Simula, Inc.

Robert F Monks

Jeffrey A Mears

Christopher Karl DeLap

Steven M Motoyama

Howard A Lindsay

A method of fabricating complex hollow composite structures from laminates of fiber reinforced synthetic resins. The structures are fully monocoque tubes with no seams. The tubes are manufactured by wrapping a hollow semi-rigid inner mandrel made of thermoplastic material such as polystyrene or ABS (acrylonitrile-butadiene-styrene co-polymer) with layers of composite sheets. The sheets are made from high-strength fibers impregnated with thermosetting or thermoplastic resins. The laminated mandrel is placed in a mold, heated and inflated to a predetermined pressure. The pressure can range from 20-200 psig and even higher, while the curing temperature can range from 200.degree.-600.degree. F. The pressure generated by the expanding core produces a highly consolidated composite structure that has fewer voids, a more uniform thickness, and an increased fiber content compared to hollow composites made by other fabrication methods.

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Chandler, AZ, United States of America

Robert F Monks