Abstract: A system for mixing and dispensing a structural foam formed from two or more component foam parts mixed together in a predetermined mass ratio. At least a first one of said component parts is pre-mixed with a blowing agent and maintained under pressure. The system comprises volumetric flow sensors to measure the rate of flow of each of the component foam parts to be mixed, a feedback loop comprising a digital computer, to determine whether the predetermined mass ratio has been achieved on an instantaneous basis, and at least one gear-type variable flow controller to reduce the flow rate of said first one of the component foam parts to be mixed. The gear-type variable flow controller is adjustable by at least one of an electro-mechanical, hydraulic or electrical type braking device in response to the rate of flow data measured by said volumetric flow sensor.

Abstract: A system for mixing and dispensing a structural foam formed from two or more component foam parts mixed together in a predetermined mass ratio. At least a first one of said component parts is pre-mixed with a blowing agent and maintained under pressure. The system comprises volumetric flow sensors to measure the rate of flow of each of the component foam parts to be mixed, a feedback loop comprising a digital computer, to determine whether the predetermined mass ratio has been achieved on an instantaneous basis, and at least one gear-type variable flow controller to reduce the flow rate of said first one of the component foam parts to be mixed. The gear-type variable flow controller is adjustable by at least one of an electro-mechanical, hydraulic or electrical type braking device in response to the rate of flow data measured by said volumetric flow sensor.

Abstract: A continuous composite structure manufacturing apparatus which comprises a conveyor or conveyors for conveying one or more fabric webs along a conveying path. Each of the webs is comprised of a reinforcing fabric, a non-woven fabric, or a layered fabric. The fabric web is passed through the conveyor so that it defines an enclosed foam injection zone. A foam injection system is provided for injecting foam into the foam injection zone to form a foam core preform (or a plurality of same). One or more dies are positioned along the conveying path, to shape each of the foam core preform(s) to a desired cross-sectional profile. The individual stringers or multiple, spaced apart, stringers are produced concurrently in a continuous production process.

Abstract: A composite spring-damper and method of making same. The spring-damper has an exposed fabric layer free of structural foam and curable resin. A core formed of resilient foam defines a spring shape and a fabric layer disposed on an outer surface of the core is attached to foam core by means of the foam having substantially filled only interstices of an inner portion of the fabric layer, without substantially penetrating an outer portion of said fabric layer; whereby the fabric layer of the composite spring-damper may thereafter be substantially completely saturated with a curable material for lamination to another structure. An attached reinforcing fabric layer may be provided on the exterior surface of the fabric layer, in which case the fabric layer may be entirely saturated and only the attached fabric layer substantially free of foam.

Abstract: A continuous composite structure manufacturing apparatus which comprises a conveyor or conveyors for conveying one or more fabric webs along a conveying path. Each of the webs is comprised of a reinforcing fabric, a non-woven fabric, or a layered fabric. The fabric web is passed through the conveyor so that it defines an enclosed foam injection zone. A foam injection system is provided for injecting foam into the foam injection zone to form a foam core preform (or a plurality of same). One or more dies are positioned along the conveying path, to shape each of the foam core preform(s) to a desired cross-sectional profile. The individual stringers or multiple, spaced apart, stringers are produced concurrently in a continuous production process.