Abstract: A method of forming a synthetic article by open forming techniques by providing a fluid composition containing a predominant quantity of synthetic resin and having a capability for delayed, substantial gas evolution. To produce reinforced articles, the composition is applied to the reinforcement at a temperature below a predetermined gas evolution temperature and is subjected to fluid spreading conditions to thoroughly wet the elements of reinforcement. Subsequently, the fluid composition reaches the predetermined temperature, the resultant gas evolution effectively expands the composition while it remains in thorough wetting contact with the reinforcement elements, and the resin then solidifies and cures to produce an intimately reinforced, expanded article. In important embodiments the preponderant gas evolution results from the reaction of an organic hydroperoxide with an isocyanate in the presence of a surfactant.

Abstract: A composite base structure (70) and end fitting (26) are secured together by a composite joint to form a graphite-epoxy composite nacelle diagonal strut (20). The elongated base structure (70) has a wall (72) formed of a cured epoxy reinforced with layers of graphite fibers (100, 102, 104, 106) extending in elongated and transverse directions. The layers of fibers in the elongated direction (100, 104) and transverse direction (102, 106) extend onto a large diameter end (52) of a conical end portion (46) of an end fitting (26) and terminate on the conical portion adjacent a small diameter end (60). The layers of the elongated and transverse fibers (100, 102, 104, 106) are interlayered with layers (110, 112, 114, 116, 118) of graphite fibers generally circumferentially wrapped on the conical portion (46), the layers on the conical portion being impregnated with the cured epoxy.

Abstract: Reinforcing fiber materials such as rovings, webbings, and other fiber materials are impregnated with a resinous binder material in such a manner that gaseous inclusions are avoided whereby a surprising increase in the strength of the fiber compound material is achieved. For this purpose the liquid resinous binder material is applied substantially only to one side of the reinforcing material which is then moved through an absorbing zone in which the liquid resinous binder material penetrates the reinforcing material substantially completely as a result of a predetermined residence time and temperature in the absorbing zone. Gas inclusions are removed by adsorption and/or by expulsion.

Abstract: The disclosure relates to a technique for winding multiple layer flat electrical coils. Each coil is wound from the inside outward and neither end of the coil comes in contact with the interior of the winding. The system is capable of producing an epoxy-impregnated flat coil of variable circumference, shape, thickness, number of turns, and wire gauge. Coils are wound in pairs using a unitary length of wire, one coil being wound at the same speed of the other, and in the same direction.

Abstract: A dispenser of continuous resin wetted filaments has a container of a size suitable for hand holding, the container holding a supply of resin. A drum or reel of dry filament is positioned either inside or outside the container. The filament passes over filament guides in the container and through an outlet nozzle. The wetted filament is dispensed by attaching it to a former and then pulling the device away from the former. The device may include a filament tensioner so that the operator can vary the tension of the dispensed filament.

Abstract: A bifilar resistance element for use in preparing heating elements used in thermal bonding and the like, wherein two electrically conducting wires are embedded in a thermoplastic sheath which is fusible when sufficient current is passed through the bifilar resistance element. A heating element is prepared by joining the pair of wires in a length of the bifilar resistance element together at one end to form an electrically conductive path and then winding the length into a spiral shape. Two articles of thermoplastic material may be bonded together by placing the heating element in a recess simultaneously adjacent both articles with a pair of leads to the heating element extending externally from the two articles to be bonded, and applying an electrical current so that the thermoplastic sheath and a portion of the adjacent articles themselves are fused, to bond the articles together upon cooling.

Abstract: Forces are applied to cut fibres in a prescribed fashion to cause them to move in a predetermined manner toward and to be deposited on a mould surface in a controlled oriented fashion.

Abstract: An energy absorbing beam is shown which may be manufactured by wrapping several side-by-side strands of resin coated filaments about an increasing number of pins mounted upon a base. The base then becomes part of a mold to which heat and pressure is applied for forming the coated filaments into a beam having a variable cross section with variable thickness. Devices for fastening the beam may be molded into the beam by passing the coated filaments about the fasteners as the filaments are wrapped about the pins.

Abstract: An insulated heat bondable electrically conductive material includes an electrically conductive substrate, a base coat on the substrate of electrically insulating, heat resistant, cured resin, and an overcoat of heat curable acrylic polymer upon the base coat forming a heat bondable acrylic polymer coating thereon.The disclosure also includes: an insulated heat bondable magnet wire; a bondable enamel coated, insulated electrical conductor; an article; a dynamoelectric machine; a method of making an insulated, heat bondable metal substrate; and, a method of self-bonding a plurality of turns of a magnet wire.

