A composite member (10) features a unique ply geometry which contributes to improved bending strength. The composite is constructed of a plurality of plies, each comprising a fiber component disposed within a polymer matrix. An inner ply (16) has a fiber component (18) which has fibers which are circumferentially extending. An intermediate ply (22) has first axially extending fibers (24) which are disposed about the circumference of the composite, as well as second axial fibers (30) which are interwoven with helically oriented fibers (36) and embedded in a polymer matrix (14). An outer layer (38) is similar to the inner layer as it features circumferentially extending fibers (40) which are embedded in a polymer matrix.
The composite materials may be used to manufacture a wide range of items which require light weight combined with high strength.
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1. A tubular composite structural member having a plurality of plies, each ply being defined by a fiber component disposed within a polymer matrix, said composite member having the improvement comprising
A. at least one inner ply having circumferentially extending fibers, B. at least one outer ply having circumferentially extending fibers, and C. at least one intermediate ply having i) first axially extending fibers in circumferentially-spaced sets with circumferential gaps between each set of the first fibers, and ii) second axially extending fibers in circumferentially-spaced sets disposed in said circumferential gaps, each said second fiber being interwoven with helically oriented fibers, said inner, outer and intermdiate plies forming a tubular, elongate composite structural member. 2. A composite structural member according to
4. A composite structural member according to
5. A composite structural member according to
6. A composite structural member according to
7. A composite structural member according to
8. A composite structural member according to
9. A composite structural member according to
10. A composite structural member according to
11. A composite structural member according to
12. The composite structural member according to
13. A composite structural member according to
14. A composite structural member according to
15. A composite structural member according to
16. A composite structural member according to
19. A composite structure according to
(A) at least a first clockwise helically oriented ply having (i) first clockwise helically oriented fibers in circumferentially-spaced sets with first circumferential gaps between each set of the first fibers, (ii) second helically oriented fibers in circumferentially-spaced sets disposed in said first circumferential gaps, and (iii) third fibers interwoven with said second fibers, and (B) at least a second counter-clockwise helically oriented ply having (i) fourth counter-clockwise helically oriented fibers in circumferentially-spaced sets with second circumferential gaps between each set of the fourth fibers, (ii) fifth helically oriented fibers in circumferentially-spaced sets disposed in said second circumferential gaps, and (iii) sixth fibers interwoven with said fifth fibers.
21. In a tubular composite member according to claim 20, the further improvement comprising at least one inner ply having circumferentially extending fibers, said inner ply being interior to said first and second plies. 22. In a tubular composite member according to claim 20, the further improvement comprising at least one outer ply having circumferentially extending fibers, said outer ply being exterior to said first and second plies. 23. In a tubular composite member according to claim 20, the further improvement comprising at least one axially oriented further ply disposed interior to one of said first and second plies and exterior to the other of said first and second plies. 24. An elongated tubular composite member having the improvement comprising a ply having an axially extending first fiber component helically oriented relative to the elongation of the composite member and having a clockwise extending second fiber component interwoven with a counterclockwise extending third fiber component, both of which are helically oriented relative to the first fiber component. 25. An elongated tubular composite member having the improvement comprising a ply having axially extending first fibers helically oriented relative to the elongation of the composite member and having clockwise extending second fibers interwoven with counterclockwise extending third fibers, both of which are symmetrically helically oriented relative to the first fibers. |
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This application is a continuation-in-part of U.S. Pat. application Ser. No. 366,464 filed Jun. 14, 1989, now U.S. Pat. No. 5,048,441, for "Composite Structural Member With High Bending Strength and Method of Manufacturing The Same".
This invention relates to a composite structural member having a high bending strength. More particularly, the invention is directed to a composite structural member having a unique ply geometry and construction which contributes to a high bending strength.
A number of composite materials are well known in the art and have been used for applications requiring lightweight and high strength. Such materials are constructed of one or more plies, or layers, at least some which have a fiber component embedded in a polymer matrix. The geometry of the fiber component within each layer contributes to the strength and other properties of the ultimate structure.
Many composite materials are susceptible to structural failure when subjected to excessive bending, compressive or torsional strains. It would be advantageous to provide a lightweight structure able to withstand greater forces.
