Abstract: A polymer is formed into the shape of a one-piece composite part and then solidified by curing, setting, hardening or otherwise solidifying the polymer to form a shaped polymer form having a shape that does not draw. Composite material is laid up on the form and solidified to from the composite part. The rigidity required of the form to lay up the composite part can he provided by operating in the polymer form's glassy state, forming the shaped polymer form with a hollow core and placing a rigid insert designed to draw inside the hollow core with the polymer form in its elastomeric state or through a combination of both. In its elastomeric state the form becomes pliable (without relaxing to a different memorized shape) and can he drawn out of the one-piece composite part. Because the shape of the form does not draw, the form deforms as it is drawn. If used, the rigid insert is drawn out prior to removing the shaped polymer form.

Abstract: A polymer is formed into the shape of a one-piece composite part and then solidified by curing, setting, hardening or otherwise solidifying the polymer to form a shaped polymer form having a shape that does not draw. Composite material is laid lip on the form and solidified to from the composite part. The rigidity required of the form to lay up the composite part can be provided by operating in the polymer form's glassy state, forming the shaped polymer form with a hollow core and placing a rigid insert designed to draw inside the hollow core with the polymer form in its elastomeric state or through a combination of both. In its elastomeric state the form becomes pliable (without relaxing to a different memorized shape) and can be drawn out of the one-piece composite part. Because the shape of the form does not draw, the form deforms as it is drawn. If used, the rigid insert is drawn out prior to removing the shaped polymer form.

Abstract: Methods and apparatus for systems having deployable elements according to various aspects of the present invention comprise a system including a deployable surface and an adaptive actuator including a polymer foam. In one embodiment, the system comprises a vehicle including a deployable wing comprising an exterior surface. The exterior surface may be adjusted by adjusting the shape, size, position, and/or orientation of the adaptive actuator.

Abstract: A telescoping structure includes an alignment mechanism to keep aligned an inner structure member and outer structure member, as the members translate relative to one another to extend or retract the telescoping structure. The alignment mechanism includes multiple parts that are mechanically coupled to respective of the structure members. For example, the alignment mechanism may include sprockets or pinions (rotating, toothed elements) on one of the structure members that engage racks or chains (linear, tooth-receiving elements having recesses therein) on the other of the structure members. By keeping the telescoping structure members in alignment with other during telescoping translation, jamming is prevented or at least made less likely. The parts of the alignment mechanism may also be used to provide force for extending or retracting the telescoping structure, for example using a motor move the tooth elements and/or the tooth-receiving elements to cause relative translation of the structure members.

Abstract: Methods and apparatus for systems having deployable elements according to various aspects of the present invention comprise a system including a deployable surface and an adaptive actuator including a polymer foam. In one embodiment, the system comprises a vehicle including a deployable wing comprising an exterior surface. The exterior surface may be adjusted by adjusting the shape, size, position, and/or orientation of the adaptive actuator.

Abstract: A reconfigurable air vehicle wing may be selectively reconfigured to increase its chord. The wing has a leading edge portion and a trailing edge portion that are moved relative to one another to change the chord of the wing. The wing may be reconfigured from a compact configuration with a smaller chord, to and expanded configuration with a larger chord. The wing may include a foam material that forms part of the outer surface of the wing when the wing is in the expanded configuration. The foam may be a shape memory foam. Alternatively the leading edge section and the trailing edge section may be composed substantially fully of rigid materials. In either case the trailing edge section may be hingedly coupled to the leading edge section.

Abstract: A wing, such as a wing for an unmanned aerial vehicle (UAV), includes a beam or box that can be selectively expanded from a collapsed condition, to increase the thickness of the wing. The beam may include a pair of plates that are close together when the beam is in a collapsed condition, and separate from one another to put the beam in an expanded condition. The plates may be substantially parallel to each other, and may have shape memory foam and/or resilient devices, such as coil springs, between them, in order to provide a force to separate the plates before, during, and/or after deployment of the wing. The expandable/collapsible beam may have a lock mechanism to lock it into place when the beam is in an expanded condition.

Abstract: A method of evaluating material properties of polymeric materials includes making one or more material samples or slabs, with each of the samples or slabs having a pair of material layers in contact with one another. The layers are layers of organic matrix polymer material that have different characteristics from each other, for example having a difference in composition and/or cure characteristics. Characteristics of the test slabs and the interface between the layers can be determined by examining curvatures of the test slabs. A number of samples may be made up having the same material in a first layer, and range of different materials in the respective second layers. The range may cover a range of various material compositions and/or cure characteristics.

Abstract: A nose cone formed from a shape memory alloy (SMA) having a recoverable strain of at least 2% collapses about the dome for storage, deploys at launch to protect the sensor dome and reduce drag during atmospheric flight and is shed to allow sensing for terminal maneuvers. The SMA is shape-set at elevated temperatures in its Austenite phase with a memorized shape having a radius of curvature greater than that of the sensor dome to reduce aerodynamic drag. The temperature is reduced and the SMA collapsed to conform to the curvature of the sensor dome within the recoverable strain for storage. A first mechanism is configured to return the collapsed SMA to its memorized shape at launch or prior to going supersonic. In one embodiment, the SMA is stored below its Martensite finish temperature in a temperature-induced Martensite phase in which case the mechanism heats the SMA above the Austenite finish temperature to return the material to its memorized shape.

