Abstract: A rotor yoke manufactured by a process comprising preparing a molded rotor yoke in a closed cavity tool and possibly machining at least one portion of the molded rotor yoke to form the rotor yoke. In the preferred embodiment, the preparing of the molded rotor yoke is accomplished by applying layers of uncured low-flow composite material and a layer of uncured high-flow adhesive; substantially enclosing the uncured molded rotor yoke in the closed cavity tool; and applying pressure so as to compress the uncured molded rotor yoke; and curing the uncured molded rotor yoke. During the curing process, the high-flow adhesive bleeds out of the molded rotor yoke, thereby preventing marcels from forming through movement of the low-flow composite material.

Abstract: A rotor yoke manufactured by a process comprising preparing a molded rotor yoke in a closed cavity tool and possibly machining at least one portion of the molded rotor yoke to form the rotor yoke. In the preferred embodiment, the preparing of the molded rotor yoke is accomplished by applying layers of uncured low-flow composite material and a layer of uncured high-flow adhesive; substantially enclosing the uncured molded rotor yoke in the closed cavity tool; and applying pressure so as to compress the uncured molded rotor yoke; and curing the uncured molded rotor yoke. During the curing process, the high-flow adhesive bleeds out of the molded rotor yoke, thereby preventing marcels from forming through movement of the low-flow composite material.

Abstract: A method of making a composite rotor yoke includes preparing a molded rotor yoke in a closed cavity tool and possibly machining at least one portion of the molded rotor yoke to form the rotor yoke. In the preferred embodiment, preparing the molded rotor yoke is accomplished by applying layers of uncured low-flow composite material and a layer of uncured high-flow adhesive; substantially enclosing the uncured molded rotor yoke in the closed cavity tool; applying pressure so as to compress the uncured molded rotor yoke; and curing the uncured molded rotor yoke. During the curing process, the high-flow adhesive bleeds out of the molded rotor yoke, thereby preventing marcels from forming through movement of the low-flow composite material.

Abstract: A method of making a rotor yoke includes preparing a cured composite rotor yoke preform on a single-sided curing tool and machining at least one portion of the cured rotor yoke preform to form a rotor yoke. In one embodiment, preparing the cured composite rotor yoke is accomplished by applying successive layers of uncured polymeric composite material to a single-sided tool in a configuration to produce an uncured rotor yoke preform; disposing a semi-rigid caul to an untooled side of the uncured rotor yoke preform; enclosing the uncured rotor yoke preform and the semi-rigid caul by substantially hermetically sealing a vacuum bag to the tool; substantially evacuating a volume defined by the vacuum bag and the tool of air; and heating the uncured rotor yoke preform, sometimes under pressure, to form the cured composite rotor yoke preform.

Abstract: A method of making a composite rotor yoke includes preparing a molded rotor yoke in a closed cavity tool and possibly machining at least one portion of the molded rotor yoke to form the rotor yoke. In the preferred embodiment, preparing the molded rotor yoke is accomplished by applying layers of uncured low-flow composite material and a layer of uncured high-flow adhesive; substantially enclosing the uncured molded rotor yoke in the closed cavity tool; applying pressure so as to compress the uncured molded rotor yoke; and curing the uncured molded rotor yoke. During the curing process, the high-flow adhesive bleeds out of the molded rotor yoke, thereby preventing marcels from forming through movement of the low-flow composite material.

Abstract: An uncured, composite rope includes at least one inner tow of structural fibers of a first material and a plurality of outer tows of structural fibers disposed about the at least one inner tow, the structural fibers of at least one of the plurality of outer tows being made from a second material that is different from the first material. The uncured, composite rope further includes an uncured polymeric resin impregnated into the at least one inner tow and the plurality of outer tows.

Abstract: A torque coupling for a rotor head of a rotary-wing aircraft is configured for rotation with a mast and for causing rotation of an attached yoke. The coupling has trunnions that rotate with the mast and extend generally radially. Pad-bearing assemblies each have a central member coupled to one of the trunnions with a laminated spherical bearing and have laminated pad bearings affixed to opposing sides of the central member. The laminated bearings have alternating rigid and elastomeric layers. A bearing mount is affixed to each pad bearing and is connected to a yoke for rotating the yoke with the mast. The pad-bearing assemblies allow for relative motion between each central member and the associated trunnion and between each central member and the bearing mounts through elastic shear deformation, and this allows for gimballing of the attached yoke relative to the mast.

Abstract: A method of making a rotor yoke includes preparing a cured composite rotor yoke preform on a single-sided curing tool and machining at least one portion of the cured rotor yoke preform to form a rotor yoke. In one embodiment, preparing the cured composite rotor yoke is accomplished by applying successive layers of uncured polymeric composite material to a single-sided tool in a configuration to produce an uncured rotor yoke preform; disposing a semi-rigid caul to an untooled side of the uncured rotor yoke preform; enclosing the uncured rotor yoke preform and the semi-rigid caul by substantially hermetically sealing a vacuum bag to the tool; substantially evacuating a volume defined by the vacuum bag and the tool of air; and heating the uncured rotor yoke preform, sometimes under pressure, to form the cured composite rotor yoke preform.

Abstract: An uncured, composite rope includes at least one inner tow of structural fibers of a first material and a plurality of outer tows of structural fibers disposed about the at least one inner tow, the structural fibers of at least one of the plurality of outer tows being made from a second material that is different from the first material. The uncured, composite rope further includes an uncured polymeric resin impregnated into the at least one inner tow and the plurality of outer tows.

Abstract: A torque coupling for a rotor head of a rotary-wing aircraft is configured for rotation with a mast and for causing rotation of an attached yoke. The coupling has trunnions that rotate with the mast and extend generally radially. Pad-bearing assemblies each have a central member coupled to one of the trunnions with a laminated spherical bearing and have laminated pad bearings affixed to opposing sides of the central member. The laminated bearings have alternating rigid and elastomeric layers. A bearing mount is affixed to each pad bearing and is connected to a yoke for rotating the yoke with the mast. The pad-bearing assemblies allow for relative motion between each central member and the associated trunnion and between each central member and the bearing mounts through elastic shear deformation, and this allows for gimballing of the attached yoke relative to the mast.