Thiokol Corporation

Morton Thiokol Inc.

Dean C Youngkeit

Bradley W Smith

David R Nelson

A canister loaded solid propellant rocket motor. The canisters are prepared separately and loaded with solid propellant whereby the scrap rate may be reduced after which they are installed in a monolithic case which affords stiffness continuity over the length of the rocket motor to prevent guidance system upsetting free play. In order to reduce the complexity of installation of the membrane seal assembly for each pulse, of a multi-pulse rocket motor the bulkhead therefor is manufactured integral with the case of the respective canister and becomes the forward closure thereof. For a multi-stage rocket motor, the monolithic case may be stepped and tapered, and the stages severable therefrom as they burn out by primer cord. A tight fit may be provided between a canister and the monolithic case by constructing the canister case to form a tight fit with the monolithic case at ambient temperature, lowering the temperature of the canister to a temperature which permits its insertion in the monolithic case, and allowing the canister to warm to ambient temperature.

Method of making solid propellant canister loaded rocket motor

A process and equipment for making seamless composite tubes. Composite material is applied on a mandrel which includes an inflatable bladder and inserted in a single piece mold. The bladder is pressurized for pressing the composite material against the mold wall for molding and curing thereof. In order to prevent seizing of the tube by the mold and thus allow easy removal of the cured tube, the mold is composed of a composite of resin impregnated carbon fiber material wherein the carbon fiber material has a negative coefficient of thermal expansion along the length thereof and is oriented at an angle of between about 15 and 40 degrees relative to a radial plane of the mold. In order to eliminate the use of inefficient and inconvenient cure ovens, a heat generating element is disposed internally of the mandrel for curing of the composite material.

Equipment for making composite tubes including an inflatable heated

A multi-pulse or multi-stage canister loaded solid propellant rocket motor. The canisters are prepared separately and loaded with solid propellant whereby the scrape rate may be reduced after which they are installed in a monolithic case which affords stiffness continuity over the length of the rocket motor to prevent guidance system upsetting free play. In order to reduce the complexity of installation of the membrane seal assembly for each pulse, the bulkhead therefor is manufactured integral with the case of the respective canister and becomes the forward closure thereof. For the multi-stage rocket motor, the monolithic case may be stepped and tapered, and the stages severable therefrom as they burn out by primer cord.

Solid propellant canister loaded multiple pulsed or staged rocket

A radiation gathering reflector and a method of making a radiation gathering reflector. Resin impregnated fibrous material is wound onto a mandrel which has a pair of opposing surfaces of revolution each of which has a shape corresponding to a predetermined shape of the inner reflector surface, and the resin is allowed to polymerize to form a composite which includes two integrally connected structural support members. An equatorial cut is formed in the composite to separate the support members from each other and from the mandrel. Then, a reflective surface is formed on the inner surface of at least one of the separated support members for gathering radiation. Alternatively, the reflective surface is formed on the surface of the mandrel and the resin impregnated fibrous material is wound onto the reflective surface and allowed to polymerize to form the composite. The forming of the radiation gathering reflector by a polar winding process such that a greater mass of material is located at the center portion is preferred to provide increased structural support at the center portion for attachment of radiation absorbing components so that the support member may have a thin edge portion and therefore require less material, be inexpensive, and be of lighter weight. Such a radiation gathering reflector also preferably includes a plurality of strengthening ribs which extend between the center portion and the edge portion and which cross each other in diamond-shaped configurations to provide increased strength and stiffness to the reflector support member.

Radiation gathering reflector and method of manufacture

A method and apparatus for making a composite component. For making a non-cylindrical composite component such as a nozzle, a longitudinal winding of at least one fiber strand impregnated with resin is applied onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the mandrel rotational axis. A transverse tape is then spirally cut from the layer and wound onto a component mandrel. The wound transverse tape is then compacted and cured and the mandrel removed. A nozzle exit cone is also disclosed made from such transverse tape so that the fiber strand portions are short enough that they do not follow the curvature of the nozzle and thereby peel. The windings are shingled onto the nozzle exit cone so that only one end of each of the fiber strand portions is exposed to the nozzle surface. The fiber strand portions are oriented at a predetermined angle which may be optimized for erosion resistance and stress requirements. In order to form a cylindrical composite component, a cylindrical component mandrel is rotated about its rotational axis in a stationary position, at least one transverse tape of resin impregnated fiber strand portions is supplied to the mandrel in position for rolling onto the mandrel, the transverse tape which is rolled onto the mandrel is compacted and cured, and the mandrel is removed. Apparatus for forming both small cylindrical components such as space strut tubes and large cylindrical components such as rocket motor cases or launch canisters in accordance with this method are also disclosed. Such apparatus may include ultrasonic heads for heating the resin in particular if a thermoplastic resin is used for high impact resistance.

Method for making a composite component using a transverse tape

Resin evenly applied to the surface of rotatable drive roller applicator is worked into the fibers of a band of fibrous material one ply thick by fiber tension, without abrasion. Resin is pumped to the roller applicator through a spring loaded applicator block in sealing contact with the surface of the applicator. The resin is pumped by a piston and cylinder pump at a rate determined by the rate of rotation of the applicator roller and thereby in accordance with the rate at which the fibrous band is pulled from the surface of the roller.

Apparatus for coating fiber materials with resin

Resin evenly applied to the surface of rotatable drive roller applicator is worked into the fibers of a band of fibrous material one ply thick by fiber tension, without abrasion. Resin is pumped to the roller applicator by a piston and cylinder pump at a rate controlled by the rate of rotation of the applicator roller and thereby in accordance with the rate at which the fibrous band is pulled from the surface of the roller.

Growing community of inventors

Willard, UT, United States of America

Dean C Youngkeit