Abstract: A 360° tool for making a one-piece composite tubular structure, such as a skin of an acoustic liner, is adjustable between a molding position and a non-molding position. The tool includes a base, a fixed segment mounted to the base, first and second doors hingedly connected on either side of the fixed sector, and third door hingedly connected to the second door. The third door has a circumferential extent that is less than one-fourth that of either the first or second door. Sealing members are provided between the doors. Collectively, the fixed sector, and the first, second and third doors have a predetermined shaped surface that corresponds to a portion of the contour of the tubular structure to be formed. After composite material is applied on the outer surfaces of the fixed sector and the doors, a vacuum bag is formed to surround the composite material and also the joint areas on the inner surface of the tool. The entire tool may be placed in an autoclave for curing.

Abstract: A linerless tank structure has a body that defines an enclosed interior volume. The body has a cylindrical section having an axis of symmetry and a dome section coupled with the cylindrical section. The construction of the pressure vessel includes multiple fiber plies. At least one of the fiber plies is a helical ply having fibers traversing the dome helically about the axis of symmetry. At least a second of the fiber plies is a braided or woven ply.

Abstract: For a method for manufacturing a hollow shaft with at least one integral flange made of fiber composite, a plurality of intersecting windings of fiber material are applied onto a core. Moreover, the core has, for each flange, a radial spreader ring with an axial bearing surface. The windings are laid over an outer circumferential portion of the respective spreader ring and fixed. One or several inserts made of fiber material are inserted in the area of the spreader ring between the windings. The fixing of the wound fiber material is released, but is first still held on the spreader ring. Portions of the windings are then pulled off from the outer circumferential portion of the spreader ring and brought to rest on the axial bearing surface of the spreader ring in order to form a partial portion of a flange.

Abstract: An apparatus and method are provided for replacing a creel in a fiber placement machine, by sequentially moving replaceable creels into place on the fiber placement machine, via tracks and/or guide rails, as one or more spools in a previously operating creel are exhausted, and removing the creel having the one or more exhausted spools, to thereby allow fiber placement to continue from the replacement creel while the creel having one or more exhausted spools of material is replenished. An auto-splice apparatus and method are incorporated into the replaceable creel and fiber placement machine, for assisting in the exchange of replaceable creels.

Abstract: An apparatus and invention are provided for accelerating an added tow to match the lay-down speed of other tows exiting a compaction roller of a fiber placement head, by driving the added tow with an add roller operatively coupled to be driven at the same peripheral speed as a feed roller having a peripheral speed matching the peripheral speed of the compaction roller.

Abstract: A composite ring gear (10) with a metallic gear insert (30) has at least one filament (34) wound about the gear insert and an eyelet (32) a plurality of times. The filament is adapted to withstand a portion of a tensile load transmitted between the insert and the eyelet. The insert, eyelet and filament are then embedded in a composite material.

Abstract: The present invention relates to a tubular-shaped component (19) for an aeronautical fuselage made of composite materials comprising an outer skin (1) without joints having a cylindrical or cylindrical-conical shape, a plurality of stiffeners or stringers (2) longitudinally arranged in said outer skin (1) and a plurality of anchoring elements (3) for anchoring other elements to subsequently be incorporated transversally arranged between said stiffeners or stringers (2). The invention also comprises a jig (18) comprising a support body (12) and a plurality of panels (9) that can shift between an extended position (10) and a retracted position (10?) in both directions and a process for manufacturing said component (19) in the last step of which once the tubular component (19) is formed and cured, it is separated from the jig (18) by means of a longitudinal movement after the shifting of those elements of the jig (18) preventing it, and particularly the panels (9) that can be shifted.

Abstract: A composite wind turbine tower, method for fabricating a composite wind tower and an apparatus for forming a composite wind tower. The tower includes a first layer and a second layer, each having a matrix material and a plurality of reinforcing fibers disposed in the matrix material. The tower further includes a core layer disposed intermediate to the first layer and the second layer. The tower is capable of being partially or fully fabricated on-site.

