Abstract: A shock attenuation barrier including a plurality of layers successively arranged including a first layer, a second layer having a plurality of molded geometric shapes, a third layer including foam, a fourth layer having a plurality of molded geometric shapes and a fifth layer. Cavities defined by inside surfaces of the geometric shapes and a surface of the foam layer preferably are filled with a shock absorbing filler material.

Abstract: A self-deploying inlet for an air breathing missile including an inlet body having a natural shape which defines a deployed condition for the air inlet, wherein an air deflecting surface is provided thereby. The inlet body is made from a material having a flexibility which enables the inlet body to flex from the deployed condition to a stowed condition, and a resiliency which biases the inlet body toward the deployed condition when in the stowed condition. The air inlet further includes a sealing connector system for connecting the inlet body to the vehicle in a manner which enables the inlet body to move between the stowed condition and the deployed condition. The natural spring force provided by the resiliency of the inlet body, along with the aerodynamic forces to which the inlet is subjected during missile flight, are sufficient to cause the inlet to self-deploy to the deployed condition from the stowed condition without the need for a deployment actuator.

Abstract: A self-deploying airfoil for a missile or the like of the type that is launched from a launch tube, the airfoil being formed of a flexible and resilient material and being movable by its own resilience from a stowed position in close proximity to the exterior surface of the missile when it is in the launch tube to a deployed position when the missile leaves the launch tube wherein it extends outwardly from the missile to provide lift and stabilize the flight of the missile. The airfoil comprises in its deployed position a first panel extending laterally outwardly from both sides of the missile and being secured at its midportion to an adjacent exterior surface of the missile, a pair of second panels secured at their outer ends to the outer end of the first panel and extending inwardly toward the missile, and a third panel secured at its midportion to an adjacent exterior surface of the missile opposite the first panel.

Abstract: A pressure vessel liner for fuel tanks used to store high pressure gasses including methane or compressed natural gas includes thermoplastic materials exhibiting low permeability and mechanical properties resistant to thermal and pressurization strains over the operating cycle of the fuel tanks. The pressure vessel liner is made from a material selected from the group consisting of modified nylon 6 or nylon 11. The present invention also discloses a method of forming a reinforced composite fuel tank wherein the pressure vessel liner is overwrapped with both low-angle helical and high-angle helical filament windings. The high-angle helical windings are overwrapped around the liner across at least the cylinder-to-dome transition region at angles between 60.degree. and 88.degree. with respect to the longitudinal axis of the liner. High angle helical filament windings at these angles eliminate excessive composite windings typically added to account for weak transition points in these regions.

Abstract: An improved rocket motor and a method for its manufacture are characterized by the provision of a thermoplastic elastomer binder in the outer casing, the insulation layer, and the propellant. When the motor is heated to the melting point of the binder, the bondlines between the propellant and insulation and between the insulation and casing are simultaneously fused to form a unitary motor structure.

Abstract: Impact intrusion barrier device for a vehicle door of the type which includes spaced inner, outer and side door panels defining a door cavity therebetween, and which is movably connected between forward and rear door pillar members. The device includes a beam member positioned in the door cavity and adapted to extend between the pillar members. The beam member is curved outwardly along a longitudinal axis thereof and has a pair of beam end portions which are operable to move longitudinally away from one another on adjacent outwardly facing surfaces of the side door panels or the pillar members when an inward force is applied to the beam member until the end portions contact abutment surfaces on the side door panels or the pillar members, thereby absorbing energy therefrom and initially directing the force laterally away from the interior of the vehicle and into the pillar members either directly or through the side door panels.

Abstract: Conformal fuel tank which includes an elongate, flexible or rigid, tubular member having a storage chamber therein. The tubular member is bent into a coiled configuration which can conform to a variety of irregular two and three dimensional shapes. Preformed saddle members are provided which include channel members thereon which receive bent portions of the tubular member and maintain them in a bent condition which corresponds to the curved channels. Cap members are provided on the end portions of the tubular members for closing the storage chamber, thereby enabling fuel to be stored therein. The tubular member may include an inner core made of a nylon monomer or copolymer, an intermediate layer around the core made of a fiber-reinforced composite material, and an outer protective layer of polyurethane or the like. The conformal fuel tank is particularly adapted for use in storing fuel such as methane or propane under high pressure in irregular spaces available in a vehicle or the like.

