Abstract: A system for applying insulating tape to a three-dimensionally curved conductor, particularly of the type used in high voltage applications. A wrapping ring having an axis of rotation is oriented with respect to the conductor such that the axis of rotation is always placed on the spinning point of the insulating tape, the spinning point being at the location where the tape tangentially contacts the conductor during wrapping. Such an orientation of the wrapping ring avoids the formation of pockets at the curved places of the conductor.

Abstract: This invention relates to a method and apparatus for fabricating a composite structure and, in particular, to a method and apparatus for fabricating a hollow composite structure having a dense laminated wall formed by bonding and curing a plurality of resin-preimpregnated fiber sheets or tapes under heat and pressure.Hollow composite structures may be formed by applying layers of resin-impregnated fabric material onto a pressure bag covering a rigid mandrel, disposing the assembly of the mandrel, pressure bag, and uncured composite layers within an outer mold, transmitting heat to the composite material to cure the resin and applying pressure within the flexible pressure bag to act against the composite material during the curing operation to assure proper dimensions, density, structural properties and wall thickness of the cured composite structure.

Abstract: A hollow symmetrical structure in the form of a preselected body of revolution, and a method of making same. The structure comprises a plurality of a predetermined number of identically shaped and sized exact involute surface plies which are successively disposed and joined circumferentially in a contacting, stack-like layered, and overlapping relationship. Each ply is made of the same material and with the same ply pattern which is configurated and structured such that the plies made from using it fit together prefectly and their respective boundaries form the preselected body of revolution, without the defects induced by the prior art, such as wrinkles and pattern distortion.

Abstract: The present invention is directed to a hollow, flexible rod (20) having a body portion (21), a tip portion (23) and a transition portion (24) between the body and tip portions. A plurality of reinforcing strands (30) of a first material extend longitudinally within the body portion (21) and into the transition portion (24). A plurality of reinforcing strands (31) of a second material extend within the tip portion (23) and into the transition portion (24). The reinforcing strands of the first and second materials overlap one or more integer multiples (N) along the circumference of the rod. The present invention is also directed to the method whereby independent prepreg sheets (26,28) formed of the first and second reinforcing strands (31,30) are cut to a tapered apex (33 or 34) and overlapped to a predetermined, interrelated extent longitudinally (T) and laterally (S). So overlapped, the prepreg sheets (26,28) are simultaneously wound onto a mandrel (29) and cured to produce the aforesaid rod (20).

Abstract: In a single-face corrugator of the type in which the corrugated paper is held by suction against the lower corrugated cylinder, the latter includes, outside its inner chamber filled with saturated heating vapor, separate longitudinal channels in the peripheral body of the cylinder. Each channel is connected to the exterior via axial channels and elongate grooves machined in the periphery of the cylinder, and can be connected to a suction apparatus via two hollow and sealed circular arcuate sectors bearing on the part of the face of the cylinder associated with the holding region on the latter. The grooves are staggered and machined in circumferential portions of the periphery of the cylinder so as to extend over several corrugations thereof. An additional blowing sector permits detachment of the corrugated paper.

Abstract: A machine for manufacturing curvilinear convex wooden frames includes a base frame having a feeding bench mounted thereon over which is fed a continuous wooden strip which is wound up on a revolving pattern to form a rough frame of the desired thickness. The feeding bench is movable relative to the base frame and its movement is coordinated with the revolving pattern under control of a power cylinder to maintain the surface of the feeding bench tangent at all times to the revolving pattern.

Abstract: A strand prepreg which comprises (i) a resin composition comprising 100 parts by weight of thermosetting resin having a softening point of 60.degree. C. or less and about 5 to 60 parts by weight of epoxy resin having a number average molecular weight of 5,000 or more and (ii) about 20 to 80% by volume strands of carbon fibers, glass fibers, aromatic polyamide fibers and the like, wherein the strands are impregnated with the resin composition.

Abstract: The invention is a method for the manufacture of hollow bodies, particularly pipes, from fabric reinforced resin by forming a coil of fabric impregnated with resin, which is dried, preheated, and introduced into a preheated mold. The coil is pressed axially into the mold between a preheated borer defining the interior shape of the pipe, and a sleeve, and the resin impregnated in the fabric is polymerized. The product is useful in the manufacture of nozzles for missiles or the like.