Abstract: An architectural column includes a tubular column body having a longitudinal axis extending from a first end to a second end, at least one inner layer, at least one support layer and at least one outer layer, wherein the support layer includes a composite fabric having fibers and a bonding resin.

Abstract: The invention describes the production and utilization of a multi-layer composite material, a polyester resin and/or vinyl-ester resin based adhesive with special composition, applied on the surface or between the layer of the enforced object, which is made of unsaturated polyester resin and/or vinyl-ester resin based, glass-fiber reinforced, pre-made band shaped prepreg material, which can be used on surface of cylindrically symmetric objects like piers, pipes, pillars, etc. to strengthen their stability, endurance and resistance. This material can also be used to repair certain small irregularities on the enforced objects surface. Initiators and substances are added to the prepreg's matrix material, such as poly-?-caprolacton; acetyl-acetone and alkyl-(acrylate)-methacrylate type monomers to result in networking of the resins. Peroxides decompose due to activator compounds coming from diffusion on the surface of the adhesive substance.

Abstract: In a method and a tool for forming an elongate, hollow article of a fiber-reinforced composite material one end of an article laminate applied to a tool bar is placed in engagement with or is supported by an anvil of the tool so as to control the direction of longitudinal movement of the cured article relative to the tool bar during the cooling and dismantling phase.

Abstract: To fabricate a composite item, a first end effector is selected from a plurality of end effectors to apply tows to a form. The first end effector includes an integrated creel configured to store spools of the tow on an assembly of spindles. The assembly of spindles is substantially parallel to a longitudinal axis of the first integrated creel. The first end effector is secured to a positioning device. The tows are applied to the form and the tows are compacted on the form with a compaction device. The assembly of spindles are disposed circumferentially about the compaction device.

Abstract: A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. Ribs are formed on a smooth hard base tool. Expansion blocks are placed in the shallow cavities formed by the ribs and the base tool, and held in place by a synthetic elastomer-based adhesive while a skin is placed over the ribs, expansion blocks, and base tool. The assembly is then placed in a vacuum bag and autoclave cured. After cooling, the expansion blocks are removed and the formed structure is removed from the hard base tool. This abstract is provided to comply with the rules requiring an abstract, and is intended to allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

Abstract: A method of manufacturing a unitary seamless section of an aircraft fuselage comprises disposing a thin lay-up mandrel element onto the outer shell surface of a cylindrical inner mandrel shell, thereby forming a mandrel with a lay-up surface. A plurality of resin impregnated stiffener fibers may be layed-up within a plurality of stiffener channels in the lay-up surface to form a plurality of stiffeners or stringers. The method further includes laying up a plurality of resin impregnated skin fibers onto the lay-up surface while the mandrel rotates to form a unitary pre-cured section of an aircraft fuselage.

Abstract: The present invention relates to a one-piece closed-shape structure and a method for manufacturing a one-piece closed-shape structure. In particular, the present invention relates to a one-piece fuselage and a method for manufacturing a one-piece fuselage. One embodiment of the method of the invention involves the use of molding technology, tooling technology, the integration of the molding and tooling technology, and fiber placement to manufacture a one-piece closed shape structure.

Abstract: An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. Multiple composite material delivery heads simultaneously deliver material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery heads inside the interior mandrel surface. A connecting mechanism connects the material delivery heads to the gantry beam and provides motion of the material delivery heads relative to the interior mandrel surface.

Abstract: A two roll impregnator for impregnating fiber reinforcement for use in filament winding operatives contains two abutting rolls, at least one and preferably both having an elastomeric surface. Resin is constrained within a bath whose lower surfaces are defined by the abutting rollers and side dams. Fiber reinforcement is drawn over a first roller through the resin bath and between the closed nip of the abutting rollers, where full impregnation is fostered, excess resin removed, and the impregnated fiber degassed. Substantially dripless operation can be maintained.