Abstract: A tailorable, roll-bonded, insensitive munitions motor case and method of production. The motor case comprises a sheet of fiber reinforced thermoplastic, thermoset or other suitable material rolled to form a case with a tubular configuration having at least one layer of material, and a coating of adhesive on at least part of said sheet for bonding the sheet to itself for maintaining the tubular configuration. The adhesive has a bond-strength breakdown temperature which is below the autoignition temperature of the housed propellant, thereby enabling the case to separate and un-roll when the breakdown temperature is reached to preclude dangerous propellant pressurization within the case. The method of production includes the steps of applying an adhesive to the sheet, rolling the sheet around a cylindrical tool to form a tubular case having at least one layer, and curing the case. Preferably the case is cured while on a tool which has a coefficient of thermal expansion which is greater than that of the sheet.

Abstract: A prestressed thermoformed panel, comprising an inner thermoplastic layer having fine grooves on the outer surfaces thereof, and outer fiber-reinforced thermosetting layers bonded to the outer surfaces of the inner layer. The grooves of the inner layer are of a size, pattern and orientation similar to that of the fibers of the thermosetting materials so that at least some of the fibers are positioned in the grooves to enhance the strength of the panel. In the method of forming the panel, the inner and outer layers are heated to approximately the fusion temperature of the thermoplastic material while applying inward pressure on the outer layers in the direction of the inner layer to bond them thereto. The pressure is less than the extruding pressure of the thermoplastic material. Thereafter, the thermosetting outer layers are cured, and the inward pressure on the outer layers is maintained until the temperature is at least 50.degree. F. below the fusion temperature of the thermoplastic material.

Abstract: A prestressed thermoformed panel, comprising an inner thermoplastic layer having fine grooves on the outer surfaces thereof, and outer fiber-reinforced thermosetting layers bonded to the outer surfaces of the inner layer. The grooves of the inner layer are of a size, pattern and orientation similar to that of the fibers of the thermosetting materials so that at least some of the fibers are positioned in the grooves to enhance the strength of the panel. In the method of forming the panel, the inner and outer layers are heated to approximately the fusion temperature of the thermoplastic material while applying inward pressure on the outer layers in the direction of the inner layer to bond them thereto. The pressure is less than the extruding pressure of the thermoplastic material. Thereafter, the thermosetting outer layers are cured, and the inward pressure on the outer layers is maintained until the temperature is at least 50.degree. F. below the fusion temperature of the thermoplastic material.

Abstract: A structural panel comprises truncated polyhedral elements projecting from a base sheet, with the base sheet and truncation surfaces providing increased bonding areas for external face sheets. Mass produced, identical panels which are nestable for shipping and storage may be combined in an interlocking arrangement to form a combined panel which is nearly isotropic in its reaction to external loads.

Abstract: A solar energy collector has, as its basic component, a molded multipocketed collector panel, the pockets of which are modified polyhedral shapes, to increase exposed surface and heat transfer areas. This panel, having various polyhedral pockets in combination with glazing and a back cover, provides an overall, structurally sound collector which may have degrees of curvature ranging from flat to compound to spherical. A through-window ventilation receptacle may be used to support the collector, and may also serve as a plenum, if desired, to facilitate intake and distribution of room air.

Abstract: Structural cores in the form of open-ended polyhedrons joined together al common edges or sides are generating high industrial interest because of the great strengths they possess relative to their weights. A structural core medium of interwoven fibrous filaments coated with plastic is highly satisfactory, but it has the disadvantage that it is very difficult, if not heretofore impossible, to produce in other than planar, sandwich or cylindrical form. A jig for the fabrication of such cores has not come into existance. This invention provides a jig which makes possible the fabrication of such polyhedral structural cores.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not readily yield articles having desired strength properties. Using both thermoplastic and thermosetting resins in the process results in articles embodying fabrication stresses akin to those in prestressed concrete.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not always yield articles having desired strength properties. It has been suggested that both thermoplastic and thermosetting layers be used to making the articles stronger. However it was virtually impossible to bond the layers together. A process is provided herein for obtaining that bond.

Abstract: Thermoforming, utilized for making articles from sheets of thermoplastic ins, does not readily yield articles having desired strength properties. Using both thermoplastic and thermosetting resins in the process results in articles embodying fabrication stresses akin to those in prestressed concrete.