Accordingly, an object of the present invention is to provide a composite structure having a ply geometry which contributes to improved strength, particularly bending strength. Another object is to provide a lightweight elongate composite structural member having high strength. It is also an object to provide a convenient and efficient method of manufacturing such composite structural members. Other objects of the invention will be apparent to those of ordinary skill in the art upon reading the following disclosure.
The present invention relates to a composite structural member having improved strength. The composite member is generally elongate and may have various cross-sectional tubular, i.e. hollow, profiles such as circular, rectangular, square and the like. The composite is constructed of a number of plies, each of which has a fiber component disposed within a polymer matrix. The ply geometry of a composite structure that has at least three plies is such that inner and outer plies have continuous, circumferential fibers which are oriented at an angle of between ±30° to ±90° relative to the longitudinal axis of the composite structural member. There is at least one of each such inner and outer circumferential plies. The circumferential fibers provide crush strength, and reinforce axially-extending fibers against buckling failure. The resistance to crush strength is in part a function of the cosine2 or sine2 of the foregoing angle between the circumferential fiber orientation and the longitudinal axis of the member.
The composite structure also has at least one intermediate ply having first axially extending fibers in circumferentially spaced sets with circumferential gaps between each set of the first fibers. A set of second axially extending fibers is disposed between each set of first axially extending fibers. These second axial fibers are interwoven with helically oriented braiding fibers, which are disposed at an angle of between ±5° and ±60° relative to the longitudinal axis of the composite member. Both the first and second axial fibers are oriented substantially parallel, i.e. at an angle of approximately 0° to the longitudinal axis of the member. Preferably, each set of first and second axial fibers comprises two adjacent fibers. The first and second sets of axial fibers cooperate to render the wall thickness throughout the composite substantially uniform.
The circumferential fibers and the braiding fibers may be a variety of fiber materials, including aramid, carbon, graphite and glass, with a modulus greater than ten million psi. The axial fibers may be of fiber materials such as carbon, graphite, ceramic, boron and glass, and with a modulus of at least twelve million psi to withstand bending stresses. The matrix component of the composite, i.e. that portion of the structure excluding the fibers, typically has as its major component a polymer resin and/or ceramic able to penetrate and bond well to the fiber component and able to form secure bonds between the plies. The matrix material, which is selected to be compatible with the manufacture of the composite, preferably is a thermoset material such as epoxy or polyester resin, catalyzed by anhydrides, polyamides or aliphatic amines. In addition, thermoplastic materials such as polyphenylene sulfide, polyethersulfone, polyethylene terephthalate, nylon, polypropylene, polycarbonate, acetal, and polyetheretherketone can be used. The matrix component can also comprise ceramic materials.
FIG. 1 is a side view, partially broken away, of a composite member, shown as manufactured on a removable mandrel, of the present invention.
FIG. 2 is a cross sectional view of a partially constructed composite member of the present invention, illustrating the innermost ply of the composite.
FIG. 3 is a cross sectional view of a partially constructed composite member of the present member, illustrating the innermost ply and the first axial fibers of the intermediate ply.
FIG. 4 is a cross sectional view of a partially constructed composite member of the present invention, illustrating the innermost and intermediate plies.
FIG. 5 is a cross sectional view of a composite member of the present invention having inner, intermediate and outer plies.
FIG. 6 is a detailed fragmentary, cross-sectional view of the intermediate ply, from a portion of FIG. 4.
FIG. 7 is a schematic illustration of a sail mast manufactured from a composite member of the present invention.
FIG. 8 is a simplified schematic view of the method of manufacturing composite structural members according to the present invention.
FIG. 9 is a graph of maximum bending deflection as a function of composite length for various composite constructions.
FIG. 10 is a view of the composite section of FIG. 6, rotated 90°, showing one of the braided axial filaments.
61to form the first axially extending ply 90 of FIG. 11: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine. 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarns is fixed at 1.9 rpm.
The liquid matrix material is liberally applied to the fibers as they are being braided about the mandrel at station 58B.
As the mandrel traverses through braider 61, the following fiber components are applied: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarns is fixed at 1.9 rpm. In addition, the complete braiding apparatus is rotating at 7.5 rpms in a clockwise direction.
This rotating braiding apparatus fabricates a first helically-oriented intermediate ply 92, such as shown in FIG. 11. Accordingly, the axially extending fiber components 24 and 30 of that intermediate ply are helically oriented, relative to the axis 20, and the braiding fiber components 36 are helically oriented relative to the components 24 and 30.