Abstract: An improved elongated blade or blade spar comprises successive low-pitch circumferentially wrapped convolutions of a synthetic resin impregnated tape having elongated cut glass and substantially parallel and equal length filaments wherein successive convolutions are overlapped approximately 50% and wherein the axis of the elongated strands lie at an angle of less than 30.degree. from the elongated spar axis. Preferably, resin impregnated filamentary strands are circumferentially wrapped around the mandrel substantially parallel with the direction of the tape wrap between selected tape layers. The improved blade spar mandrel wrapping apparatus includes a split ring support for the mandrel and through which the mandrel extends. The support ring halves may be separated, moved and rejoined during the mandrel wrapping process.

Abstract: Electrical insulation for an elongate current carrying body, e.g. an underwater cable for carrying very high voltages, is provided by winding a tape round the body under tension, the tape being made of a film of an axially orientated polymer having a thickness less than 200 microns, and preferably between 10 and 50 microns, a significant degree of crystalline order, a high tensile strength, a high modulus of elasticity, and the ability to cling to itself.

Abstract: A tubular fiber reinforced composite shaft is formed (as described) which integrally incorporates a metal sleeve or connection at the end thereof. Initially a metal sleeve having circumferentially spaced recesses on the outer periphery thereof is positioned upon a segment of a mandrel. Fibrous material bearing a non-solidified resinous material is applied around the mandrel and around the recesses in the sleeve. Portions of the previously applied fibrous material bearing the non-solidified resinous material are pressed into the recesses. Additional fibrous material bearing the non-solidified resinous material is applied to the previously applied fibrous material. The resinous material next is solidified to form a tubular composite shaft whereby a secure torsion-transmitting connection is made with the sleeve, and the mandrel is removed.

Abstract: An improved elongated blade or blade spar comprises successive low-pitch circumferentially wrapped convolutions of a synthetic resin impregnated tape having elongated cut glass and substantially parallel and equal length filaments wherein successive convolutions are overlapped approximately 50% and wherein the axis of the elongated strands lie at an angle of less than 30.degree. from the elongated spar axis. Preferably, resin impregnated filamentary strands are circumferentially wrapped around the mandrel substantially parallel with the direction of the tape wrap between selected tape layers. The improved blade spar mandrel wrapping apparatus includes a split ring support for the mandrel and through which the mandrel extends. The support ring halves may be separated, moved and rejoined during the mandrel wrapping process.

Abstract: A tubular fiber reinforced composite shaft comprises a shaft body formed of a plurality of integrally bonded circumferential plies of solidified fiber reinforced resinous material. A metal sleeve is mounted in at least one end of the shaft body. A layer of adhesive material is disposed between an outer surface of the metal sleeve and an inner surface of the shaft body to bond the sleeve to the body. A portion of the body located adjacent an inner end of the adhesive layer is of enlarged radial thickness. A portion of the sleeve located adjacent the inner end of the adhesive layer may be of enlarged radial thickness.

Abstract: A tubular fiber reinforced composite shaft is formed (as described) which integrally incorporates a metal sleeve or connection at the end thereof. Initially a metal sleeve having longitudinal grooves is positioned upon a segment of a mandrel. The grooves are inclined in a direction extending longitudinally inwardly and radially outwardly. Fibrous material bearing a non-solidified resinous material is applied around the mandrel and around the grooves in the sleeve. An annular lock ring having radially inwardly projecting ridges is inserted axially over the fibrous material whereby the ridges press the fibrous material into the grooves in the sleeve. The resinous material is then solidified to form a tubular composite shaft whereby a torsion-transmitting connection is made with the sleeve.

Abstract: A tubular fiber reinforced composite shaft is formed (as described) which integrally incorporates a metal sleeve or connection at the end thereof. Initially a metal sleeve having knurls on its outer surface is positioned upon a segment of a mandrel. Fibrous material bearing a non-solidified resinous material is applied around the mandrel and around the knurls and is locked between spaced knurl projections. Additional fibrous material bearing the non-solidified resinous material is applied to the previously applied material. The resinous material next is solidified to form a tubular composite shaft whereby a secure torsion-transmitting connection is made with the sleeve, and the mandrel is removed. Alternatively, an outer sleeve can be inserted after the additional fibrous material has been applied to the first-named sleeve. The outer sleeve has knurls on an inner surface thereof and is pressed against the fibrous material as by swagging.