Abstract: The present invention provides a method of forming hybrid and composite filters, which are more durable than that of the prior art. The method of forming a hybrid tubular filter includes wrapping a first layer of fiber, wrapping a filtering material and then wrapping a second layer of fiber. A mandrel is retained in a lathe chuck or the like and an end of fiber is attached to the mandrel. A fiber guide moves parallel to a length of the mandrel according to the direction of a control device. The method of forming a composite tubular filter includes wrapping a first layer of fiber around a mandrel.

Abstract: Composites are provided having improved strength and rigidity, with respect to mass or volume, as compared to known polymeric composites or polymeric composites in combination with metal reinforcement. The composites of the present invention are metallic-polymeric composites and are comprised of polymeric composites and metallic composites. Such metallic-polymeric composites provide for composite parts having improved strength and/or rigidity, with respect to mass or volume, compared to other composite parts. The composite parts of the present invention have potential utility, for example, as aerospace craft leading edges, bodies, panels, and control surfaces.

Abstract: A method for the production of curved thread-reinforced tubular structures composed of rubber layers and of strengthening layers and an accompanying device. In one aspect, the method includes the application of a first rubber layer to the circumference of mandrels driven forward in a feed direction (X) and winding on of a multiplicity of parallel reinforcing threads, having defined thread angles (?) with respect to the feed axis (x), by means of a bobbin creel, to form a first thread ply. The mandrels are led through a rotating deflection element surrounding the mandrels and the reinforcing threads are guided so as to be distributed on the inner circumference. An application of a covering rubber layer may be performed (after the optionally multiple execution of the previous steps, alone or in combination). The mandrels are led through the deflection element of the bobbin creel eccentrically in the region of the deflection element.

Abstract: A method for manufacturing a drum assembly for an internal drum-type imaging apparatus, and a drum assembly produced using the method. The drum assembly defines an imaging surface which is at least semi-cylindrical. A drum skin defines an imaging surface, and is releasably wrapped around a cylindrical mandrel, which has an axis. The mandrel and wrapped drum skin have a first radius. A drum includes more than one drum portion, and is attached to the drum skin over an at least semi-cylindrical interface. The drum has a radius slightly greater than the first radius, and the drum and attached drum skin cooperate to define a vacuum chamber. A fluid bearing is generated between the drum skin and the mandrel, preferably by pressurizing the vacuum chamber, in order to separate the drum skin from the mandrel. The drum and attached drum skin are then moved relative to the mandrel and in a direction parallel to the axis to remove the drum assembly from the mandrel.

Abstract: A thin ribbon spirally wound polymer conduit and method of forming, wherein a helical reinforcing bead is interposed adjacent overlapping layers of ribbon. Further, a method of continuously forming spirally wound conduit wherein a sacrificial layer, preferably having a different base polymer to that of the conduit, is first applied to the former before the conduit is formed overtop.

Abstract: An aircraft part manufacturing device for automated composite lamination on a mandrel surface of a tool having a rotational axis includes a mechanical supporting structure that supports multiple material delivery heads. The tool is moveable and rotatable relative to the mechanical supporting structure. The mechanical supporting structure provides for axial translation of the material delivery heads relative to the mandrel surface while the mandrel surface is rotated for laying down courses of composite material over the entire mandrel surface of the tool. The position and movement of each of the plurality of material delivery heads is individually adjustable. Arm mechanisms provide motion of each material delivery head in a direction normal to the mandrel surface; rotation about an axis normal to the mandrel surface; circumferential position adjustment in a hoop direction relative to the mandrel surface; and axial position adjustment relative to the other material delivery heads.

Abstract: An arrangement (1) for guiding individual reinforcement filaments (2) onto a carrier (3) has a positioning disc (4) with a plurality of filament guides (9) arranged distributed on a circular ring of the positioning disc (4). The carrier is moveable in the direction of the carrier axis (X). The arrangement also includes a rotationally symmetrical deflecting element (5). The positioning disc (4) and the deflecting element (5) each concentrically surround the carrier (3). The deflecting element (5) is mounted within the positioning disc (4) and aligned axially to the positioning disc (4). The inlet-end peripherally extending inner edge (6) of the deflecting element (5) faces toward the carrier (3) and is curved. The filament guides (9) open directly at the curved inner edge (6).

