High Strength, Lightweight Cable/Tape for Cargo-Handling Winches

This program will develop a high performance flat braided tension member for cargo handling hoists on the Army's CH47 Advanced cargo Aircraft (ACA). The development of much thinner tape, made possible by use of high strength liquid crystal polymer, PBO, will increase the available tension member length, offering greater stand off capability. Alternatively, the thinner tape will enable a smaller diameter winch, thus further reducing the hoist system weight. Foster-Miller will use a unique flat braiding process to produce a flat tape that will support an 18,000 lb. load with a safety factor of 5:1. The flat braid will greatly reduce the transverse expansion of the tape when wound on the drum under a load. Flat braiding will allow the needed electrical wires to be integrated into the tape and still be thinner than the current tape. Foster-Miller will work closely with Breeze Eastern Inc. who is considered the leader in hoist development for helicopters. The Phase I program will develop braid design and result in fabrication and preliminary testing of braided tape. Testing will include fatigue tests around a simulated winch. A Phase II program is anticipated to produce a 100 ft. length of tape that can be installed on an aircraft hoist system and tested. Foster-Miller will work closely with Breeze Eastern, Inc. to develop a tape that can be integrated into their current tape hoist system. A lighter, more robust tape and hoist system is anticipated as the Phase II program result. BENEFITS: Foster-Miller is actively pursuing further production and development opportunities for our flat braiding technology. Flat braiding offers capabilities no other braider can offer. We believe that the cargo tape product is a perfect example of the types of products Foster-Miller can produce. It is the intention of Foster-Miller to pursue various commercialization routes for the cargo tape technology.