Abstract: A tubular fiber reinforced composite shaft is formed by providing a metal sleeve having a plurality of circumferentially straight surface segments on the outer periphery thereof. The sleeve is positioned upon a segment of a mandrel. Fibrous material bearing a non-solidified resinous material is applied to the mandrel and the circumferentially straight surface segments of the sleeve. The resinous material is solidified with portions thereof lying flush against the circumferentially straight surface segments to create a torsion-transmitting connection with the metal sleeve.

Abstract: Two coaxial metal pipes, whose confronting extremities are each provided with a plurality of peripheral ribs of staggered height separated by two or more peripheral grooves, are interconnected by a coupling sleeve of fiber-reinforced thermosetting resin subdivided into several coaxially interleaved and independently deformable cylindrical shells each terminating in a pair of internal beads engaged in a respective peripheral pipe groove. The shells, increasing in axial tensile strength from the innermost to the outermost one, are preferably separated from one another by interposed antibonding layers of thermoplastic resin. A resinous filler can be inserted between the pipe extremities for electrically insulating them from each other. The shells of the coupling sleeve can be formed by coiling resin-coated filaments around the pipe axis, advantageously with application of an antifriction layer on each inner shell before the thermosetting material thereof has been fully hardened.

Abstract: A profiled vehicle wheel rim is manufactured by spirally winding a continuous strip of ductile sheet metal onto a profiled former, with an adhesive interposed between the turns, under forces which deform the strip from the flat state to adopt the shape of the former. In a preferred construction a disc for the wheel is interposed between two axially separable parts of the former so that the windings bend down over the axial extremities of the periphery of the disc, thus entrapping it in an annular channel of the formed rim.

Abstract: A method of fabricating double-curvature shells from meridional petaloid sections consisting in that the prefabricated meridional petaloid sections are joined consecutively with one another in a number required for making a shell. The meridional petaloid sections are made from a flexible material and in the process of their joining they are successively coiled into a spindle-shaped roll for storage and transportation and the double-curvature shell is made by applying an axial force to at least one of the roll ends for uncoiling the roll and simultaneously imparting a longitudinal curvature to said sections after which the first and the last sections are joined with each other. The method according to the invention permits fabrication of high-quality double-curvature shells of any volume from any flexible material, it is highly efficient, calls for low expenditures of labor and funds, is simple and convenient in practice.

Abstract: A reinforced plastic composite structure, particularly a pipe, is disclosed herein. The composite pipe, which resists acid attack even in underground applications where the pipe is subjected to external loading stresses, typically includes at least an inner zone, e.g. a resin impregnated fibrous sheet and an outer zone including a layer or layers of fibers. A cured polymeric resin matrix bonds the fibrous sheet and the fibrous layers together in a laminar relationship. The improvement disclosed herein comprises incorporating into this polymeric resin matrix a particulate substance which has specific particle size limitations and which is selected from the group consisting of portland cement, marble dust or a mixture thereof.

Abstract: A method of making hollow aircraft rotor blades from laminated material. An xpandable mandrel is first made from curable materials and then a composite build-up of epoxy material is made by layering a plurality of prepreg plies of curable material over the expandable mandrel. The mandrel and build-up of epoxy materials are then placed in a mold and pressure is applied to expand the mandrel which, in turn, expands the build-up of material against the mold. The mandrel and composite build-up of material are then cured and the mandrel becomes an integral part of the rotor blade.

Abstract: A method for manufacturing unidirectionally fiber reinforced resin products characterized by application of a given initial tension to the fibers at curing of the resinous material and an apparatus for manufacturing the same which essentially comprises means keeping the fibers under a given tension at curing of the resinous material. With the application of initial tension to the fibers, an initial distortion of the fibers is much reduced and a product of uniform quality and great strength is provided.

