Lockheed Martin Corporation

Leland Stanford Junior University

Martin Marietta Materials, Inc.

Alan K Miller

Stephen Lee Bailey

Theodore Rosario

Chris Dumlao

Eric Abrahamson

Les Fisher

Kristina Lauraitis

Karthik Ramani

Micha M Gur

Nicholas John Nagurny

Michael Jacoby

Bryan Hurlbut

Michael M Garcia

Wendy Lin

A spar platform comprises one or more continuous-fiber composite tubes fabricated at or near the intended site use of the platform. In some embodiments, the spar platform includes a relatively longer central tube and relatively shorter peripheral tubes. In some other embodiments, the spar platform is a single long tube. In some embodiments, the spar platform supports a wind turbine assembly. The continuous-fiber composite tubes are formed, in either a vertical or horizontal orientation, using a modified vacuum assisted resin transfer molding process.

On-site fabricated fiber-composite floating platforms for offshore applications

A method and apparatus for a reusable resin distribution line for use in conjunction with a resin transfer molding apparatus is disclosed. The apparatus includes a soft tool and a hard tool (i.e., mold). In the illustrative embodiment, two inflatable bladders are disposed on a side of the soft tool, wherein a bridge spans the bladders. The soft tool is coupled to the bridge. When the bladders are inflated, the bridge moves away from the hard tool, drawing the soft tool away from the hard tool in the region between the bladders. This creates a temporary passage or reusable resin distribution line for distributing resin to a reinforcement constituent disposed between the soft tool and the hard tool.

Vacuum-assisted resin transfer molding process with reusable resin distribution line

A process and apparatus for multi-shot, liquid-resin-molding of continuous-fiber composite articles is disclosed. The process involves the step-wise fabrication of an article wherein continuity of the fibers is maintained between the multiple workpieces of the finished composite article.

Process and apparatus for molding continuous-fiber composite articles

A dry fabric seal for use with tooling for liquid resin molding processes and a method for creating the seal are disclosed. In the illustrative embodiment, the seal comprises an annular resin reservoir, a level of resin within the reservoir, a device for controlling the resin level, and a perforated pressure plate that forms one wall of the reservoir. The seal is created by controlling the level of resin between the tooling (e.g., the inner and outer molds, etc.) so that air cannot leak in (for vacuum processes) or out (for pressurized processes) between the fibers in the fabric near the top of the molds.

Article comprising a dry fabric seal for liquid resin molding processes

A method and apparatus for maintaining constant compaction pressure in a vertically oriented resin transfer molding apparatus.

Process and apparatus for vacuum-assisted resin transfer molding of very tall articles

A pipe comprising a flexible membrane that is disposed over a plurality of spaced-apart tendons is disclosed.

Tendon-supported membrane pipe

A method for forming a large diameter and very long pipe comprises forming a plurality of pultruded segments via pultrusion and joining the segments along the lengthwise edges thereof.

Pultruded arc-segmented pipe

A load bearing deck structure is made from at least one sandwich panel formed of a ploymer matrix composite material. The sandwich panel comprises a plurality of substantially hollow, elongated core members having side walls, the core members being provided with an upper facesheet and a lower facesheet. Each facesheet is formed integrally with the side walls of the core members and at least one of the side walls is disposed at an oblique angle to one of the upper and lower facesheets so that the side walls and facesheets define a polygonal shape when viewed in cross section.

Modular polymeric matrix composite load bearing deck structure

A load bearing support structure in the form of a traffic-bearing highway bridge including at least one modular structural section. The at least one modular structural section includes at least one beam, the at least one beam containing a pair of lateral flanges and a medial web between and extending below the flanges. A load bearing deck is positioned above and supported by the flanges of the at least one beam. The at least one beam and load bearing deck are preferably formed of a polymer matrix composite material. Each of the flanges of the at least one beam is positioned on and supported by one of a plurality of support members. Alternatively, the load bearing deck containing at least one sandwich panel is suitable for applications such as barge decks, hatchcovers, and other load bearing wall applications. Methods of constructing a support structure utilizing the modular structural section and support members are also provided.

