Contoured crushable composite structural members and methods for making the same
First Claim
1. A contoured structural member, comprising:
- at least one contoured inner layer comprising a composite material;
at least one contoured outer layer comprising a composite material;
at least one intermediate layer comprising a material with a cellular configuration; and
at least one initiator.
1 Assignment
0 Petitions
Accused Products
Abstract
The present invention provides contoured crushable composite structural members and methods for making the same. The contoured structural members comprise composite materials sandwiching a support or stabilizing structure. The contoured structure can be provided by tube rolling (or roll wrapping) the composite materials and the support structure together and then, if necessary, bonding them or connecting them. The structural members are made crushable by incorporating an initiator into the structures of the members. With a contoured, crushable, and generally non-flat structure, applications for the structural members of the present invention are nearly limitless.
-
Citations
35 Claims
-
1. A contoured structural member, comprising:
-
at least one contoured inner layer comprising a composite material;
at least one contoured outer layer comprising a composite material;
at least one intermediate layer comprising a material with a cellular configuration; and
at least one initiator. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
-
-
12. A contoured structural member, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material; and
at least one intermediate layer having a geometric cellular configuration; and
at least one initiator. - View Dependent Claims (13, 14)
-
-
15. A contoured structural member, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material; and
at least one intermediate layer having a ribbed structure connecting the at least one inner layer and the art least one outer layer; and
at least one initiator. - View Dependent Claims (16)
-
-
17. A contoured structural member having at least one end, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material; and
at least one intermediate layer having a ribbed structure connecting the at least one inner layer and the art least one outer layer; and
at least one initiator located from about ½
inch to about 2 inches away from the at least one end.
-
-
18. A contoured structural member, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material;
at least one intermediate layer having a honeycomb structure connecting the at least one inner layer and the art least one outer layer; and
at least one initiator.
-
-
19. A closed, contoured structural member having at least one end, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material;
at least one intermediate layer having a honeycomb structure connecting the at least one inner layer and the art least one outer layer; and
at least one initiator located from about ½
inch to about 2 inches away from the at least one end.
-
-
20. A closed, contoured structural member, comprising:
-
at least one contoured inner layer comprising a reinforced resin matrix material;
at least one contoured outer layer comprising a reinforced resin matrix material;
at least one intermediate layer having a honeycomb structure being substantially contiguous with the at least one inner layer and the art least one outer layer; and
at least one initiator located from about ½
inch to about 2 inches away from the at least one end.
-
-
21. A method for making a contoured structural member, comprising:
-
providing at least one inner layer comprising a composite material;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;
providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;
providing at least one initiator; and
connecting the at least one inner and outer layer to the at least one intermediate layer. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30)
-
-
31. A method for making a contoured structural member, comprising:
-
roll wrapping at least one inner layer comprising a reinforced resin matrix material over a substrate;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a ribbed structure; and
roll wrapping at least one outer layer covering the at least one intermediate layer, the at least one outer layer comprising a reinforced resin matrix material;
providing at least one initiator;
connecting the at least one inner and outer layer to the at least one intermediate layer; and
removing the substrate.
-
-
32. A method for making a contoured structural member having at least one end, comprising:
-
providing at least one inner layer comprising a composite material;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;
providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;
providing at least one initiator not located near the at least one end; and
connecting the at least one inner and outer layer to the at least one intermediate layer.
-
-
33. A contoured structural member made by the method comprising:
-
providing at least one inner layer comprising a composite material;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;
providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;
providing at least one initiator; and
connecting the at least one inner and outer layer to the at least one intermediate layer.
-
-
34. A contoured structural member made by the method comprising:
-
roll wrapping at least one inner layer comprising a reinforced resin matrix material over a substrate;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a ribbed structure; and
roll wrapping at least one outer layer covering the at least one intermediate layer, the at least one outer layer comprising a reinforced resin matrix material;
providing at least one initiator;
connecting the at least one inner and outer layer to the at least one intermediate layer; and
removing the substrate.
-
-
35. A contoured structural member having at least one end made by the method comprising:
-
providing at least one inner layer comprising a composite material;
roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;
providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;
providing at least one initiator not located near the at least one end; and
connecting the at least one inner and outer layer to the at least one intermediate layer.
-
Specification