A method and apparatus for constructing a tubular assembly 40 comprising an inner portion (24) and a further portion (23) surrounding the inner portion. The inner portion (24) comprises reinforcement (37) and the further portion (23) being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus comprises an assembly station (220) comprising a wall (253). The apparatus comprises means for advancing the inner portion (21) along a first path (231) extending passed the wall (253), and means for advancing the strip (50) along a second path (232) and causing the strip to encircle the wall (253) and thereby wrap about and surround the inner portion (21). The apparatus further comprises means (321) for introducing resinous binder into the reinforcement (37) as the strip (50) is being wrapped about the inner portion (21).

An eversion liner for lining a pipe includes an impermeable outer portion, inner and outer strength portions inside the impermeable outer portion, and a middle portion including at least one felt layer radially between the inner and outer strength portions. At least one of the inner and outer strength portions is formed from a unitary sheet of strength material that includes parallel chopped strands of fiber. The longitudinal edge margins of the sheet of strength material are positioned in overlapping engagement and joined together by joining structure. The parallel chopped fibers can be oriented transverse to the length of the liner. The joining structure can prevent reduction in a width of the overlapped edge margins as the liner expands during eversion.

A manufacturing method for a high-pressure tank is a manufacturing method for a high-pressure tank including a reinforced layer formed such that an electrically conductive fiber bundle impregnated with thermosetting resin is wound around a liner. The manufacturing method includes: a step of preparing the tank in which the uncured reinforced layer is formed on the liner; a first heating step of heating the uncured reinforced layer by low-frequency induction heating so the thermosetting resin is softened; and a second heating step of, after the first heating step, heating the softened reinforced layer by high-frequency induction heating so that the softened reinforced layer is hardened.

An in-situ melt processing method for forming a fiber thermoplastic resin composite overwrapped workpiece, such as a composite overwrapped pressure vessel. Carbon fiber, or other types of fiber, are combined with a thermoplastic resin system. The selected fiber tow and the resin are prepared for impregnation of the tow by the resin. The resin is melted; and, carbon fiber is impregnated with the melted resin at the filament winding machine delivery head. The molten state of the composite is maintained and is applied, in the molten state, to the heated surface of a workpiece. The portion of the surface being wrapped is heated to the melting point of the thermoplastic resin so that the molten composite more efficiently adheres to the heated surface of the workpiece and so that the uppermost layer of fiber resin composite is molten when overwrapped resulting in better adherence of successive layers to one another.

A pressure vessel includes a liner including a cylindrical body and a dorm portion continuous with at least one end of the body in an axial direction and includes a reinforced fiber sheet covering an outer side of the liner and made of fabric. The reinforced fiber sheet includes first yarns arranged on the body and the dorm portion such that yarn main axes of the first yarns extend in the circumferential direction of the liner and second yarns arranged on the body and the dorm portion such that yarn main axes of the second yarns extend in the axial direction of the liner. A total number of the first yarns or the second yarns that exist per unit length in the axial direction of the liner is smaller in the dorm portion than in the body.

An in-situ melt processing method for forming a fiber thermoplastic resin composite overwrapped workpiece, such as a composite overwrapped pressure vessel. Carbon fiber, or other types of fiber, are combined with a thermoplastic resin system. The selected fiber tow and the resin are prepared for impregnation of the tow by the resin. The resin is melted; and, carbon fiber is impregnated with the melted resin at the filament winding machine delivery head. The molten state of the composite is maintained and is applied, in the molten state, to the heated surface of a workpiece. The portion of the surface being wrapped is heated to the melting point of the thermoplastic resin so that the molten composite more efficiently adheres to the heated surface of the workpiece and so that the uppermost layer of fiber resin composite is molten when overwrapped resulting in better adherence of successive layers to one another.

Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

A method and apparatus for constructing a tubular assembly 40 comprising an inner portion (24) and a further portion (23) surrounding the inner portion. The inner portion (24) comprises reinforcement (37) and the further portion (23) being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus comprises an assembly station (220) comprising a wall (253). The apparatus comprises means for advancing the inner portion (21) along a first path (231) extending passed the wall (253), and means for advancing the strip (50) along a second path (232) and causing the strip to encircle the wall (253) and thereby wrap about and surround the inner portion (21). The apparatus further comprises means (321) for introducing resinous binder into the reinforcement (37) as the strip (50) is being wrapped about the inner portion (21).

A method and an article of manufacture are disclosed for reinforcing various structures, such as pipes, ducts, vessels, tanks, silos, chimneys, columns and the like, constructed from various materials including steel, concrete, masonry, wood, plastics, and the like. Some of the various structures may be used to transport water, gas, oil, and the like. Multiple layers of various material sheets, each sheet having substantially the same or different properties, may be wrapped around or be attached to the inside of a structure to be reinforced. The multiple layers together constitute a structure reinforcement wrap (SRW) and in an embodiment it may include a 3D fabric layer surrounded by other reinforcement layers to reinforce the structure against external and internal loads, such as weight, impact load, blast load, internal pressure, ballistic load, and the like. In some embodiment the SRW may only include 3D fabric layers.

Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.