Abstract: An improved filament winding method and apparatus for fabrication of composite material products is based on a mechanism that rotates filaments around a non-rotating mandrel. The primary filaments in predetermined patterns tend to move on the mandrel and thus such filaments are fixed in position relative to the mandrel by over-wrapping them with secondary filaments applied over the primary filaments. The winding mechanism functions by rotating filament spools around a non-rotating mandrel rather than rotating the mandrel to pull the filaments onto the mandrel. The mandrel is axially translated through the center of the winding mechanism or the winding mechanism is translated over a stationary mandrel which is supported in such a manner as to provide for such translation.

Abstract: The present invention is an apparatus for inserting yarns into a reinforcement material along their longitudinal path. The apparatus for moving yarn and for constraining yarn movement, such as yarn brakes, are each actuated at the appropriate time. The yarn is prevented from buckling by a hollow member of a diameter only slightly greater than the yarn, when the yarn is pushed on. The reinforcement material may be woven or non-woven fabrics, cellular foams, or combinations that may include fabrics, foams or air gaps. “Yarn” in this case is taken to include any textile yarn, monofilament, coated yarns, and the like.

Abstract: Reinforcement preforms and methods for making same for use in fiber-reinforced composite materials structures are disclosed, in which the reinforcement preforms comprise first and second reinforcement preform elements which include strength reinforcement fibers that are in desired directional orientation. The first element has a cross-fiber surface which extends transverse of its constituent strength reinforcement fibers and is in contacting juxtaposition to a selected surface region of the second element, forming an abutment therebetween. Abutment strength reinforcing fibers, which may optionally be introduced in situ by a continuum of fibers, such as a yarn or thread, extend through at least a portion of said second element and its said selected surface region, the abutment, said cross-fiber edge surface, and into the first element substantially in the direction of orientation to its constituent strength fibers to which its cross-fiber surface is transverse.

Abstract: Embodiments of this invention include pressure differential barrier members for separating selected substances from fluid, gaseous and/or liquid, and methods of making same. They include separation material which, with respect to the fluid to be treated, is pervious and exhibits desired separation capabilities. They may also, at least in part, include material which is substantially impervious to the fluid. They include bridges spanning flow paths to form lateral flow paths, and they may also include flow paths that are unbridged. All flow paths through such embodiments are either through structural elements which themselves have desired separation capabilities or are occupied by separation material that is pervious to the fluid being treated and is of such desired characteristics.

Abstract: Fiber reinforced composite structures and preforms for making same, and methods for making such structures and such preforms, are disclosed. In the preforms, at least two constituent elements are woven from yarns made from material of desired characteristics and the elements are joined at a juncture therebetween by fibrous material that is common to and integral with said elements. At least one of the elements includes at least one internal pocket that is adapted to contain a reinforcement member that produces improved shear stiffness and/or shear strength in the preform when it is matrix infiltrated. In preferred embodiments, three such elements are oriented at right angles to each other, with reinforcement pockets included in two of the three elements. Preforms so made may then be infiltrated with matrix material.

Abstract: Filters, catalytic converters and the like, for separating particulate matter and/or other constituents from a stream of gas or liquid so arranged that substantially all of the fluid passing through the filter must pass through separation material which permits the passage of the fluid therethrough while separating out and retaining the selected substances. Continuums of material are arranged parallel to each other in planar arrays, with periodic spacings between the continuums in each array. Such arrays are superimposed to form a "laminated" grouping, with each continuum in each array angularly oriented with respect to and in contact with the continuums in each next adjacent array which that continuum crosses. Internal distribution paths for the fluid thereby formed by the spacings between the continuums include passageways which extend laterally within each layer and cross-array or translaminar distribution channels produced by aggregations of intersecting paths of the lateral array channels.

Abstract: A woven fabric gap filler with carbon fiber yarns providing a central gap filling group section of large diameter warp yarns assuming a triangular sectional shape with tab portions extending respectively from the respective apexes of the triangular filler section to be held between lay-up of opposing graphite epoxy fabric rib and flange sheets for integration therewith and to retain the apexes of the filler section against shrinkage when the assembly is heat treated. Under stress of the hard plastic structural unit, the forces will be passed through transverse fabric woof yarns as well as through longitudinal warp yarn strands so as to resist breakdown of hard plastic within the gap filling section of the structural unit when stressed.