The United States of America As Represented by the Administrator of the

United States of America As Represented by the Administrator of Nasa

Joseph M Marchello

Robert M Baucom

Norman J Johnston

Donald A Sandusky

Roberto J Cano

Steven Paul Wilkinson

Jeffrey A Hinkley

John J Snoha

Harry L Belvin

The invention is an apparatus and method for producing a hybrid boron reinforced polymer matrix composition from powder pre-impregnated fiber tow bundles and a linear array of boron fibers. The boron fibers are applied onto the powder pre-impregnated fiber tow bundles and then are processed within a processing component having an impregnation bar assembly. After passing through variable-dimension forming nip-rollers, the powder pre-impregnated fiber tow bundles with the boron fibers become a hybrid boron reinforced polymer matrix composite tape. A driving mechanism pulls the powder pre-impregnated fiber tow bundles with boron fibers through the processing line of the apparatus and a take-up spool collects the formed hybrid boron-fiber reinforced polymer matrix composite tape.

Process of making boron-fiber reinforced composite tape

A method and apparatus for determining the mass density of a moving filament is provided. The method includes the steps of providing a filament across two supports, tensioning the filament, inducing a vibration into the filament segment between the supports, reinforcing the vibration using an amplified feedback signal, detecting the vibrational frequency data, processing the data using a fast-fourier transform analysis, and then displaying the frequency. The use of the feedback signal results in a self-tuning resonant loop. Open loop versions may also be used. The apparatus includes a base supporting a fixed support and a transducer which in turn supports a moveable support. The transducer vibrates the moveable support transversely to the direction of travel of the filament, thereby inducing a transverse vibrational mode. The output of the transducer is amplified and used to drive a second amplifier to produce a self-tuning resonant loop. In the open loop version a signal generator is used to drive the transducer through a frequency range, during which the amplitude peak is identified.

Apparatus and method for determining the mass density of a filament

A process for preparing uni-tape prepreg from polymer powder coated filamentary towpregs is provided. A plurality of polymer powder coated filamentary towpregs are provided. The towpregs are collimated so that each towpreg is parallel. A material is applied to each side of the towpreg to form a sandwich. The sandwich is heated to a temperature wherein the polymer flows and intimately contacts the filaments and pressure is repeatedly applied perpendicularly to the sandwich with a longitudinal oscillating action wherein the filaments move apart and the polymer wets the filaments forming a uni-tape prepreg. The uni-tape prepreg is subsequently cooled.

Dry powder process for preparing uni-tape prepreg from polymer powder

A heated shoe and cooled pressure roller assembly for composite prepreg application is provided. The shoe assembly includes a heated forward contact surface having a curved pressure surface. The following cooled roller provides a continuous pressure to the thermoplastic while reducing the temperature to approximately 5.degree. C. below glass transition temperature. Electric heating coils inside the forward portion of the shoe heat a thermoplastic workpiece to approximately 100.degree. C. above the glass transition. Immediately following the heated contact surface, a cooled roller cools the work. The end sharpened shape of the heated shoe trailing edge tends to prevent slag buildup and maintain a uniform, relaxed stress fabrication.

Composite prepreg application device

A shaped towpreg ribbon having a cross-sectional geometry which promotes intimate lateral contact between adjacent composite tows was prepared. The cross-sectional geometry is non-rectangular and promotes intimate lateral contact between adjacent towpreg ribbons during normal processing.

Non-rectangular towpreg architectures

This invention is a process for the uniform application of polymer powder particles to a filamentary material in a continuous manner to form a uniform composite prepreg material. A tow of the filamentary material is fed under carefully controlled tension into a spreading unit, where it is spread pneumatically into an even band. The spread filamentary tow is then coated with polymer particles from a fluidized bed, after which the coated filamentary tow is fused before take-up on a package for subsequent utilization. This process produces a composite prepreg uniformly without imposing severe stress on the filamentary material, and without requiring long, high temperature residence times for the polymer.

Growing community of inventors

Hampton, VA, United States of America

Joseph M Marchello