavities are formed at opposite ends of the central channel in which to receive and retain respective axle bearings. A hollow air pocket is established so as to extend around and through the interior of the hub in order to occupy a majority of the volume of the hut) and thereby reduce the overall weight of the wheel. A scalloped wheel retaining rim is formed around the circumference of the hub to which an outer urethane tire is bonded to enable the wheel to roll along a flat surface.

Abstract: A one-piece non-metallic nut ring for surrounding and supporting an electrical connector attached to a bulkhead or other flat panel. The nut ring includes a planar backplate and threaded nuts extending outwardly therefrom. The backplate and nuts are coextensively and continuously connected to one another by compression molding a matrix of resin impregnated, non-metallic fibers. The non-metallic fibers are preferably short chopped fibers that are randomly dispersed within the matrix in directions extending generally parallel to the plane of the backplate. The nut ring of this invention is characterized as being of relatively light weight, corrosion resistant, non-conductive and able to withstand detection by radar.

Abstract: A bushing roller bearing having particular application for use in a wing flap assembly of an aircraft by which a wing flap is raised or lowered. The bearing includes metallic, coaxially aligned outer and inner races and a non-metallic intermediate liner disposed therebetween. The inner race is coupled to and rotatable with a shaft that is interconnected with the wing flap. The outer race is adapted to rotate (i.e. ride) along a wing flap track at the wing of an aircraft. The intermediate liner is formed from a self-lubricating composite material which reduces wear and friction between the outer and inner races. The intermediate liner floats through the bearing, such that a clearance exists between the liner and the races to permit the liner to be displaced laterally and radially. By virtue of the intermediate liner, the susceptibility of the bearing excessive wear, to lock-up and possible failure is reduced.

Abstract: A method for making a non-metallic rod end bearing assembly to be interconnected with a control rod. The assembly comprises a rod end bearing and a hollow collar, such that the rod end bearing can be coupled to one end of the control rod by way of the collar. The rod end bearing and hollow collar are made by first impregnating respective reinforcement of non-metallic fibers with a resin. The resin impregnated fibers are then compression molded into the desired shape. By virtue of the present method, a rod end bearing assembly is available which is characterized by a longer life, greater resistance to corrosion and wear, and a superior weight-to-strength ratio relative to conventional rod end bearing assemblies that are manufactured from metal.

Abstract: A fastener member and method of formation are provided wherein a bolt and nut are formed from a block of resin-impregnated fibers woven in a first, second and third plane each perpendicular to the other wherein the fibers in the first plane extend continuously and longitudinally through the fastener member and the fibers in the second and third plane extend to form the peaks and valleys of the helical thread.

Abstract: A fastener member and method of formation are provided wherein a bolt and nut are formed from a block of resin-impregnated fibers woven in a first, second and third plane each perpendicular to the other wherein the fibers in the first plane extend continuously and longitudinally through the fastener member and the fibers in the second and third plane extend to form the peaks and valleys of the helical thread.