Abstract: A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Abstract: A composite material made of multiple filament bands is disclosed. The filament bands are wound to create a composite material. The filament bands may be impregnated with a solid or semi-solid resin. The filament bands are wound in multiple orientations to form a sheet of composite material. Additionally, the composite material may be made to have a varying number of layer and fiber orientations throughout the sheet of composite material. In another embodiment, a composite component requiring multiple layers and fiber orientations may be substantially manufactured during a filament winding process.

Abstract: A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Abstract: A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Abstract: A composite material made of multiple filament bands is disclosed. The filament bands are wound to create a composite material. The filament bands may be impregnated with a solid or semi-solid resin. The filament bands are wound in multiple orientations to form a sheet of composite material. Additionally, the composite material may be made to have a varying number of layer and fiber orientations throughout the sheet of composite material. In another embodiment, a composite component requiring multiple layers and fiber orientations may be substantially manufactured during a filament winding process.

Abstract: A vacuum waste containment system to operate in situations where limited water is available and discharge of liquid and waste is undesirable. The system is powered by an external vacuum source. The vacuum draws the waste into a holding tank through an air water separator. The majority of the liquid and waste is deposited into the tank while the residual water is separated and drained back into the tank before reaching the vacuum source. The system has been designed for low weight to be reliable and require minimum maintenance.

Abstract: A fuel tank for aircraft includes a rigid securement for securing the tank to the aircraft, a skin connected to the securement, and a liner inside the skin. The skin includes an elastic fiber and a tensile fiber embedded in a flexible matrix. In one embodiment, the elastic fiber and the tensile fiber are wound in layers within the flexible matrix, and the elastic fiber is wrapped spirally about the tensile fiber. The elastic fiber is preferably an elastomeric fiber such as an elastic, segmented polyurethane fiber. The tensile fiber is preferably an aramid polymer fiber such as an aromatic polycarbonamide fiber. The flexible matrix may be formed of natural rubber or neoprene rubber. When the tank is filled, the elastic fiber lengthens until the tensile fiber resists further stretching. The elastic fiber tends to contract as the tank is emptied, substantially reducing the storage space required by the tank. The tank is nestable when empty, but is nonetheless substantially ready to receive fuel.

Abstract: A vacuum waste containment system to operate in situations where limited water is available and discharge of liquid and waste is undesirable. The system is powered by an external vacuum source. The vacuum draws the waste into a holding tank through an air water separator. The majority of the liquid and waste is deposited into the tank while the residual water is separated and drained back into the tank before reaching the vacuum source. The system has been designed for low weight to be reliable and require minimum maintenance.

Abstract: A vacuum waste containment system to operate in situations where limited water is available and discharge of liquid and waste is undesirable. The system is powered by an external vacuum source. The vacuum draws the waste into a holding tank through an air water separator. The majority of the liquid and waste is deposited into the tank while the residual water is separated and drained back into the tank before reaching the vacuum source. The system has been designed for low weight to be reliable and require minimum maintenance.

Abstract: A method of forming a three-dimensional composite structure. Uncured portions of the composite structure are first assembled between a initially rigid heat-softening inner layer of ABS plastic and a hard outer mold surface. Prior to curing of the composite structure, pressure and heat is applied to the ABS layer to soften the layer. Thereafter, pressure is applied to the side of the ABS layer opposite from the composite structure, thereby to compact the uncured portions of the composite structure against the hard outer mold. Stiffening beams may be incorporated into the composite structure, so as to yield a lightweight, strong composite structure that can be used as a pressure vessel in an aerospace vehicle.

Abstract: A combination step and extension ladder manufactured of composite material such as fiberglass is disclosed. The inner and outer side rails are molded fiberglass so that the fibers are angularly oriented with respect to the longitudinal axis of the respective side rail. Hinges are provided on each of the inner side rails of the ladder so that the ladder may be folded and unfolded from a step ladder configuration to a straight extension ladder configuration and vice versa. The inner side rails are telescopically mounted within channeled outer side rails so that the inner side rails can be extended to increase the height of the ladder in either configuration. The outer side rails have a foam strip molded into one side such that the ladder rungs between the outer side rails are supported by both the fiberglass and the foam strip.