Modular polymer matrix composite support structure and methods of

A load bearing support structure in the form of a traffic-bearing highway bridge including at least one modular structural section. The at least one modular structural section includes at least one beam, the beam comprising a pair of lateral flanges and a medial web between and extending below the flanges. The beam preferably has a flat floor. A load bearing deck is positioned above and supported by the flanges of the at least one beam. The beam and load bearing deck are preferably formed of a polymer matrix composite material. The beam is positioned on and supported by one of a plurality of support members. The beam has a contoured shape configured to be matably supported by a support member having a reciprocally configured contoured shaped. Alternatively, a flat or L-shape support member can be utilized. Further alternatively, the load bearing deck comprising at least one sandwich panel is suitable for applications such as barge decks, hatchcovers, and other load bearing wall applications. Methods of constructing a support structure utilizing the modular structural section and support members are also provided.

Two pieces of composite material are simultaneously joined together throughout an interface between the two pieces, by induction heating the interface region with an induction coil placed, at least in part, adjacent to the bonding region, and forcing the composite material at the interface together while heating. The approach is particularly useful in joining pieces having 'long interfaces' whose longitudinal dimension is substantially larger than its transverse dimension, for example the long interfaces between aircraft wing stiffeners and skins. The induction coil is configured so that, at any one longitudinal location along the interface, the primary current flowing therethrough does not flow in opposite directions in the portions of the coil overlying the interface, and preferably flows in substantially the same direction throughout the interface. Unheated 'cold spots' in the interface being bonded, which would not bond properly, are thereby avoided. An electrically nonconductive but thermally conductive material may be placed between the induction coil and the composite material pieces to act as both a heat sink and a pressure-applying tool. Bonding may be enhanced by placing a susceptor made of the same materials as the composite materials being bonded but having a higher electrical conductivity, in the interface between the two composite material pieces prior to induction heating.

Joining of composite materials by induction heating

A process for continuously and progressively forming components from fiber-containing composite material workpieces having a deformable matrix introduces transverse bends into a workpiece that moves through the apparatus in a longitudinal or travel direction. Transverse bending of the composite material is accomplished in a kinematically admissible manner to avoid misalignment or failure of the composite material. A net bending deformation is introduced at a free transverse edge as the composite workpiece moves in a longitudinal direction, by pairs of compound roller elements between which the workpiece passes as it moves through the apparatus. The net deformation introduced at the free transverse edge is moved and distributed through the composite material workpiece during successive passes through the forming machinery, to form the final shaped component.

Process for forming fiber composite materials

An apparatus for continuously and progressively forming components from fiber-containing composite material workpieces having a deformable matrix introduces transverse bends into a workpiece that moves through the apparatus in a longitudinal or travel direction. Transverse bending of the composite material is accomplished in a kinematically admissible manner to avoid misalignment or failure of the composite material. A net bending deformation is introduced at a free transverse edge as the composite workpiece moves in a longitudinal direction, by pairs of compound roller elements between which the workpiece passes as it moves through the apparatus. the net deformation introduced at the free transverse edge is moved and distributed through the composite material workpiece during successive passes through the forming machinery, to form the final shaped component.

Apparatus for forming fiber composite materials

An apparatus and process for continuously and progressively forming components from fiber-containing composite material workpieces having a deformable matrix, wherein bending of the composite material is accomplished by pairs of roller elements between which the composite passes as it moves through the apparatus, and wherein the workpiece may be locally heated within the extent of the roller elements. Rotation of each roller is individually and independently controllable to drive the workpiece forward, retard motion of the workpiece, or freewheel. Retarding motion of selected rollers induces tensile stresses in the workpiece, which counteract the compressive stresses induced during bending so as to maintain the alignment of the fibers. Bending is preferably accomplished by positioning the pairs of roller elements to continuously introduce longitudinally adjacent bends of appropriate magnitudes and senses into the workpiece so that the laminar length of the workpiece remains substantially unchanged throughout the entire forming operation.

Growing community of inventors

Santa Cruz, CA, United States of America

Alan K Miller