Abstract: A process and apparatus for the continuous production of fiber reinforced plastic grating articles and other elongated structures of varying cross section configurations are provided wherein continuous strands of fibers are coated with a thermosetting plastic resin material and woven into a pattern defined by upper and lower molding teeth arranged on continuous upper and lower molding tracks. The molding tracks rotate and cause the molding teeth to mesh, forming a molding cavity, wherein heat is applied to set the plastic resin. The fiber reinforced plastic grating articles formed by this process and apparatus have a unique cross-sectional configuration and arrangement of fibers providing for increased strength and reduced resin usage.

Abstract: A carbon fiber reinforced composite coil spring is provided which is made from a braid formed of carbon fibers oriented at a preferred angle to the braid axis of approximately plus or minus 45.degree. and impregnated with a resin which serves as a substantially continuous matrix phase. Longitudinal reinforcing fiber may be incorporated into the braid to prevent it from straightening under longitudinal tension. The carbon fiber reinforced composite coil spring is formed by wrapping the braid, impregnated with a non-solidified resin, within a groove which extends helically along the surface of a helical mandrel and solidifying the resinous matrix material, and then removing the solid composite coil spring from the helical mandrel.

Abstract: A method of fabricating an energy absorbing structure for a vehicle comprises the steps of (a) winding a continuous resin wetted filament around a number of attachment points at the opposite ends of a jig to form an array of parallel strands, (b) displacing and tensioning the strands by means of first cross bars substantially at right angles to the strands, (c) winding a second array of parallel strands between the attachment points over said first cross bars, (d) displacing said second array onto said first array by means of second cross bars lying parallel and in between the first cross bars, (e) laying a third array of strands over said first and second cross bars and between said attachment points, and (f) curing the structure. The structure may then be fixed to the interior of a vehicle door panel.

Abstract: Filament band width uniformity is maintained in a filament winding process and apparatus therefor by a guide disposed between a winding eye and the mandrel about which the filaments are wound. The guide maintains a constant band payout angle with respect to the eye thereby maintaining uniform transverse reaction forces applied to the band by the eye.

Abstract: A new composition of matter comprises the product of the amassment of two or more arrays of glass roving or other suitable filaments, each of which array has been coated or impregnated with one of two complementary resin systems, preferably thermosetting polyester resin systems. Each such complementary resin system comprises substantially the same or functionally similar resin and each further comprises a curing agent, for example, in the case of polyester resin an organic peroxide, which curing agent differs from the curing agent in the other resin system. The resin system of each array further comprises suitable accelerator which is substantially ineffective to promote the curing agent of the resin system in which it is incorporated, but which does effectively promote the curing agent of the other, complementary resin system. Upon amassment of the separate arrays the two accelerators act synergisticly in the combined resin system.

Abstract: A method and apparatus for use in helical filament winding operations, wherein the filament to be wound is axially displaced a predetermined amount as it is drawn about a traction roller by a driven form or mandrel on which the filament is to be wound, whereby the degree of axial displacement of the filament on the traction roller determines the angle of helical wind on the winding surface. A filament guide is provided comprising a traction roller about which, in operation, the filament to be wound is drawn to rotate the roller. A means is provided which contacts the filament in order to axially displace the filament on the traction roller a predetermined amount with respect to filament input and filament output paths thereby defining the helix angle of wrap on the form. This filament contact means is movable, under force as applied thereon by the filament leaving the roller, between predetermined limits in a direction parallel to the axis of the roller.

Abstract: A fiber reinforced epoxy resin article in which a Lewis base is employed as the catalyst for the addition reaction of a phenolic or alcoholic hydroxyl group and the oxirane group of the epoxy resin. The resin system has improved flexibility and pot life and the cured article has improved chemical resistance.

Abstract: A method is described for the production of porous bodies from vitreous silica without the use of tools. Vitreous silica wool and/or threads are wound in layers on a form. After the coil has attained a certain minimum thickness, the threads of each succeeding layer are permanently bonded by heating the threads of the preceding layer at the points where the threads cross. The form is removed, and then the threads on the inside of the body are bonded together.The bodies are used for the production of high-purity blocks of silicon for solar cells.

