Abstract: The invention is a process and apparatus for forming structural members from layers of uncured composite material. The apparatus comprises a first station having at least one tape dispensing module, a second station where tape layers that have been deposited on a tool are vacuum treated in order to remove air entrapped between layers of the tape, and a track system which enables movement of the tool between the first and second stations as well as a tool storage station. The process of building the structural members comprises dispensing tape from each of the modules at the first station onto a tool, then removing entrapped air from between layers of deposited tape, then dispensing further layers of tape, then removing entrapped air, etc., until the desired tape configuration has been achieved. Until such built-up structural member is cured, it is stored in racks in the tool storage station. A unique "partial ply" module is disclosed for applying tape segments to the side forming surfaces of the tool.

Abstract: A method and apparatus for moving a first carrier tape in a first direction along a path, and a second tape toward the first tape, both in an incremental manner. After each increment of movement of the first tape, the second tape is advanced a proportional increment into overlying contact with the first tape. A press squeezes the first and second tape layers together, and a cutting mechanism is actuated to sever the overlying segment of second tape. The incremental movements of the first and second tapes are regulated so that the length of each second tape segment laid on the first tape is equal to the distance of travel of the first tape in the first direction. The direction of movement of the first tape is reversed so that at least one layer of second tape can be applied to the first tape.

Abstract: A method for producing a composite structural beam, particularly a sine wave beam, is disclosed utilizing as an essential feature, the bonding of the junctures of the sine wave web to the opposite flange areas of the beam with a fibrous braided material. The braiding is carried out during assembly of the composite web and composite flange components, prior to curing the components. In one embodiment the braided material extends along the entire height of the web, as well as along the flange areas, and is bonded thereto. In another embodiment the braided material does not extend along the entire height of the web, but only along the opposite edge portions of the web adjacent the junctures thereof with the flanges, the central portion of the web having no braided material applied thereto.

Abstract: A method for producing T-section integrally stiffened reinforced panels formed of parallel stringers or stiffeners having a T-section, formed of fiber reinforced resin, co-cured to a skin component to be reinforced, also formed of fiber reinforced resin, comprises first forming a rubber-like, e.g., silicone rubber, form block containing T-shaped grooves corresponding to the T-section stiffeners. Lay-ups in the form of fiber reinforced partially cured thermosetting resin T-shaped stiffeners are then forced into the grooves of the rubber-like form block in spaced parallel relation therein, and the center of the T-section stiffeners between the flanges thereof is filled with unidirectional tape comprised of fiber reinforced partially cured thermosetting resin. An outer skin formed of fiber reinforced partially cured thermosetting resin fabric is then placed over the rubber-like form block and the T-section stiffeners therein.

Abstract: A novel method is disclosed for the manufacture of a hollow graphite-epoxy structural part with high composite density and using tooling that eliminates the necessity of autoclave and similar high external pressure curing equipment. The method of manufacture in part involves the use of a rigid hollow frangible mandrel and superimposed flexible pressure bag element which subsequently develops high internal pressures in the part being processed during composite curing stages.