An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

Placement of nanofibers and yarns comprised of nanofibers onto a substrate are described. The nanofiber yarns are difficult to manipulate with precision given that the diameters can be as little as 5 microns or even less than one micron. As described herein, a placement system is described that can place nanofiber yarns on a substrate at pitches less than 100 μm, less than 50 μm, less than 10 μm, and in some embodiments as low as 2 μm. In part, this precise placement at small pitches is facilitated by the use of coarse and fine adjustment translators, and a guide connected to a compliant flange. The compliant flange and the guide facilitate consistency of location of a nanofiber yarn.

Methods and systems are disclosed for encasing various structures with a seamless continuous sleeve, where the presence of existing supports does not allow slipping a sleeve over the structure. In these methods strips of fabrics smeared with or saturated by resin are helically or non-helically wrapped or placed around desired shape mandrels that are located around a support of the structure. As the resin is partially cured, a portion of the sleeve segment is moved away from the mandrel, leaving the rest of the sleeve on the mandrel to be attached to the next will-be-fabricated sleeve segment. The process will continue as many times as needed to create a sleeve of a desired length. In various embodiments the strength of the sleeves varies at different locations. In some embodiments the gaps between the sleeves and the structures are filled with gas, liquid, solid, or any other materials.

Methods and systems are disclosed for encasing various structures with a seamless continuous sleeve, where the presence of existing supports does not allow slipping a sleeve over the structure. In these methods strips of fabrics smeared with or saturated by resin are helically or non-helically wrapped or placed around desired shape mandrels that are located around a support of the structure. As the resin is partially cured, a portion of the sleeve segment is moved away from the mandrel, leaving the rest of the sleeve on the mandrel to be attached to the next will-be-fabricated sleeve segment. The process will continue as many times as needed to create a sleeve of a desired length. In various embodiments the strength of the sleeves varies at different locations. In some embodiments the gaps between the sleeves and the structures are filled with gas, liquid, solid, or any other materials.

A method for manufacturing a high pressure tank includes a step of forming a reinforcing pipe portion including a straight pipe portion and reduced-diameter portions, a step of forming reinforcing dome portions, a step of forming a joined body by joining the reinforcing pipe portion and the reinforcing dome portions, and a step of forming an outer helical layer on an outer face of the joined body. The reinforcing dome portions are disposed with opening ends of the reinforcing dome portions positioned on outer faces of the reduced-diameter portions of the reinforcing pipe portion.

The present disclosure provides a high-efficiency filament helical winding device, which includes a frame body and a plurality of multi-filar guides. The frame body is provided with a through-hole, the plurality of multi-filar guides distributed in a circumference along a center of the through-hole are rotationally connected to the frame body and filament is extended out from each multi-filar guide in the plurality of multi-filar guides, and the frame body is provided with a first driving mechanism that drives each multi-filar guide to rotate.

A method of forming a hose includes: extruding a web of plastics material from a first extruder; helically winding the extruded web about a mandrel or at least one rotating rod to form a wall of the hose; feeding an electrical wire into a second extruder; extruding a bead of plastics material around the electrical wire from the second extruder such that the extruded bead includes the electrical wire at a location within a cross-section of the extruded bead; cooling the extruded bead to cool the plastics material adjacent the location to prevent migration of the electrical wire away from the location; re-heating the extruded bead to cause outer surface portions of the plastics material of the extruded bead to become molten; and helically winding the extruded bead onto and about an external surface of the wall to provide the wall a support helix that incorporates the electrical wire.

A method of forming a hose includes: extruding a web of plastics material from a first extruder; helically winding the extruded web about a mandrel or at least one rotating rod to form a wall of the hose; feeding an electrical wire into a second extruder; extruding a bead of plastics material around the electrical wire from the second extruder such that the extruded bead includes the electrical wire at a location within a cross-section of the extruded bead; cooling the extruded bead to cool the plastics material adjacent the location to prevent migration of the electrical wire away from the location; re-heating the extruded bead to cause outer surface portions of the plastics material of the extruded bead to become molten; and helically winding the extruded bead onto and about an external surface of the wall to provide the wall a support helix that incorporates the electrical wire.

A polar end ring mechanism for use with composite pressure vessels. The end ring is designed to support a pressure vessel during its formation via filament winding. The end ring helps define an opening at one of the polar ends of a tank. Spikes positioned along a portion of the end ring help prevent rotation or translation of the tank during formation and provide an improved mechanical lock with the tank body. A cap may then be secured to the polar end ring after formation in order to close the pressure vessel.

An pneumatic plug for sealing a pipeline. The pneumatic plug includes a tubular member that extends in an axial direction from a first end to a second end. The tubular member includes a rubber layer and an elastomeric band. The rubber layer extends from the first end to the second end of the tubular member. The elastomeric band is disposed on a top of the rubber layer. The elastomeric band is positioned between the first end and the second end of the tubular member.