Abstract: A method is provided giving a bundle of glass fiber strands improved integrity. A plurality of glass fiber strands are contacted with a fine, particlized, thermoplastic material in an amount up to about 0.5% by weight of the dried combined plurality of glass fiber strands in a forced gas chamber. The plurality of glass fiber strands containing the thermoplastic material is heated so that the thermoplastic material is softened on the plurality of strands thereby holding the strands together in such a manner that the plurality of strands can be processed without separating, but when the plurality of strands are chopped or woven the strands separate.

Abstract: Carbon-carbon fiber composites suitable for use in aircraft brake discs are made by extruding an aqueous gelled mixture containing chopped carbon fibers and a binder-thickening agent into the form of an elongated ribbon wherein the fibers are aligned in the direction of fluid flow. The ribbon is then arranged into a spiral configuration to form a flat disc shaped article with the fibers oriented in the circumferential direction. The disc shaped article is dried, heated to a sufficiently high temperature to carbonize the binder in the mixture and then impregnated with a liquid carbonaceous binder followed by heating the article to at least a carbonizing temperature in order to densify the product.

Abstract: Hollow fiber apparatus for the fractionation of fluid, especially useful as an artificial kidney, is disclosed, characterized principally in that it comprises:a mandrel in the form of a truncated cone towards the ends of which two so-called end walls are situated, which surround the said mandrel and by which hollow fibers are held, the fibers extending from one end wall to the other, at least one of the end walls being sealed and traversed by the open ends of the hollow fibers,an outer casing of which the inner wall is in the form of a truncated cone at least along the greater part of its length near the hollow fibers.means for the intake and/or discharge of the fluid which circulates inside the hollow fibers, andmeans for the intake and/or discharge for the fluid which circulates over the outer wall of the fibers.Process and apparatus for manufacturing the hollow fiber apparatus are also disclosed.

Abstract: A laminated friction member, such as a clutch facing comprising a friction element comprising aramid fibers and a reinforcing element formed of non-aramid fibers, the elements being impregnated with and bonded together by means of heat-curable cement.

Abstract: A process and apparatus are disclosed for the simultaneous preparation of several hollow fiber devices especially useful for fluid fractionation operations, wherein at least one hollow fiber is wound around means, at least three in number, located in different planes thereby obtaining with this fiber an envelope having a polygonal section, which can be cut in at least two places as it is formed, so as to obtain at least two distinct groups of hollow fiber lengths. Various specific embodiments are described.

Abstract: A method of manufacturing a fiber-reinforced plastic body of irregular geometrical shape including winding a ring of fibers such that different sections of the ring around its periphery correspond in contour to sections of the body. The sections of the ring are cut from the remainder of the ring, and the sections joined together, such as by bonding to each other, to form the final body. The cut sections may be mechanically processed before joining them together. The fibers run approximately parallel to the outer contour of the finished body.

Abstract: A hollow filament separatory module utilizing an annulus of semi-permeable hollow filaments with open ends encased in a potting compound and a collection chamber communicating with said open ends adjacent the potting compound with access surface means formed in the potting compound wherein the open ends appear, said filaments having ends thereof encapsulated by the introduction of potting medium into the interfilament interstices under the urging of vibratory energy and thereafter creating said open ends by cutting of ends and potting medium at a time in the curring cycle of the potting compound prior to its final cure.

Abstract: The disclosure embraces a process and apparatus for producing a roving package of strands of glass fibers or filaments bearing a coating material including converging the strands into a linear bundle or roving with the strands oriented into a ribbonized formation and winding the bundle or roving into a package in an enclosed chamber and heating the package in the chamber sufficiently during its formation to cause the coating material on the strands to cohere the glass strands of the bundle or roving together so that upon cooling of the package the ribbonized roving can be readily unwound or removed.

Abstract: The disclosure relates to a construction for a wrapped elongated structure, a method of manufacturing an apparatus to manufacture the wrapped elongated structure. The wrapped elongated structure has an elongated core. An adhesive tape having one adhesive surface is applied to the surface of the core along the length thereof with the adhesive surface facing away from the core. Tape wrapping is spirally wrapped around the core and the applied adhesive tape in order that each turn of the tape wrapping contacts the adhesive surface of the adhesive tape. The adhesive tape secures the tape wrapping in its spiral form with respect to the elongated core. The wrapped elongated structure may also structure may also included an elongated core, a first tape wrapping spirally wrapped around the core, an adhesive tape having two adhesive surfaces applied on the spiral first tape wrapping, and a second tape wrapping spirally wrapped around the adhesive tape.