Abstract: A novel flexible ferrule is provided. The ferrule is a hollow tapered tube having walls formed from a plurality of layers of continuous graphite fiber-reinforced plastic sheet material in which the graphite fibers of one layer of sheet material are at an obtuse angle ranging from about 110.degree. to about 140.degree. relative to the fibers in the next superimposed graphite layer of sheet material. Interposed between and alternating with the graphite layers are layers of woven fiberglass material, the glass fibers of which are at right angles to each other.

Abstract: A turf-like product suitable for use as a golf tee surface is constructed of artificial turf units which are strung on a plurality of tie rods which are secured at both ends. Each turf unit comprises a number of superimposed layers of a polymeric tape having slits which are transverse to the length of the tape. Holes are programmed in determined frequency along the length of each layer by a heated plunger which passes through the layers of tape. The layers of tape are fused together at the circumference of each hole whereby integrity in the turf unit is obtained. The programmed holes are also used as a mechanical device to construct the pile surface by means of the tie rods. The superimposed layers may be formed by winding the tape on a skein winder.

Abstract: A method for producing a fishing-rod in which at least one piece of trapezoidal glass fiber fabric having warp and weft yarns intersecting each other is provided. The fabric is impregnated with thermosetting plastic and is wound about a tapered mandrel with the narrower end portion of the fabric being directed toward the reduced diameter end portion of the mandrel. At the same time as the winding, a bundle of long carbon fibers is interposed between each adjacent turn of the glass fiber fabric with the carbon fibers extending in the longitudinal direction of the mandrel. The thus obtained assembly is heated to set the thermosetting plastic, and then the mandrel is removed from the assembly.

Abstract: A novel golf shaft and its method of fabrication is disclosed. The shaft comprises a tapered, scrolled, oblong blank of thin laminated sheet material having alternating laminae of woven glass fabric and resin impregnated unidirectional graphite fibers. The fibers are arranged in a predetermined specific angle of orientation with respect to the longitudinal axis of the shaft.

Abstract: The invention relates to a method and apparatus for making hollow, resin-impregnated fibrous fabric articles. Specifically, it relates to a method wherein a reusable mandrel is made sufficiently rigid to receive a lay-up of the article to be manufactured. The rigidized assembly is placed within a female mold, derigidized and expanded to apply pressure from within, thereby forcing the lay-up against the interior of the mold. Heat is applied to cure the resin, producing an article having a very high degree of dimensional accuracy.

Abstract: A boat hull is made by winding a layer of glass-fibre around a male mould, winding a layer of foam sandwich material on top of the glassfibre, and then winding a second layer of glassfibre on top of the foam.

Abstract: A coned joint for the purpose of structurally joining two filament wound es, having dissimilar diameters, into a single launch tube. After being joined together, the assembled tubes have a straightness equal to or better than a comparable rolled or fabricated metal tube in addition to being lighter and less costly to produce.

Abstract: A preformed radiator hose and a method of manufacturing such a hose are disclosed herein. A long length of an uncured hose is first fabricated by alternately wrapping layers of an uncured elastomer and fiber reinforcements around a straight mandrel. The uncured hose is then removed from the straight mandrel and cut into shorter segments. Each of these segments is then placed on a contoured mandrel having a shape corresponding to the intended configuration of the final hose and cured by heating. Although the fully cured hose does have a permanent shape, because of the unique arrangement of the reinforcements, etc., it has sufficient deformability to be easily slipped off the mandrel.

Abstract: A method of making endless power transmission belts each having at least a toothed outside surface is provided by building a belt sleeve on a drum and providing a reusable tubular polymeric curing jacket having a toothed inside surface around the sleeve with the teeth thereof adjacent the sleeve and curing the sleeve with the jacket therearound while subjecting the jacket to pressure such that the toothed inside surface of the jacket defines corresponding outside teeth on the sleeve; and, upon cooling the jacket and sleeve such jacket is readily removed for reuse thereby substantially reducing the cost of providing a toothed outside surface on a belt sleeve and belts defined therefrom.