Abstract: A mobile platform personnel berth unit and a method for creating the mobile platform personnel berth unit are provided. A male mandrel is created defining an inner mold line surface of the berth unit. The male mandrel is overlayed with one or more layers of filament strips. The filament layers are thermally cured to create an integrated structural member. The male mandrel is then removed from the structural member. The structural member is profile shaped to create a semi-finished berth unit having a top, a bottom and a pair of integral side panels. Additional entrance and back panels as well as access panels and connecting hardware are then added to complete the berth unit.

Abstract: A method for manufacturing a connection for composite tubing is disclosed. The method includes maintaining tension on the composite fibers while “winding in” the connector to the composite tubing. The tension on the fibers results in the fibers bridging across traps of the connector as they are being wound. The bridging results in improved load bearing characteristics of the connection.

Abstract: A machine and method for moulding a composite of complex nodal structure includes laying down under CNC a reinforcement (38) of constant cross-section repeatedly into and along channels (26) of a mold (24) and through nodes of the structure, closing the mold, impregnating it with resin and curing the resin.

Abstract: A fiber reinforced plastic article is disclosed which include a liner, at least one single material fiber layer wound on the liner, and at least one composite fiber layer wound on the single material fiber layer. The at least one single material fiber layer and the at least one hybrid fiber layer are impregnated with resin.

Abstract: A method and apparatus for fabricating a complex, three-dimensional structure (12), such as a truss, from composite fiber/resin includes pulling a plurality of continuous fibers (50) from a feed source (62) along a processing path (58) about a longitudinal axis (14). At least some of the fibers are wound around the longitudinal axis in opposite directions (70,72) by rotational elements to form helical and reverse helical components (30, 34) that intersect at nodes (26,28). Select nodes are engaged by engagement members (84) and are maintained radially outwardly from the longitudinal axis by a support frame (80) to create sequential discrete segments (22) in the helical and reverse helical components. The select nodes can be engaged and maintained from outside the helical and reverse helical components. Resin can be applied to the fibers by resin applicator (90) and cured.

Abstract: Process and system for fabricating a multidirectional fibrous reinforcement designed to be a porous preform for producing a part made of a composite material. Reinforcing thread is deposited in successive layers on a support surface. A binder is provided in association with the reinforcing thread so as to adhere the reinforcing thread to the support surface and the successive layers of thread. The reinforcing thread is pressed against the support surface in a manner that exerts a pressure substantially perpendicular to the support surface at the point where the thread is deposited. The binder may be pre-applied to the support surface or it can be applied simultaneously with the reinforcement thread.

Abstract: The present invention relates to methods of debonding a tooling for a fuselage. In particular, the present invention relates to methods of debonding a tooling for a fuselage using a debonding agent. In one implementation, isopropyl alcohol is applied to a tooling to break the cohesive bond between the tooling and the fuselage.

Abstract: The present invention relates to pre-filled contained media volumes and methods of media filling using pre-filled contained media volumes. In particular, the present invention relates to apparatus and methods of media filling a tooling for a fuselage using pre-filled contained media volumes. In one implementation, the pre-filled contained media volume comprises a bag formed of a porous fabric and media located in that bag. The pre-filled contained media volume is attached to a tooling prior to filling the tooling with additional media.

Abstract: The present invention is directed to components of fiber-reinforced plastics which can also be used as load-bearing components in mechanical and automotive engineering. A construction for such components is created that can be used flexibly and enables a defined design of the components. A method is created for this purpose that makes it possible to design and produce such load-bearing components to specific requirements. The method can be automatable and can make highly replicable results possible. The components thus produced of a fiber-reinforced plastic can have low weight with high strength properties and can be economical to produce.

