Abstract: Control and stabilizing cables and tendons for high altitude aircraft and airships having lightweight, high strength and low CTE are disclosed, along with a method and machine for fabrication of same. The cable is comprised of a fiber prepreg tow encased in a polymer sleeve with one bobbin at each end to facilitate connections. Consolidating the fiber prepreg tow along the length of the cable using high temperature shrink tubing, such as polyvinylidene fluoride (PVDF), allows for eliminating the twisting of the fiber prepreg tow, thus reducing the number of wraps around the bobbins. Eliminating the twists in the fiber prepreg tow also reduces the length of fiber needed, and therefore the overall change in length of the control cable with temperature variations is reduced. Additional cable strength can be achieved by adding and holding significant tension on the fiber prepreg tow by applying weight during the curing process.

Abstract: Control and stabilizing cables and tendons for high altitude aircraft and airships having lightweight, high strength and low CTE are disclosed, along with a method and machine for fabrication of same. The cable is comprised of a fiber prepreg tow encased in a polymer sleeve with one bobbin at each end to facilitate connections. Consolidating the fiber prepreg tow along the length of the cable using high temperature shrink tubing, such as polyvinylidene fluoride (PVDF), allows for eliminating the twisting of the fiber prepreg tow, thus reducing the number of wraps around the bobbins. Eliminating the twists in the fiber prepreg tow also reduces the length of fiber needed, and therefore the overall change in length of the control cable with temperature variations is reduced. Additional cable strength can be achieved by adding and holding significant tension on the fiber prepreg tow by applying weight during the curing process.

Abstract: Control and stabilizing cables and tendons for high altitude aircraft and airships having lightweight, high strength and low CTE are disclosed, along with a method and machine for fabrication of same. The cable is comprised of a fiber prepreg tow encased in a polymer sleeve with one bobbin at each end to facilitate connections. Consolidating the fiber prepreg tow along the length of the cable using high temperature shrink tubing, such as polyvinylidene fluoride (PVDF), allows for eliminating the twisting of the fiber prepreg tow, thus reducing the number of wraps around the bobbins. Eliminating the twists in the fiber prepreg tow also reduces the length of fiber needed, and therefore the overall change in length of the control cable with temperature variations is reduced. Additional cable strength can be achieved by adding and holding significant tension on the fiber prepreg tow by applying weight during the curing process.

Abstract: Control and stabilizing cables and tendons for high altitude aircraft and airships having lightweight, high strength and low CTE are disclosed, along with a method and machine for fabrication of same. The cable is comprised of a fiber prepreg tow encased in a polymer sleeve with one bobbin at each end to facilitate connections. Consolidating the fiber prepreg tow along the length of the cable using high temperature shrink tubing, such as polyvinylidene fluoride (PVDF), allows for eliminating the twisting of the fiber prepreg tow, thus reducing the number of wraps around the bobbins. Eliminating the twists in the fiber prepreg tow also reduces the length of fiber needed, and therefore the overall change in length of the control cable with temperature variations is reduced. Additional cable strength can be achieved by adding and holding significant tension on the fiber prepreg tow by applying weight during the curing process.

Abstract: A method for making large vehicle body sections, skins, and panels, including three dimensional sections, skins, and panels, using carbon fiber filaments comingled with thermoplastic polymer filaments to form comingled fibers. The first step is the manufacture of a composite preform using the comingled fibers. The comingled fibers are chopped by a fiber chopper unit mounted on a robot arm to create chopped comingled fibers that are sprayed and set on a preform mold to create a comingled fiber preform. The second step is forming the comingled fiber preform into a composite laminate using heat and pressure to consolidate the comingled fibers on a tooling surface. The disclosed method can be used for making large and contoured thermoplastic composite panels, skins, or sections suitable for light aircraft, automobiles, eVTOL's and other panel applications at a high production rate.

Abstract: Thermoplastic composite preforms for continuous fiber thermoplastic composite structural profiles and a system and method of manufacture for structural profiles utilizing thermoplastic filaments comingled with high strength fibers such as carbon fibers and braided into complex preforms suitable for automated press forming is disclosed. Utilizing flexible preforms in lieu of conventional rigid thermoplastic pre-preg material forms allows for manufacture of complex shapes, including both straight and curved shapes by an automated process.

Abstract: Integrated pultruded composite profiles such as rotor wings and blades for electric vertical take-off and landing aircraft, light helicopters, wind turbines, and other rotor wing applications and integrated design and processing methods for making same are disclosed. The present invention provides a plurality of web ribs for stiffening and supporting an outer skin which can comprise fabric plies, a metallic skin, or a thermoplastic composite skin. A process and method to continuously pultrude integrated composite airfoil profile with variable aerodynamic twist is also disclosed. Utilization of a stranded metallic wire rope that enables the leading edge weight to be continuously in-situ fed into the pultrusion process and effectively retained in the pultruded product is also disclosed. Utilization of fiber reinforcement impregnated with matrix resin that is loaded with high density powder for the leading edge weight is also disclosed.

Abstract: Composite profiles, such as rotor blades, airfoils, I-beams, and box beams having non-uniform cross sections, and a system, method and process for pultrusion of composite profiles. The pultrusion of a heavier or thicker cross section portion of the composite profile is performed in-line and upstream from pultrusion of a thinner or lighter portion of the pultruded profile using a separate die for the thicker portion of the cross section, or leading edge slug, in order to optimize the processing conditions, productivity, and consistency of the composite profiles.