The liquid matrix material is liberally applied to the fibers as they are being braided about the mandrel at station 58C.
As the mandrel traverses through a second braider 61 60, the following fiber components are again applied to form the second axially extending ply 94 of FIG. 11: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarns is fixed at 1.9 rpm.
The liquid matrix material is again liberally applied to the fibers as they are being braided about the mandrel at a second station 58C.
The mandrel then traverses through braider 64. The following fiber components are applied to form the second helically-oriented intermediate ply 96 of FIG. 11: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the apparatus holding the 36A and 36B yarn is fixed at 1.9 rpm. In addition, the complete braiding apparatus is rotating at 7.5 rpm in a counter-clockwise direction to form the helical orientation of intermediate ply 96 of FIG. 11. The helical orientation of ply 96 is opposite to the orientation of the first helically-oriented ply 92.
There is an additional braiding apparatus, not shown in FIG. 8., which is identical to that which is described above for braider 60.
The liquid matrix material resin is liberally applied to the fibers as they are being braided about the mandrel at station 58D.
The fiber component 40 is wrapped about mandrel in a clockwise direction at 1.9 rpm.
At station 58E, the liquid expoxy resin and catalyst mix is applied to the mandrel at the position where the fiber component 18 is wrapped about the mandrel.
The mandrel and fiber plies with uncured liquid expoxy then pass through tape compacting machine 68. Two rolls of 1/2 wide cellophane tape sold by Century Design, Inc. San Diego, Calif. are rotated about the mandrel at a rate of 30 rpm.
The mandrel and uncured plies are then disengaged from the traverse apparatus 70, and the assembly is suspended vertically in a convection hot air oven. The tube is then cured at 140 Deg. C. for 8 hours.
The mandrel is then removed from the part with a mandrel extraction machine.
The tape is then unwound as per the preceeding general description.
The resulting structure has the following properties:
The final tube weight=4.5
Material Modulus (0 Deg.)=12.5 Msi
Modulus (90.0 Deg)=4.6
Modulus (45 Deg.)=12.9
Density of Laminate=1.57 g/cm3
The following structure is an example of a composite member which is designed to resist combined bending and torsional loading. The structure is produced in a continuous fashion.
The materials used in this example are given below.
| ______________________________________ |
| Component (Ref. No.): |
| Inner-Ply |
| Circumferential |
| Fiber (18) |
| Material: Carbon Fiber 12K |
| Type: Toray T700S |
| Supplier: Toray Industries |
| Properties: Modulus = 33.5 Msi |
| Density = 1.8 g/cm3 |
| Max strain = 2.1% |
| Component (Ref. No.): |
| Axial Fiber (24A) |
| Material: Carbon Fiber |
| Type: 12k G30500 |
| Supplier: BASF |
| Properties: Modulus = 34 MSI |
| Density = 1.77 g/cm3 |
| Component (Ref. No.): |
| Axial Fiber (32) |
| Material: Carbon Fiber |
| Type: 12k G30500 |
| Supplier: BASF |
| Properties: Modulus = 34 MSI |
| Density = 1.77 g/cm3 |
| Component (Ref. No.): |
| Braiding Yarn (36A) |
| Material: S2-Glass |
| Type: S2CG1501/3 |
| Supplier: Owens-Corning |
| Properties: Modulus = 12.0 MSI |
| Density = 2.48 g/cm3 |
| Component (Ref. No.): |
| Braiding Yarn (36B) |
| Material: S2-Glass |
| Type: S2CG1501/3 |
| Supplier: Owens-Corning |
| Properties: Modulus = 12.0 MSI |
| Density = 2.48 g/cm3 |
| Component (Ref. No.): |
| Circumferential |
| Fiber (40) |
| Material: Carbon Fiber 12K |
| Type: Toray T700S |
| Supplier: Toray Industries |
| Properties: Modulus = 33.5 Msi |
| Density = 1.8 g/cm3 |
| Max strain = 2.1% |
| ______________________________________ |
The catalyst material used in this Example has a cure which is fast enough to harden the matrix while the composite is being pulled through the die assembly. For this example, the resin is:
Epoxy: Der 330, from Dow Chemical
Catalyst: AC-DP-1, from Anhydrides & Chemicals, Inc.