Abstract: A fabric sleeve having lengthwise yarns of a low friction material and circumferential threads of a bondable material is secured on a mandrel utilizing in particular the heat shrinkage of the circumferential threads but also the axial shrinkage of the low friction material. After cooling, the sleeve is impregnated with a liquid resin and may be stored for future use utilizing the ends of the mandrel for support and handling. When required, the resin is cured to form a rigid tube. The tube has an internal bearing surface a predetermined size larger than the mandrel and may be readily withdrawn from the tube and then cut to selected lengths to comprise the desired bearings.

Abstract: A hose construction including a corrugated and a curved construction and method of making same are provided and the hose construction comprises at least one layer portion made primarily of an elastomeric material having randomly distributed elongated fibers embedded therein in substantially parallel relation with the fibers extending in a helical pattern about a reference axis of the hose construction and at an angle relative thereto.

Abstract: The present invention relates to an apparatus and method for making a flexible duct of wire-reinforced construction made from a plurality of adhesive-coated polymeric tapes. The tapes are simultaneously applied from angularly oppositely disposed directions in conjunction with application of a reinforcement wire to provide a helix construction with overlapping convoluted edges to provide a duct of predetermined length.

Abstract: A lightweight structural part is formed of band-shaped fiber strands woven into a lattice-type structure. Each fiber strand is made up of a number of carbon fiber rovings impregnated with a synthetic resin. The rovings in each strand are arranged in at least two layers with a plurality of rovings in each layer. The fiber strands are disposed in spaced relation in the lattice-type structure and are woven in a repetitive pattern. In forming a structural part or a support, the lattice-type structure can be cut into sectors or other shapes with the shapes being joined together, if necessary, to provide the desired finished configuration.SUMMARY OF THE INVENTIONThe present invention is directed to a lightweight structural part formed of carbon fiber-reinforced plastic which is constructed from carbon fiber rovings wound on a mandrel and subsequently processed by pressing.Carbon-fiber-reinforced plastics are used for structural parts which must have a high rigidity and a very low specific weight.

Abstract: A machine for and a method of forming a continuous tubing of flexible material, said tubing being wound in helical fashion and having interlocking edge portions. The machine includes a pair of spaced askew related rollers about which a strip of flexible material is wound, one of the rollers having a plurality of annular fins spaced apart the width of the strip of flexible material to partially receive the strip between portions of adjacent fins. The other of said rollers may have a single annular fin. Guide means contact external surfaces of edge interlocking portions of the wound strip. Both of said rollers are driven at the same speed. In the method of forming such a flexible continuous tube the improvement comprises positively engaging internal surfaces of turns of the strip being wound for advancing the strip in one direction and positively engaging external surfaces of a portion of at least one turn of the strip being wound for guiding the strip on the pair of rollers.

Abstract: A composite wheel, for a heavy duty vehicle, having a barrel member with an inner layer of laminated tape structure wound on an out of round shaped mandrel. The barrel member has a plurality of formed sections of chopped fibers in an epoxy resin. The inner surface of each section conforms to the out of round tape structure and the outer surface forms the tire bead retainers and drop center portion of the wheel. An outer layer of laminated tape structure surrounds the formed sections. A wheel web member, made of chopped fibers in an epoxy resin has its outer surface conforming to the out of round configuration of the barrel member. The web member is made of two sections which are secured to the barrel member.

Abstract: The method of filament winding on a corrugated form to thereby form a cylindrical corrugated part includes the steps ofCausing relative motion between said form and a glass fiber applicator,Wrapping a glass fiber band with a resin coating thereon on said form in a spiral pattern without bridging over said corrugations in said form,Permitting said glass fiber to harden on said form thereby forming said corrugated part, andRemoving said hardened part from said form after a predetermined period of time.The apparatus has a collapsible corrugated form arranged with its axis of rotation substantially horizontal. An applicator is supported for reciprocating fore and aft movement with respect to preselected surface(s) of the form. Proper orientation of the applicator with respect to the form permits a band of resin coated glass fiber strands to be spirally wrapped on the corrugated form without bridging over the corrugations.

Abstract: A process of wrapping a substrate to insulate or protect it, wherein a tape comprising a cross-linked copolymer derived from an ethylenically unsaturated hydrocarbon and a carboxylic acid ester having ethylenic unsaturation is wrapped around the substrate, and subsequently shrunk. Although the tape is cross-linked, it nevertheless fuses sufficiently to bond to itself to form an integral structure. The substrate can if desired be removed, the tape serving as the inner layer to a hose.