Abstract: Composite products and related methods are disclosed. In some examples, methods of filament winding composite components and products, such as a sleeve and/or a mandrel for use in down-hole applications, are disclosed. The winding of components can involve using a percentage of fiber roving strands that are blown during manufacture such that they have fiber loops that when wound as layers forms bridges across the discrete layers to enhance the inter-laminar strength of the composite product.

Abstract: This disclosure discloses that a composite material, and its method of manufacture, can be provided where the composite material includes a synthetic fiber veil and a thermosetting polymer adhesive as a corrosion protection coating for steel sucker rods, pony rods and continuous sucker rods.

Abstract: A sucker rod terminus assembly is provided for use in downhole wells. The sucker rod terminus assembly includes a plurality of parallel composite strands forming an elongate rod and a metallic terminus fitting. The terminus fitting has a cavity with a proximal opening to receive the rod end. The cavity includes a plurality of frustum shaped chambers. Preferably, the frustum shaped chambers have different sizes or shapes wherein at least a frustum chamber's proximal end diameter, distal end diameter, or length is different than an adjacent frustum chamber's proximal end diameter, distal end diameter, or length. Even more preferably, each frustum chamber is diametrically larger than the frustum chamber positioned proximally to it. Preferably, the sucker rod assembly further includes a spreader plate, preferably made up of a plurality of pieces and a hardened material to affix the rod to the terminus fitting.

Abstract: A continuous length composite sucker rod assembly is provided for use in down-hole wells. The assembly can include a plurality of parallel composite strands forming an elongate rod. The strands can be encapsulated with a thermoplastic polymer by co-extrusion. A terminus can be affixed to both ends of the length of sucker rod by splaying the strands out into a conical cavity within the terminus and casting a polymer wedge plug. The resulting sucker rod assembly can be readily coiled in a transportable diameter by virtue of the composite strands being able to twist when the rod is coiled and untwist when the rod is un-coiled.

Abstract: A composite sucker rod assembly is provided for use in down-hole wells. The sucker rod assembly includes a plurality of parallel composite strands forming an elongate rod. Preferably, both ends of the rod are fitted with metallic terminus fittings. Each terminus fitting has a tapered cavity with a proximal opening to receive a rod end. The cavity is tapered so as to flare outwardly from said cavity's proximal opening toward the cavity's distal end. The sucker rod assembly further includes a spreader plate, preferably made up of a plurality of pieces, which has holes to receive and splay out the plurality rod strands. A hardened material, such as a hardened resin, is introduced into the cavity and allowed to harden to affix the rod to the terminus fitting. Preferably the hardened resin is compressed by a connection member.

Abstract: Dual directional latch devices or connectors are described wherein a first connector component and a second connector component have a first latched position and a second latched position when moving in a first direction and wherein movement in a second direction is also possible when a restriction feature is overcome. As described, opposing magnetic forces, pneumatic pressure, spring force, and a crushable force may be incorporated so that further movement in the second direction must overcome the restriction feature. The dual direction latch devices may be used with articles of manufacture such as with implantable medical devices, door panels, airplane panels, and drilling devices to name a few.

Abstract: Device, system, and method to adhesively bond a sleeve to a mandrel are disclosed. The sleeve and the mandrel may be used as part of frac plug or a bridge plug in oil and gas applications. The bonded adhesive connection with grooves is strengthened to reliably achieve higher levels of lap shear strengths than attainable by conventional means.

Abstract: A canted coil spring made from multi-metallic wire to achieve combinations of desired material characteristics of different metals is discussed. Wire to be used in canted coil springs can have two or more metals oriented co-axially along such wire, such as an outer layer of one metal having one set of properties, and a core of a different metal having a different set of properties, that will achieve a single solid, multi-metallic wire with enhanced performance over a single material canted coil spring. Such features may be found advantageous in electrical applications, such as where both high electrical conductivity and high strength properties are desired.

Abstract: Composite products and related methods are disclosed. In some examples, methods of filament winding composite components and products, such as a sleeve and/or a mandrel for use in down-hole applications, are disclosed. The winding of components can involve using a percentage of fiber roving strands that are blown during manufacture such that they have fiber loops that when wound as layers forms bridges across the discrete layers to enhance the inter-laminar strength of the composite product.

Abstract: Device, system, and method to adhesively bond a sleeve to a mandrel are disclosed. The sleeve and the mandrel may be used as part of frac plug or a bridge plug in oil and gas applications. The bonded adhesive connection with grooves is strengthened to reliably achieve higher levels of lap shear strengths than attainable by conventional means.

Abstract: A high strength filament reinforced thermoplastic polymer film is provided for use in various applications with properties that are stronger than rip-stop nylon or polyester woven fabric. As disclosed, a sailboat spinnaker is provided made from high strength filament reinforced thermoplastic polymer film. The sailboat spinnaker may he bonded or thermo welded together along seams to form a finished spinnaker. The seams, being welded or bonded, can have enhanced performance over conventional rip-stop nylon or polyester fabric spinnakers that are sewn together. The spinnaker clews (attach) points can also be reinforced with one or more thermoplastic polymer film layers and/or adhesive backed woven fabric reinforcements with loops in lieu of conventional metal rings and webbing sewn in place.

Abstract: An electrical contact assembly made from a stamped housing, having a first end with a spring groove housing formed over a canted coil spring in order to provide spring retention to a pin or post inserted into the housing. On the other end of the stamped housing, a wire/cable crimp assembly is formed. The spring, groove housing may be formed having an opening for insertion of the pin or post that is either substantially parallel or perpendicular to the base of the housing.