Abstract: A method of making a filament wound pressure vessel. A thermoplastic liner is filament wound with a commingled roving containing thermoplastic and reinforcing filaments. The wound tank is partially filled with a cooling liquid and the wound tank is heated to a temperature which is sufficient to vaporize a portion of the liquid to pressurize the liner at a preselected set pressure and sufficient to fuse the thermoplastic matrix, but insufficient to significantly soften the liner.

Abstract: A method of forming a blown micro-fiber filtration unit having multiple overlapping layers of fibrous material and an active material applied over said layers, The fibrous material layers being fused together.

Abstract: A method for manufacturing a hub in particular for bicycles and the like, wherein a winding device comprising at least a first shaping device is provided, a predetermined quantity of fibers is deposited on said first shaping device, at least a first cross-linking agent is deposited on at least part of the fibers, said first shaping device is inserted into a second shaping device and said first shaping device with at least said fibers and at least said first cross-linking agent is expanded toward said second shaping device, wherein said shaping devices are matched relative to each other such that an expanded body comprising said fibers and said cross-linking agent has a substantially even thickness.

Abstract: An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. A composite material delivery head delivers material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery head inside the interior mandrel surface. A connecting mechanism connects the material delivery head to the gantry beam and provides motion of the material delivery head relative to the interior mandrel surface.

Abstract: Integrally stiffened and formed, load carrying structures comprising a plurality of elongated thin-walled tubes placed co-extensively in a complementary side-by-side fashion which together form a hollow structure having a desired external contour. Integral skins forming the external and internal surfaces of the structure cooperatively therewith. The structure can be formed with an underlying internal support member spanning the interior of the load carrying structure, thereby connecting opposite sides of the structure together. Also, each of the tubes are wound with fibers in controlled orientations generally paralleling the direction of the loads applied to the tubes to optimize the strength to weight ratio of the tubes.

Abstract: A releasable mechanism such as a cap is adapted for use with an access sheath having an elongate tube and a handle structure disposed at a proximal end of the tube. The releasable mechanism is sized and configured to fit the handle structure, which is shaped like the bell of a horn, to further facilitate use with surgical instrumentation. The releasable mechanism may operate as a separate cap that snaps onto the handle structure to provide access pathways to the sheath. The releasable mechanism may also be disposed at a proximal end of a surgical instrument to be introduced into the access sheath such that it may be interlocked with the sheath. In a method of manufacturing a kink-resistant sheath, a wire is initially coated with a plastic material, the coated wire is then wrapped around a mandrel forming a plurality of windings, and the wound coated wire is heated until the plastic material melts and bonds the windings to form a wire-reinforced sheath.

Abstract: Pile weatherstripping having an integral fin is made by wrapping a fin material around a traveling mandrel or band, winding pile material around the fin material and the band, attaching a pair of backer elements to the pile material along opposite edges of the band, and then cutting the fin material and the pile material to produce simultaneously two pile weatherstrips. Stationary and traveling elements may be employed to facilitate cutting and produce fin above the pile weatherstrips.

Abstract: Multi-application head for fiber strips, consisting of a spool carrier (1), on which a plurality of spools are attached (2) as suppliers of the application strips (3), which are fed separately into the proximity of the application area (4), where they pass through a feed port, passing through guide combs (5 and 6) which position them according to a collateral distribution and through rollers (7 and 8) which drive each one of the strips (3) towards the application area (4).

Abstract: A pair of rollers (2), constituting the seat and the traction means for the formwork (3) to be reinforced, are established on a bench (1). A pair of upper pressure rollers (12) act, at the same time, on the formwork. On the same bench (1) there are also placed, laterally with respect to the formwork (3), a pair of longitudinal guides (15) for the movement, in parallel to the formwork (3) of a carriage (14) wearing the fiberglass mesh delivering reel (13), said reel (13) being furthermore mounted on the carriage (14) with the possibility to rotate around the vertical axis, in order to vary the orientation of the fiberglass mesh with respect to the formwork (3).