Abstract: A combination step and extension ladder manufactured of composite material such as fiberglass is disclosed. The inner and outer side rails are molded fiberglass so that the fibers are angularly oriented with respect to the longitudinal axis of the respective side rail. Hinges are provided on each of the inner side rails of the ladder so that the ladder may be folded and unfolded from a step ladder configuration to a straight extension ladder configuration and vice versa. The inner side rails are telescopically mounted within channeled outer side rails so that the inner side rails can be extended to increase the height of the ladder in either configuration. The outer side rails have a foam strip molded into one side such that the ladder rungs between the outer side rails are supported by both the fiberglass and the foamstrip.

Abstract: Securement of flat heat exchange surfaces, particularly fins to tubular conduits of a heat exchanger. The heat exchange material is formed into upper and lower, or first and second pieces having longitudinal, partially circular recesses parallel to the length of a tube for engaging opposite sides of the tube. The radii of the recesses corresponds to the outer diameter of the tube. The recesses extend through less than 180.degree. so that the flat parts of the heat exchange surface are spaced leaving a gap prior to securement to the tubes. The two pieces are initially formed to interengage in such a way that they can be joined by lock seaming on opposite sides of the tube. Forces are applied to the interengaged pieces, forcing them together, stretching the heat exchange material at the recesses, thereby producing a tight interference fit between the heat exchange surfaces and the tube to provide minimum resistance to conduction of heat and at the same time securing the pieces together by lock seaming.

Abstract: Securement of flat heat exchange surfaces, particularly fins to tubular conduits of a heat exchanger. The heat exchange material has longitudinal, partially circular recesses parallel to the length of a tube for engaging opposite sides of the tube. The radii of the recesses corresponds to the outer diameter of the tube. The recesses extend through less than 180.degree. so that the flat parts of the heat exchange surface are spaced prior to securement to the tubes. Forces are applied normally to the surfaces, forcing them together, stretching the heat exchange material at the recesses, thereby producing a tight interference fit between the heat exchange surfaces and the tube to provide minimum resistance to conduction of heat. Securement may be by spot welding, riveting, or otherwise. The tube remains round and undeformed so the cross sectional heat exchange area remains the same.

Abstract: Contoured load carrying filament reinforced matrix structure which may be in the form of an airfoil or hydrofoil and comprising a plurality of elongated coextensive tubes disposed in side-by-side relationship to form a tube assembly and individually of sufficient cross section to project substantially from one side to the other of the cross sectional contour of the foil with the opposite cross sectional extremities of such tubes cooperating to form a composite cross sectional contour defining the contour of such foil. A skin is wrapped around the composite tube assembly and is bonded thereto to secure such filament wound tubes in position and provide for good load distribution when such foil is loaded.

Abstract: A servo valve control system exemplified by way of temperature controlled gas valves. Multiple slave pressure regulating valves are utilized supplying multiple burner manifolds. The first valve of the group of valves is modulated in response to temperature. The outlet pressure of each valve is utilized to bias and thereby modulate the next pressure regulating valve. The first valve, preferably is also controlled in response to an outdoor temperature sensor.

Abstract: A tubular member which is ideally suited as a drive shaft for transmitting power from an engine to a remote station such as the drive shaft for a helicopter tail rotor or a remotely mounted propeller or rotor and a method of fabricating said member. The tubular member has a cylindrical body portion and at least one conical end portion with an integral, radial flange upstanding therefrom. The wall of the tubular member is composed of a plastic having embedded therein at least one layer of continuous filaments of fibrous reinforcing material with each layer of such material comprising two adjacent thicknesses of filaments. The filaments are in parallel alignment in each thickness and in diagonal orientation between thicknesses at a first helix angle in the cylindrical body portion and at a second, greater helix angle, in the conical end portion.

Abstract: There is disclosed a method of manufacturing a filament wound blade including the steps of forming a spar by winding a plurality of resin impregnated filaments in side-by-side relationship between a pair of spaced apart spools. The spools are held in their spaced apart orientation to maintain the filaments in their unidirectional orientation and a flexible bondable bag fitted over the spar filaments and inflated to assume a generally cylindrical configuration. Resin impregnated shell filaments are wound in a helical pattern about such bag to form a shell and the bag then deflated and placed in a female mold defining the desired contour of such blade, and such bag then re-inflated to thereby cause the shell to assume such desired contour.