Abstract: A line guide for a fishing rod having a circular laminate (14) of resin-impregnated graphite fibers and a linear foot laminate (13) of resin-impregnated graphite fibers. The foot is attached to the circular laminate by winding some of the fibers (14) of the circular laminate underlying the foot and others (14') overlying the foot, and then heat-curing the assembly to produce a monolithic line guide and foot structure (12).

Abstract: A filament winding apparatus having means associated with the winding ring thereof for automatically widening the space between the guide surfaces of the ring at predetermined intervals so as to allow for the removal of any residue or debris which may accumulate therein during operation and cause filament breakage. The apparatus is particularly suitable for winding fibers, such as carbon fibers, which have a susceptibility to shed or fragment during winding, and thereby cause an accumulation of debris in the winding ring.

Abstract: A solar heat collector panel comprising a flat spiral coil of pipe (preferably plastic) having an inlet at the inside and outlet at the outside, the inlet conduit extending out behind the coil. A plurality of approximately radial ribs is attached behind the coil to support the coil spaced from the surface on which it is installed to create a dead air space, prevent dry rot of the supporting surface, hold the coil level and stiffen the panel. A sheet of plastic material is caused to adhere to the back of the coil by adhesive and vacuum molding. The method of fabricating the panel is described in detail. This invention is an improvement on U.S. Pat. No. 4,014,314.

Abstract: Polyalkylenetrimellitate imide polyalkylenetrimellitate ester imides suitable for use as self-bonding varnish coatings for magnet wire, which can be produced by condensation of a trimellitic acid compound, a diprimary amine, an alkanol amine and a glycol.

Abstract: A woven structure comprising at least a continuous band around an internal axis, suitable for impregnation with resin or for internal deposition of graphite from a reactive vapor, comprises axial threads, circumferential threads, and radial threads. The device employed to produce the structure comprises principally a series of flat rings or disks, aligned and slightly spaced from each other axially, having small apertures located around their circumference or one or more helical worms, with central openings, whose successive turns are similarly provided with apertures. Radial threads are passed through homologous apertures in successive disks, or successive turns of the helical worm, and are then drawn toward the central axis by wrapping of circumferential threads around them in the axial space between adjacent disks. Axial threads are then passed between the radial threads, and are drawn by further wraps of circumferential threads.

Abstract: Reinforced plastic articles such as pipes, receptacles and sheet-like laminated structures wherein the reinforcing material comprises at least one layer of a combination of glass fibers and steel cord; processes for making same.

Abstract: The disclosure pertains to an optical display apparatus, or fiber optics magnification panel, and a method of making same. In accordance with the disclosed method, a plurality of substantially parallel relatively closely spaced optically conducting elongated strands, such as fiber optic strands, are wrapped about a spacer element. At least one additional spacer element is then positioned over the previously wrapped strands and the plurality of strands is rewrapped over the at least one additional spacer element in spiral fashion. The operation of positioning an additional spacer element over the previously wrapped strands and rewrapping the strands over the additional spacer element is then repeated a desired number of times. The resultant spirally wound construction is then severed substantially along the plane of the first-mentioned spacer element, and a resultant portion of this severing operation is angularly severed to form a pair of wedge-shaped display panels.

Abstract: The present invention relates to FRP members, the apparatus and process for making same. The FRP members are reinforced with helical strands of reinforcing material disposed in expanded helices of opposite hand, the helices of each hand being contained in discrete layers. The lead angle of each helix may be constant or varied along the length of the member independently of whether the member is cylindrical or tapered in order to provide the desired structural characteristics. The process comprises impregnating the reinforcing strands with resin and wrapping those strands onto a mandrel by apparatus in which relative rotational as well as relative translatory movement between the mandrel and a winding head may be effected to wrap the strands onto the mandrel. At least one relative movement may be selectively varied to effect the desired lead angle to the helically disposed reinforcing strands along the length of the mandrel.

Abstract: A pile weatherstripping has a continuous length of a resin anchorage base with even lengths of filaments secured to opposite sides of the base along the length of the base and extending away from the base in the same general direction on each side of the base. The filaments are long enough and dense enough to form insulating pile rows extending out of a retainer slot in which the anchorage base has an interference fit. A sheet resin fin preferably extends continuously outward from the base between the filaments on the opposite sides of the base, and such a weatherstripping is preferably made by wrapping a multifilament yarn around a plurality of bases, securing the yarn to opposite sides of the bases, and then slitting to separate each individual weatherstrip.

