초록 ▼

The invention discloses a method for fabricating a deployable, inflatable aerodynamic control structure for aerospace vehicles which has a desired noncircular or noncylindrical cross-section. In a preferred embodiment, the control structure is configured as an inflatable airfoil and includes a flexi

The invention discloses a method for fabricating a deployable, inflatable aerodynamic control structure for aerospace vehicles which has a desired noncircular or noncylindrical cross-section. In a preferred embodiment, the control structure is configured as an inflatable airfoil and includes a flexible skin and a plurality of internally disposed airfoil-shaped bulkheads or integral rib members that are arranged, spaced apart, in cross-wise fashion along the axial length of the airfoil shaped control structure. The flexible skin is fabricated as a lay up, in ordered sequence, of plural layers of elastomeric rubber material and plural ply layers of resin-impregnated yarns or fabric. The result is a fiber-reinforced pressure membrane that is flexible and compactly foldable. Rib-to-skin cloth attachments are provided to secure the airfoil-shaped integral rib members to the flexible skin whereby one end of each rib-to-skin cloth attachment penetrates the flexible skin being cured in place between elastomeric layers of the filament-reinforced pressure membrane to provide a seamless airtight sealed connection. The number and spacing of the integral rib members determine the amount of deviation from a perfect airfoil structure that is allowed, since the flexible skin will have a tendency to bulge outwardly at regions between adjacent airfoil-shaped integral rib members.

대표청구항 ▼

[ What is claimed is:] [1.] A method of fabricating a flexible filament-reinforced pressure membrane for providing an inflatable, deployable control structure for aerospace vehicles and which is deployable from a folded, compactly stowed position to an aerodynamic shape, deployed position, and where

[ What is claimed is:] [1.] A method of fabricating a flexible filament-reinforced pressure membrane for providing an inflatable, deployable control structure for aerospace vehicles and which is deployable from a folded, compactly stowed position to an aerodynamic shape, deployed position, and wherein said control structure assumes a desired noncircular or noncylindrical cross-sectional configuration when in said deployed position, the method comprising the steps of:a) providing a mandrel having a noncircular or noncylindrical cross-sectional configuration corresponding to a desired aerodynamic deployed shape for the control structure;b) interposing, in a crosswise direction of the mandrel, a plurality of integral rib members at predetermined intervals along an axial direction of the mandrel, each integral rib member being sized to define a particular cross-section of the control structure;c) applying a base layer of elastomeric rubber material on the mandrel in regions lying between the integral rib members;d) impregnating yarns of filaments with a resin formed from said elastomeric rubber material and applying a first ply layer of said impregnated yarns over said base layer of elastomeric rubber material such that said impregnated yarns of said first ply layer are oriented in a substantially axial direction of said mandrel;e) providing a plurality of woven cloth attachments, each of which having a first inboard end attached to a respective one of said plurality of integral rib members, and a second outboard end overlying a portion of said base layer of elastomeric rubber material and said first ply layer;f) applying a second layer of elastomeric rubber material so as to at least cover said second outboard ends of said cloth attachments and also cover mutually adjacent end margins of said base layer of elastomeric rubber material that form in regions surrounding said plurality of integral rib members;g) impregnating additional yarns of said filaments with said resin formed from said elastomeric rubber material and applying a second ply layer of said impregnated yarns to said mandrel by a hoop winding method such that the filaments of said second ply layer are oriented substantially transverse with respect to said axial direction of said mandrel;h) said impregnated yarns of said second ply layer being applied to provide a layer thickness greater than a corresponding thickness of said first ply layer in order to form an unbalanced ply filament wound laminate wherein the axially oriented yarns of said first ply layer are concentrated near a neutral axis of said laminate as seen in cross section view thereby facilitating concentric folding of the control structure about a center axis;i) curing the control structure so that said base and second layers of elastomeric rubber material flow together to form a seamless, airtight pressure membrane; andj) removing said mandrel from the control structure after cure.