Abstract: A non-woven depth filter cartridge includes a cylindrical mass of essentially continuous melt-blown polymer filaments and an essentially continuous traversing melt-blown polymer filament extending through the mass. The mass has a depth dimension, a longitudinal dimension, and a circumferential dimension. The mass includes a plurality of layers, each of the plurality of layers being generally oriented in the longitudinal and circumferential dimensions. The traversing filament is generally oriented in the depth dimension and extends through one or more layers of the mass. In one embodiment, the layers of the mass comprise concentric zones. The traversing filament is intentionally deposited and positioned to improve the physical properties of the filter cartridge.

Abstract: A blown micro-fiber filtration unit having multiple overlapping layers of fibrous material and an active material applied over said layers. The fibrous material layers being fused together.

Abstract: A fiber composite structural component such as a fitting, bracket, mounting or the like is produced by applying fiber material such as fiber threads or fiber yarns in an automatic circular weaving operation to a core that has at least two sections, to form a fiber material body (6). One core section is removed from the fiber material body when the weaving is completed. The body is then deformed in a mold that has the contour of the finished structural component with at least one mold core section still in the fiber material body. The deformed configuration of the structural component is then impregnated in an RTM device with a resin and hardener followed by curing. Reinforcements may be inserted or secured to the fiber material body prior to the impregnated and curing step.

Abstract: Bobbin wound coated monofilament tapes where the coating comprises between 20% and 120% by weight of said tape, and the process for bobbin winding coated monofilament dental tapes comprising combining a coating conditioning means with means for winding at substantially constant tensions to produce controlled tension bobbins that do not unwind, that dispense uniformly free from back lashing, and that are substantially free from coating displacement and winding displacement when exposed to high temperatures and high relative humidity and that have tack values from between about 0.1 and about 0.5 grams.

Abstract: An undercritical drive shaft and a method of producing the undercritical drive shaft from fiber composite material is disclosed. The drive shaft, which is produced of fiber composite material and is to be used as an undercritically operating shaft, has a high damage tolerance with respect to resistance to torsion and the manufacturing process requires lower expenditures. For the drive shaft, the fiber composite material consists of several successively individually wound-up webs of prepreg. For the method of producing the drive shaft from fiber composite material, as the fiber material, the web-shaped prepreg is wound onto the winding spindle and this prepreg is deaerated and simultaneously compressed by the winding-on of a thermoplastic woven band which is prestressed in a defined manner. The thermoplastic woven band is unwound again and additional prepreg layers are then wound up which are then deaerated and compressed in the same manner by a thermoplastic woven band.

Abstract: The present invention provides methods for producing single and multi-layered coiled hollow fiber bundles for use in separation modules whose performance can be predicted, said modules being designed to take advantage of the benefits of Dean vortices. The present invention is also directed to multi-layered coiled hollow fiber bundles for use in separation modules that are directly scalable because each layer performs substantially equivalently to the other layers when subjected to a fluid of a certain velocity such that Dean vortices are created.

Abstract: A method for the production of curved thread-reinforced tubular structures composed of rubber layers and of strengthening layers and an accompanying device. In one aspect, the method includes the application of a first rubber layer to the circumference of mandrels driven forward in a feed direction (X) and winding on of a multiplicity of parallel reinforcing threads, having defined thread angles (&agr;) with respect to the feed axis (x), by means of a bobbin creel, to form a first thread ply. The mandrels are led through a rotating deflection element surrounding the mandrels and the reinforcing threads are guided so as to be distributed on the inner circumference. An application of a covering rubber layer may be performed (after the optionally multiple execution of the previous steps, alone or in combination). The mandrels are led through the deflection element of the bobbin creel eccentrically in the region of the deflection element.

Abstract: A golf club and a primarily non-metallic golf shaft that has an overall light weight are provided. The shaft has a weighting plug located to provide a swingweight similar to a typical steel shafted golf club. A method of making the golf club and golf shaft is simple and efficient, and centers the plug in the golf shaft. The method also provides the advantage of substantially infinitely variable plug density selection within a range of densities. A set of clubs thus made increases playability by providing a range of club weights in the set.