Abstract: This disclosure describes a reinforced thermosetting resin piping system that is protected from external impact and UV damage by an outer polyurea-based layer. The embodiments described herein can be favorably used for underground and aboveground applications. In some implementations, an RTR pipe includes a core layer that includes a resin and fibers, an outer layer that includes a polyurea-based layer, and an interface layer between the core layer and the outer layer. The methods described herein also outline the process of producing the pipe structure.

Abstract: A photovoltaic module includes a plurality of ribbons; and a composite panel comprising a core layer and a skin layer supported by a surface of the core layer, where the core layer includes a core material and the skin layer is formed of a matrix material and a plurality of parallel fibers aligned with the ribbons and disposed in the matrix material. A method of making a photovoltaic module includes applying a pair of skin layers to a core layer, each skin layer including a skin material and a plurality of parallel fibers disposed in the skin material to make a composite sandwich panel; and layering a component including ribbons between the composite sandwich panel and a thin, transparent front sheet; wherein the parallel fibers are aligned with the ribbons; where the composite sandwich panel has a coefficient of thermal expansion matching the coefficient of thermal expansion of the component.

Abstract: Provided are systems and methods for repairing defects in metal pipes using a composite wrap repair system with diode laser curing.

Abstract: A thermoplastic pipe and a method for producing it are described. The thermoplastic pipe includes a hollow inner liner layer, a semi-consolidated core comprising commingled fibers, and a shrink wrap outer layer. The commingled fibers comprise at least one thermoplastic fiber and at least one reinforcing fiber. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is organized along the at least one reinforcing fiber. The method includes winding commingled fibers over the hollow inner liner layer at a designated angle to produce a core layer, covering the core layer in a heat shrinkable wrap, and heating to produce a semi-consolidated core layer. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is organized along the at least one reinforcing fiber.

Abstract: A thermoplastic pipe and a method for producing a thermoplastic pipe are provided. The thermoplastic pipe includes a liner layer, a semi-consolidated core layer comprising a prepreg polymeric fabric layer, and a shrink wrap outer layer. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is randomly distributed across the fabric. The method includes producing a hollow inner liner layer, winding a prepreg comprising a polymeric powder scattered on a fabric over the hollow inner liner layer to produce a core layer, covering the core layer in a heat shrinkable wrap, and heating to produce a semi-consolidated core layer. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is randomly distributed across the fabric.

Abstract: A filament winding assembly includes a rotating mandrel coupled to a shaft that rotates the rotating mandrel. The rotating mandrel includes a first perforated sleeve that defines holes and includes a winding surface. The rotating mandrel also includes a second perforated sleeve disposed inside the first perforated sleeve. The second perforated sleeve defines an interior volume and holes configured to form fluid pathways with the holes of the first perforated sleeve. The fluid pathways extend from the interior volume to the winding surface of the first perforated sleeve. The filament winding assembly includes a filament that is wound, under tension, around the winding surface of the first perforated sleeve. The filament winding assembly also includes a fluid source fluidically coupled to the interior volume of the second perforated sleeve. The fluid source exhausts fluid, through the fluid pathways, from the wound filament to reduce manufacturing defects of the wound filament.

Abstract: Methods, apparatus, devices, and systems for clamping hollow structures with multi-sectional composite clamps are provided. In one aspect, a method includes: sequentially clamping at least two clamp layers around the hollow structure by clamping a first clamp layer around the hollow structure by connecting one or more clamp sections of the first clamp layer to form at least one first joint and clamping a second clamp layer around the first clamp layer by connecting one or more clamp sections of the second clamp layer to form at least one second joint. The at least one second joint and the at least one first joint mismatch with each other around the hollow structure.

Abstract: This disclosure describes a reinforced thermosetting resin piping system that is protected from external impact and UV damage by an outer polyurea-based layer. The embodiments described herein can be favorably used for underground and aboveground applications. In some implementations, an RTR pipe includes a core layer that includes a resin and fibers, an outer layer that includes a polyurea-based layer, and an interface layer between the core layer and the outer layer. The methods described herein also outline the process of producing the pipe structure.

Abstract: Robotic tools, methods, and systems for repairing pipes in-situ are described. A robotic tool includes a body with an annular, cylindrical configuration with a first end and a second end opposite the first end, the body having an inner surface defining an axis; a printing arm attached to the inner surface of the robotic body using a track, the printing arm circumferentially movable along the inner surface of the body; a printing head attached to the printing arm, the printing head movable radially along the printing arm and axially relative to the printing arm; and a plurality of legs positioned at axial intervals around the robotic body, each leg pivotably attached to the robotic body at either the first end or the second end of the body and pivotable between an open position and a closed position.

Abstract: A method of manufacturing continuous fiber reinforced thermoplastic components includes receiving, by a movable die, spread dry fiber tows. The method also includes receiving, by the movable die and from a polymer extruder fluidically coupled to the movable die, molten polymer. The method also include wetting, by the movable die, the spread fiber tows with the molten polymer. The method also includes maintaining, by the movable die, the wet fiber tows spread as the wet fiber tows exit the die. The method also includes depositing, by the movable die, a layer of the wet fiber tows on a printing surface. The movable die is configured to move along the printing surface to form a thermoplastic component of one or more layers of fiber tows on the printing surface.

Abstract: A filament winding assembly includes a rotating mandrel coupled to a shaft that rotates the rotating mandrel. The rotating mandrel includes a first perforated sleeve that defines holes and includes a winding surface. The rotating mandrel also includes a second perforated sleeve disposed inside the first perforated sleeve. The second perforated sleeve defines an interior volume and holes configured to form fluid pathways with the holes of the first perforated sleeve. The fluid pathways extend from the interior volume to the winding surface of the first perforated sleeve. The filament winding assembly includes a filament that is wound, under tension, around the winding surface of the first perforated sleeve. The filament winding assembly also includes a fluid source fluidically coupled to the interior volume of the second perforated sleeve. The fluid source exhausts fluid, through the fluid pathways, from the wound filament to reduce manufacturing defects of the wound filament.

Abstract: A method of manufacturing continuous fiber reinforced thermoplastic components includes receiving, by a movable die, spread dry fiber tows. The method also includes receiving, by the movable die and from a polymer extruder fluidically coupled to the movable die, molten polymer. The method also include wetting, by the movable die, the spread fiber tows with the molten polymer. The method also includes maintaining, by the movable die, the wet fiber tows spread as the wet fiber tows exit the die. The method also includes depositing, by the movable die, a layer of the wet fiber tows on a printing surface. The movable die is configured to move along the printing surface to form a thermoplastic component of one or more layers of fiber tows on the printing surface.

Abstract: A method of manufacturing thermoplastic components includes receiving, by a movable die with an internal grooved surface that has a plurality of longitudinal grooves, spread dry fiber tows. The method also includes receiving, by the movable die and from a polymer extruder, molten polymer. The method also includes wetting, by the movable die, the spread fiber tows with the molten polymer. The method also includes moving, by the movable die, the wet fiber tows along the plurality of longitudinal grooves in a direction parallel to a length of the longitudinal grooves. The method also includes depositing, by the movable die, a layer of the wet fiber tows on a printing surface. The movable die moves along the printing surface to form a thermoplastic component of one or more layers of fiber tows on the printing surface.