Apparatus and process for producing woven, non-linear shapes from graphite fabric, and the like, and products produced therefrom

Claim 2

A process for producing a fabric wrapping having a non-linear shape suitable for conversion into an exit cone, rocket motor, and the like, comprising the steps of: (a) weaving a continuous, single length of fabric in a loom; (b) continuously wrapping the fabric as it leaves the loom and onto a rotating, non-linear wind up form inclined to the loom, to produce an integral wrapped shape, the wind up form defining a conical portion, a cylindrical portion, and an interface between the conical and cylindrical portions; (c) tensioning, contouring and aligning the fabric during the wrapping step by passing the fabric through adustable contouring, tensioning and alignment roller means and bar means inclined to the loom; (d) pressuring the contouring means onto the wrapped-up fabric to maintain a close, uniform wrapping; (e) weaving a thicker cylindrical portion than a conical portion; (f) offsetting the direction of fabric travel from the loom to the wind up form to compensate for the different distances of fabric travel; and, (g) traversing the form relative to the loom for a short distance in a single pass to control the wrapping contour at the interface and produce a suitably curved interface shape; whereby, the wrapped fabric shape has the property of being adapted for: (i) impregnating with resin; (ii) curing the resin; (iii) removal of the resin-impregnated, cured fabric from the wind up form; (iv) trimming and machining the cured fabric to produce a uniformly curved exit cone having a curved interface; and (v) providing internal threads in the cylindrical portion.

Claim 3

The process of claim 1, in which the contouring is produced by at least one contouring bar, alignment is produced by offset rollers and an idler roller positioned upwardly of the wind up form.

Claim 4

The process of claim 1, in which the wind up form is traversed relative to the loom during the wrapping step to produce a suitable interface shape and to control the wall thickness.

Claim 5

The process of claim 1, in which the cylindrical portion of the fabric wrapping is provided with a thicker wrapping of fabric than the conical portion.

Claim 6

The process of claim 1, in which the fabric is produced from fibers selected from the class consisting of: graphite, ceramic, silicon carbide, quartz, and mixtures thereof.

Claim 7

The process of claim 1, in which the wrapping speeds, fabric tension, fabric feed rates, traverse times, traverse rates, and distance traversed by the wind up form are controlled while wrapping the fabric.

Claim 8

The process of claim 1, in which the fabric wrapped shape is up to about 6 feet in diameter, and up to about 8 feet long, and having a conical wall thickness exceeding about 1/4".

Claim 11

The apparatus of claim 8, in which the contouring is produced by at least one contouring bar, and alignment is produced by offset bars and an idler roller positioned upwardly of the wind up form.

Claim 12

The apparatus of claim 8, in which the wind up form is traversed relative to the loom to produce a suitable interface shape and to control wall thickness.

Claim 13

The apparatus of claim 8, in which the cylindrical portion of the fabric wrapped shape is provided with a thicker wrapping of fabric than the control portion.

Claim 14

The apparatus of claim 8, in which the fabric is produced from fibers selected from the class consisting of: graphite, ceramic, silicon carbide, quartz and mixtures thereof.

Claim 15

The apparatus of claim 8, in which the wrapping speeds, fabric tension, fabric feed rates, traverse times, traverse rates, and distance traversed by the wind up form are controlled while wrapping the fabric.

Claim 16

The apparatus of claim 8, in wich the fabric wrapped shape is up to about 6 feet in diameter and up to about 8 feet long.

Claim 17

An integrally woven fabric shape suitable for forming into an exit cone, rocket motor, and the like, having a non-linear shape, and produced by the steps, comprising: (a) weaving a continuous, single length of fabric in a loom; (b) continuously wrapping the fabric as it leaves the loom and onto a rotating, non-linear wind up form inclined to the loom, to produce an integral wrapped shape, the wind up form defining a conical portion, a cylindrical portion, and an interface between the conical and cylindrical portions; (c) tensioning, contouring and aligning the fabric during the wrapping step by passing the fabric through adjustable contouring, tensioning and alignment roller means and bar means inclined to the loom; (d) pressuring the contouring means onto the wrapped-up fabric to maintain a close, uniform wrapping; (e) weaving a thicker cylindrical portion than a conical portion; (f) offsetting the direction of fabric travel from the loom to the wind up form to compensate for the different distances of fabric travel; and, (g) traversing the form relative to the loom for a short distance in a single pass to control the wrappint contour at the interface and produce a suitably curved interface shape; whereby, the wrapped fabric shape has the property of being adapted for: (i) impegnating with resin; (ii) curing the resin; (iii) removal of the resin-impregnated, cured fabric from the wind up form; (iv) trimming and machining the cured fabric to produce a uniformly curved exit cone having a curved interface; and (v) providing internal threads in the cylindrical portion.

Claim 18

An integrally woven fabric shape suitable for forming into an exit cone, rocket motor, and the like, having a non-linear shape, and produced by the steps, comprising: (a) weaving a continuous, single length of fabric in a loom; (b) continuously wrapping the fabric as it leaves the loom and onto a rotating, non-linear wind up form inclined to the loom, to produce an integral wrapped shape, the wind up form defining a conical portion, a cylindrical portion, and an interface between the conical and cylindrical portions; (c) tensioning, contouring and aligning the fabric during the wrapping step by passing the fabric through adjustable contouring, tensioning and alignment roller means and bar means inclined to the loom; (d) pressuring the contouring means onto the wrapped-up fabric to maintain a close, uniform wrapping; (e) weaving a thicker cylindrical portion than a conical portion; (f) offsetting the direction of fabric travel from the loom to the wind up form to compensate for the different distances of fabric travel; and, (g) traversing the form relative to the loom for a short distance in a single pass to control the wrappint contour at the interface and produce a suitably curved interface shape; whereby, the wrapped fabric shape has the property of being adapted for: (i) impegnating with resin; (ii) curing the resin; (iii) removal of the resin-impregnated, cured fabric from the wind up form; (iv) trimming and machining the cured fabric to produce a uniformly curved exit cone having a curved interface; and (v) providing internal threads in the cylindrical portion.

Claim 19

The fabric wrapped shape of claim 15, in which the cylindrical portion is provided with a thicker wrapping of fabric than the conical portion.

Claim 20

The fabric wrappd shape of claim 15, in which the fabric is produced from fibers selected from the class consisting of: graphite, ceramic, silicon carbide, quartz, and mixtures thereof.

Claim 21

The fabric wrapped shape of claim 15, having a diameter up to about 6 feet, and a length up to about 8 feet.

Claim 22

The fabric wrapped shape of claim 15, in which wrapping speeds, fabric tension, fabric feed rates, traverse times, traverse rates, and distance traversed by the wind up form are controlled while wrapping the fabric.

Claim 23

The fabric wrapped shape of claim 15, in which contouring is produced by at least one contouring bar, and alignment is produced by offset bars and an idler roller positioned upwardly of the wind up form.