Abstract: A method for producing carpeting of a type having pile yarns adhesively bonded to a backing which comprises providing a thin flexible core member having longitudinal and transverse axes, winding a continuous yarn around the core member in a direction perpendicular to the longitudinal axis so as to form a plurality of elongated loops conforming to the cross-sectional configuration of the core member, positioning the core member having the yarn wound thereon on a backing sheet so that the longitudinal axis is parallel to the sheet and the transverse axis is perpendicular to the sheet and so that one end of each of the loops contacts the backing sheet, adhering the end of the loops contacting the backing sheet to the backing sheet, cutting the other ends of the loops, and removing the core member. Carpeting characterized by good register between different colors and different heights with a high degree of flexibility in the design pattern is obtained by this method.

Abstract: A method for making hose including the steps of spiralling plies of thermoplastic tubing over a vulcanizable elastomeric tube where the tubing of successive plies are oppositely spiralled from each other; pressurizing and sealing the tubing; heating the assembly to a temperature lower than the melting point of the tubing; and vulcanizing the elastomeric tube.

Abstract: A woven structure comprising at least a continuous band around an internal axis, suitable for impregnation with resin or for internal deposition of graphite from a reactive vapor, comprises axial threads, circumferential threads, and radial threads. The device employed to produce the structure comprises principally a series of flat rings or disks, aligned and slightly spaced from each other axially, having small apertures located around their circumference or one or more helical worms, with central openings, whose successive turns are similarly provided with apertures. Radial threads are passed through homologous apertures in successive disks, or successive turns of the helical worm, and are then drawn toward the central axis by wrapping of circumferential threads around them in the axial space between adjacent disks. Axial threads are then passed between the radial threads, and are drawn by further wraps of circumferential threads.

Abstract: A flywheel for an inertial guidance system, comprising a rim reinforced by a sheet formed of one or more filaments wound around the rim and intersecting adjacent the axis of symmetry of the rim. The sheet of filaments may be reinforced by means of a binder and the flywheel may or may not include a hub at the axis of symmetry and having the filaments wound therearound.

Abstract: Methods for forming a composite ring having unidirectional filaments embedded in a polymer matrix is disclosed. The filaments are spirally wound within the ring to form a plurality of essentially circular hoops which are in coaxial alignment with the expected lines of principle force. In one embodiment the formed ring is structurally integrated into the rotor of a gas turbine engine to reinforce the rotor and to restrain the rotor blades which extend outwardly of the ring.

Abstract: This invention comprises a method for manufacturing elastomeric high pressure hose having reinforcement in the form of braided or spiral wrapped textile yarns between extruded inner and outer elastomeric layers. The method includes the steps of extruding the inner elastomeric layer over a long flexible mandrel up to about 1000 ft in length coextensively therewith, then progressively freezing portions of the layer and braiding or spiral wrapping a textile reinforcement thereover. The layer is frozen to prevent extrusion of the inner layer during the braiding. Thereafter additional elastomeric and textile layers are applied and the elastomers are vulcanized in an elongated continuous vulcanizer.

Abstract: A method for producing carpeting of type having pile yarns adhesively bonded to a backing which comprises providing a thin flexible core member having longitudinal and transverse axes, winding a continuous yarn around the core member in a direction perpendicular to the longitudinal axis so as to form a plurality of elongated loops conforming to the cross-sectional configuration of the core member, positioning the core member having the yarn wound thereon on a backing sheet so that the longitudinal axis is parallel to the sheet and the transverse axis is perpendicular to the sheet and so that one end of each of the loops contacts the backing sheet, adhering the end of the loops contacting the backing sheet to the backing sheet, cutting the other ends of the loops, and removing the core member.

Abstract: A pile weatherstripping has a continuous length of a resin anchorage base with even lengths of filaments secured to opposite sides of the base along the length of the base and extending away from the base in the same general direction on each side of the base. The filaments are long enough and dense enough to form insulating pile rows extending out of a retainer slot in which the anchorage base has an interference fit. A sheet resin fin preferably extends continuously outward from the base between the filaments on the opposite sides of the base, and such a weatherstripping is preferably made by wrapping a multifilament yarn around a plurality of bases, securing the yarn to opposite sides of the bases, and then slitting to separate each individual weatherstrip.