The die used in this example is fabricated from tool steel and has an inner bore of 3.1 cm. The die inner surface is chrome plated, and has a 25 RMS finish or finer. The length of the die is 75 cm. Throughout the manufacturing process the die is heated and maintained at a temperature of 150 degree Celcius.
The composite structure formed using the process of this example has the following properties:
Inner diameter: 2.5 cm
Outer diameter: 3.2 cm
Wall thickness: 0.35 cm
Number of plies: 7
The general manufacturing apparatus is as shown in FIG. 8 with the following additions and modifications: one braiding machine is positioned in front of winder station 52; one braider is positioned after station 52 and would rotate at 7.5 rpm in a clockwise direction, braiders two and three are positioned next; and, braider #5 rotates at 7.5 rpm in a counter-clockwise direction. There is a filament winding station like 66 in FIG. B. In addition, instead of the tape compacting machine 68, there is a heated die, 75 cm long, and a chop saw to cut the composite part to desired length.
The the manufacturing process proceeds as described below.
The mandrel used in this example is teflon anodized aluminum. The mandrel has constant diameter of 1.00 inch. It is supported as a cantilever from before the first braider.
The composite material is pulled through the heated die at a rate of 2 feet per minute.
Liquid epoxy resin and catalyst mix is applied to the mandrel at the position where fiber components 24A, 32, 36A, 36B are applied to the mandrel.
As the mandrel traverses through the first braider, the following fiber components are applied: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 86A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarn is fixed at 1.9 rpm. In addition, the braiding apparatus #2 is rotating at 7.5 rpm in a clockwise direction.
At station 58A, the liquid epoxy resin and catalyst mix is applied to the mandrel at the position where the fiber component 18 is wrapped about the mandrel.
The fiber component 18 is wrapped about mandrel in a counter-clockwise direction at 7.5 rpm. Fiber winding apparatus 52 is loaded with sixteen dispensing packages, and the machinery rotates about the mandrel, as the mandrel is traversed through the process.
As the mandrel traverses through the second braider, the following fiber components are applied: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The rpm of the 36A and 36B yarn is fixed at 1.9 rpm.
The liquid epoxy resin is liberally applied to the fibers as they are being braided about the mandrel at the braider.
As the mandrel traverses through braider #3 and braider #4, the following fiber components are applied: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarn is fixed at 1.9 rpm.
The liquid epoxy resin is liberally applied to the fibers as they are being braided about the mandrel at braider #3 and braider #4.
The mandrel then traverses through braider #5. The following fiber components are applied: 24 yarns of fiber 24A spaced in pairs equally about the mandrel, 48 yarns of fiber 32 equally spaced about the braiding machine, 24 ends yarn 36A rotating on the braiding apparatus in a clockwise fashion, and 24 ends of yarn 36B rotating on the braiding apparatus in a counter-clockwise fashion. The revolutions per minute of the 36A and 36B yarn is fixed at 1.9 rpm. In addition, the braiding apparatus #5 is rotating at 7.5 rpm in a counter-clockwise direction.
The liquid epoxy resin is liberally applied to the fibers as they are being braided about the mandrel at the fifth braiding machine.
The fiber component 40 is wrapped about mandrel in a clockwise direction at 7.5 rpm.
At station 58E, the liquid epoxy resin and catalyst mix is applied to the mandrel at the position where the fiber component 18 is wrapped about the mandrel.
The mandrel and fiber plies, with uncured liquid epoxy thereon, then pass through a steel die which is common to the art. The die has a bored hole which is 3.2 cm in diameter, and the die is heated to 150 degrees Celcius. As the part is pulled through the die it cures, and once the structure has attained sufficient integrity it is cut to desired length with a cut-off saw familiar to those schooled in the art.
In order to fully catalyze the matrix material, the structure is then placed in a heated oven for 2 hrs. and 150 degrees Celcius.
The resulting structure has the following properties:
The final tube weight=0.42 lbs/ft
Material Modulus (0 Deg.)=14.5 Msi
Modulus (90.0 Deg)=4.4 Msi
Modulus (45 Deg.)=13.4 Msi
Density of Laminate=1.5 g/cm3
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiency attained. Since certain changes may be made in carrying out the above manufacturing steps and in the composite structures set forth, without departing from the scope of the invention, all matter contained in the above description or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
It also is to be understood that the following claims are to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which as a matter of language, might be said to fall there between.
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