Abstract: An endless power transmission belt structure and method of making same comprised of a plurality of thermoplastic elastomeric layers with each layer having properties which are different from properties of an adjoining layer and each layer being particularly suited for the location and arrangement thereof in the belt structure.

Abstract: A sleeve forming method wherein a rectangular sheet of thermoplastic material is formed into a tubular shape having overlapped end portions that are sealed together by directing heated air between the end portions to soften their facing surface and pressing the end portions together to form a seam. The seam preferably is liquid-tight, so that the sleeve may be utilized to form the sidewall of a cup or nestable container wherein the sleeve is heat-shrunk about a generally frusto-conically shaped mandrel to give the container sidewall its desired shape. A two-piece container can be formed by sealing a bottom disc member to the end of the sidewall, and a one-piece container can be formed by collapsing and fusing the end of the sidewall sleeve to close the bottom of the container.

Abstract: A method for producing receptacles of a thermoplastic resin foam sheet, which comprises forming a cylinder of a rectangular-shaped uni-directionally shrinkable thermoplastic resin foam sheet which, when heated, shrinks in a first direction to a greater extent than other directions perpendicular to said first direction, so that when heated, the thermoplastic resin foam sheet will shrink toward the central axis of the cylinder; bonding the side edges of the sheet forming the cylinder; heating the foam sheet on a molding form to a temperature above the softening point of the resin, whereby the cylindrical foam sheet shrinks toward the central axis of the cylinder formed by the sheet and intimately contacts the circumferential side wall of the molding form to form a bottomless or gathered cylindrical article; and compression-molding the article under heat to form a thermostatic resin foam receptacle.

Abstract: A multiple ply wood article having a first wood veneer ply defining a generally tubular shape, which may be generally cylindrical, with a pair of confronting ends providing a first seam. A second wood veneer ply defining a generally tubular shape generally similar to the shape of the first wood veneer ply with a pair of confronting ends providing a second seam. The second wood veneer ply being disposed exteriorly of the first wood veneer ply in general surface to surface adjacency. The grain orientations of the first and second wood veneer plies being oriented generally parallel with respect to each other. Adhesive means securing the wood veneer plies to establish a multiple ply tubular body. The first and second seams are preferably in generally relative nonaligned position. Additional wood veneer plies having similar structural features may be secured over the first two plies. Closure elements may be secured to one or both ends of the tubular body in order to establish a container.

Abstract: This disclosure relates to a method of fabricating tubular bodies having at least one closed end by advancing material along a predetermined path of travel in a predetermined direction, forming the material into a tube during its advancement, placing a closure in-line with the advancement of the tube, and utilizing the motion of the advancing tube to assemble the latter with the closure.

Abstract: A high temperature tape for use in protecting a structural item to be subjected to high temperature, and the method whereby this novel tape is made are set forth. The tape is principally constituted by a number of elongated carrier fibers disposed in an essentially aligned array, and a large number of comparatively short fibers disposed in a nonwoven manner essentially transversely to the elongated fibers. The short fibers typically extend beyond the confines of the carrier fibers, at least on one side, thus to create a pliable, fringed tape capable of being wrapped for a number of turns about an item to be protected. This wrapping may be done in such a manner that the fringe formed by the short orthogonally placed fibers is available to extend over and cover previous turns of the tape. The fibers are of temperature resistant material, and various means are provided for securing the short fibers to the elongated fibers, including the use of certain resins.

Abstract: A corrugated laminate comprises at least two superimposed plies of continuous filament strands bonded together by a hardened plastic resin. The plies are biaxially pre-tensioned prior to hardening of the resin which impregnates and bonds the strands together in a generally concave parabolic configuration at each corrugation. The laminate finds particular application to tubular structures, such as sewer pipe liner and underground tanks, which contribute to the control and improvement in the quality of the nation's environment.The method and apparatus for making the laminate in the form of a desired composite structure comprises placing a first ply of unidirectional continuous filament strands upon one or more longitudinally spaced pairs of a gapped forming structure so that the ply bridges each forming gap.