Abstract: Composite structures having a single continuous skin may be formed using automated fiber placement methods. These composite structures include frameless aircraft fuselage components offering an increased interior cabin width over conventional fuselage components. The composite structures may be constructed of multiple layers of fibers and other materials placed on a fiber placement tool that includes a mandrel body surrounded by a bladder or an integral bladder/caul sheet having expansion spaces created within the caul sheet section. Uncured composite structures may be created by placing fibers around the fiber placement tool in a plurality of discontinuous segments that are capable of moving or sliding in relation to each other so that the uncured composite structure is expandable from within.

Abstract: A composite structure for aircraft having features making it resistant to structural damage when subjected to lightning strikes. Fiber tow is wound over a rotating shaping surface which is a surface of revolution. Spaced bands of tow are laid down in a helical pattern with varying spaces between bands. Some bands are typically wound at an angle of about +45.degree.. By selectively winding in one direction and then the other, a "basketweave" pattern is obtained. Typically, the tow consists of high strength fibers in a thermosetting or thermoplastic resin matrix wound to a four layer thickness. When cured, the structure has high strength and low weight and is excellent for structures such as aircraft engine cowls. The basketweave pattern gives excellent resistance to peeling and delamination upon being struck by lightning, the types of damage which are likely to occur with the usual hoop or other continuous windings.

Abstract: A filament winding payoff unit and process for applying strands of adhesive impregnated filament material arranged into a gap-free band to a rotating mandrel. A plurality of side-by-side slightly overlapped impregnated filament strands are passed over bars between tines of combs for positioning when leaving the payoff head. The payoff head is positionable toward and away from the rotating mandrel to allow for mandrel longitudinal dimension changes while maintaining the payoff head roller in contact with the mandrel at a predetermined pressure thereagainst. The payoff head is also freely pivotable horizontally to maintain a proper angle of filament application to any changing mandrel longitudinal configuration.

Abstract: A filament winding payoff head unit and process for applying strands of adhesive impregnated filament material arranged into a gap-free band to a rotating mandrel. A plurality of side-by-side slightly overlapped impregnated filament strands are passed over bars between tines of combs for positioning when leaving the payoff head. The payoff head is positionable toward and away from the rotating mandrel to allow for mandrel longitudinal dimension changes while maintaining the payoff head roller in contact with the mandrel at a predetermined pressure thereagainst. The payoff head is also freely pivotable horizontally to maintain a proper angle of filament application to any changing mandrel longitudinal configuration.