Abstract: A shape-changing structure has a superelastic metal foam structural member that changes shape (morphs) to change configuration of the structure. The superelastic metal foam structural member changes shape while maintaining a continuous outer surface, with the continuous metal foam material inside the outer surface expanding, contracting, or otherwise changing shape. The superelastic metal foam material may be heated above a transition temperature to allow it to change shape, and then cooled to cause it to increase in strength, more easily maintaining its new shape. The superelastic metal foam material may be a suitable alloy, for example a nickel titanium alloy, that exhibits superelastic (pseudoelastic) behavior. The superelastic metal foam material may be a shape memory alloy material that returns to a set shape upon moderate heating. The superelastic metal elastic foam structural member may be heated either by an internal heat source or by external heating.

Abstract: A structure includes a polymer structural member, which may include a shape memory polymer material, that can change its size and/or shape. An electromagnetic source is used to impose an electric field or a magnetic field on the polymer structural material, in order to control the shape of the material. The force may be used to change the shape of the material and/or to maintain the shape of the material while it is under load. The polymer material may be a solid material, may be a foam, and/or may include a gel. A shape memory polymer material may have mixed in it particles that are acted upon by the electromagnetic field. The structure may be used in any of a variety of devices where shape change (morphing), especially under loading, is desired.

Abstract: A shape-changing structural member has a shape-changing material, such as a suitable foam material, for example a polymer foam capable of withstanding at least 300% strain or a metal alloy foam capable of withstanding at least 5% strain. Springs, such as one or more coil springs, provide structural support for the shape-changing material. The springs may also be used to provide forces to expand and contract the shape change material. The springs may include pairs of concentric springs, one inside of another. The concentric springs may surround an underlying skeleton structure that supports the shape-changing material and/or aids in changing the shape of the material. The concentric springs may or may not be wrapped around the underlying skeleton structure. Multiple springs or pairs of springs may be coupled together using a sheet metal connector.

Abstract: Piezomagnetic, magneto-strictive, or electro-strictive material particles may also be distributed throughout the structural material of the structural member, which serve to amplify and otherwise enhance the signals from the piezoelectric material particles. The piezoelectric, electro-strictive, magneto-strictive, and/or piezomagnetic material particles may allow the structural member to exhibit an electrical and/or magnetic response to forces on the structural member, such as accelerations. This may allow the structural member to function as a force sensor or an accelerometer. Signals induced by such external forces or accelerations may be taken from the conductive pickups and used for various operations, for example, for arming a warhead of a missile or for triggering passenger safety features such as air bags in automobiles.

Abstract: Methods and apparatus for systems having deployable elements according to various aspects of the present invention comprise a system including a deployable surface and an adaptive actuator including a polymer foam. In one embodiment, the system comprises a vehicle including a deployable wing comprising an exterior surface. The exterior surface may be adjusted by adjusting the shape, size, position, and/or orientation of the adaptive actuator.

Abstract: A method of evaluating material properties of polymeric materials includes making one or more material samples or slabs, with each of the samples or slabs having a pair of material layers in contact with one another. The layers are layers of organic matrix polymer material that have different characteristics from each other, for example having a difference in composition and/or cure characteristics. Characteristics of the test slabs and the interface between the layers can be determined by examining curvatures of the test slabs. A number of samples may be made up having the same material in a first layer, and range of different materials in the respective second layers. The range may cover a range of various material compositions and/or cure characteristics.

Abstract: Methods and apparatus for systems having deployable elements according to various aspects of the present invention comprise a system including a deployable surface and an adaptive actuator including a polymer foam. In one embodiment, the system comprises a vehicle including a deployable wing comprising an exterior surface. The exterior surface may be adjusted by adjusting the shape, size, position, and/or orientation of the adaptive actuator.

Abstract: Piezomagnetic, magneto-strictive, or electro-strictive material particles may also be distributed throughout the structural material of the structural member, which serve to amplify and otherwise enhance the signals from the piezoelectric material particles. The piezoelectric, electro-strictive, magneto-strictive, and/or piezomagnetic material particles may allow the structural member to exhibit an electrical and/or magnetic response to forces on the structural member, such as accelerations. This may allow the structural member to function as a force sensor or an accelerometer. Signals induced by such external forces or accelerations may be taken from the conductive pickups and used for various operations, for example, for arming a warhead of a missile or for triggering passenger safety features such as air bags in automobiles.

Abstract: Methods and apparatus for a seal according to various aspects of the present invention include a seal operating in conjunction with a housing and a removable cover. A portion of the seal is attached to the housing and another portion of the seal is attached to the removable cover to enclose a joint between the housing and the removable cover. A cutter cuts the seal, which allows the removable cover to be removed.

Abstract: A load-bearing structural member has a continuous structural material with piezoelectric material particles mixed in throughout. The structural material may be any of a variety of suitable materials, such as polymer materials, composite materials, ceramic materials, or concrete. The piezoelectric material particles may be used for evaluating the soundness of the structural member, such as in quality control or structural health monitoring processes. The structural member may include one or more conductive pickups used for receiving signals from the structural member. The signals may be induced by introducing ultrasonic signals or vibrational resonance signals into the structural member. The response from such induced signals may be used for quality control purposes or structural health monitoring.

Abstract: A load-bearing structural member has a continuous structural material with piezoelectric material particles mixed in throughout. The structural material may be any of a variety of suitable materials, such as polymer materials, composite materials, ceramic materials, or concrete. The piezoelectric material particles may be used for evaluating the soundness of the structural member, such as in quality control or structural health monitoring processes. The structural member may include one or more conductive pickups used for receiving signals from the structural member. The signals may be induced by introducing ultrasonic signals or vibrational resonance signals into the structural member. The response from such induced signals may be used for quality control purposes or structural health monitoring.