Contoured composite structural mambers and methods for making the same

• US 20020071920A1
• Filed: 07/05/2001
• Published: 06/13/2002
• Est. Priority Date: 07/07/2000
• Status: Abandoned Application

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Dale Francis Obeshaw
• Inventors: Obeshaw, Dale Fracis
• Application Number:
  US09/899,390
• Publication Number:
  US 20020071920A1
• Time in Patent Office: Days
• US Class Current: 428/34.1
• CPC Class Codes: A63B 60/54 with means for damping vibrations
• CPC Class Codes: B21C 37/15 Making tubes of special shape; Making tube fittings B21C37/0803, B21C37/104, B21C37/124, take precedence
• CPC Class Codes: B21C 37/154 Making multi-wall tubes
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29D 24/002 formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled totally filled B29D99/0021
• CPC Class Codes: B29D 24/004 the structure having vertical or oblique ribs
• CPC Class Codes: B29D 99/0035 rollers or cylinders having an axial length of several times the diameter, e.g. for embossing, pressing, or printing
• CPC Class Codes: B29L 2031/324 Rollers or cylinders having an axial length of several times the diameter, e.g. embossing, pressing or printing
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B62D 21/00 Understructures, i.e. chassis frame on which a vehicle body may be mounted combined frame and vehicle body B62D23/00 ; characterised by the material thereof B62D29/00
• CPC Class Codes: B62D 21/09 Means for mounting load bearing surfaces
• CPC Class Codes: B62D 21/15 having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body bumpers B60R19/02; shock absorbers in general F16F
• CPC Class Codes: B62D 29/001 characterised by combining metal and synthetic material
• CPC Class Codes: B62D 29/004 : the metal being over-moulded by the synthetic material, e.g. in a mould
• CPC Class Codes: B62D 29/005 : preformed metal and synthetic material elements being joined together, e.g. by adhesives
• CPC Class Codes: B65H 2701/5114 : Metal sheets
• CPC Class Codes: B65H 75/10 : without flanges, e.g. cop tubes
• CPC Class Codes: F16L 7/00 : Supporting of pipes or cables inside other pipes or sleeves, e.g. for enabling pipes or cables to be inserted or withdrawn from under roads or railways without interruption of traffic sleeves for supporting pipes, cables or protective tubing, between relatively movable points F16L3/01, fixation devices of optical cables in ducts G02B6/508, installation of electric cables H02G1/08
• CPC Class Codes: F16L 9/003 : with a rectangular cross-section ducting arrangements in air-conditioning or ventilation F24F13/02
• CPC Class Codes: F16L 9/006 : specially profiled F16L9/003 takes precedence
• CPC Class Codes: F16L 9/02 : of metal F16L9/16 - F16L9/22 take precedence
• CPC Class Codes: F16L 9/18 : Double-walled pipes; Multi-channel pipes or pipe assemblies
• CPC Class Codes: F16L 9/19 : Multi-channel pipes or pipe assemblies
• CPC Class Codes: Y10T 29/53652 : Tube and coextensive core
• CPC Class Codes: Y10T 428/1234 : Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
• CPC Class Codes: Y10T 428/12361 : having aperture or cut
• CPC Class Codes: Y10T 428/12375 : having member which crosses the plane of another member [e.g., T or X cross section, etc.]
• CPC Class Codes: Y10T 428/1241 : Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]
• CPC Class Codes: Y10T 428/12493 : Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/139 : Open-ended, self-supporting conduit, cylinder, or tube-type article
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24165 : Hexagonally shaped cavities

Abstract

Contoured composite structural members and methods for making the same are described. The contoured structural members comprise composite materials and the contoured structure can be provided by tube rolling (or roll wrapping) the composite materials together and then, if necessary, bonding them or connecting them. The outer surface of the structural member can be provided with a polygonal shape during the process of manufacturing. With a contoured structure and an outer polygonal shape, applications for the structural members of the present invention are increased.

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; and

wherein an outer surface of the structural member has a polygonal shape.

2. The structural member of claim 1, wherein the structural member has a closed configuration.

3. The structural member of claim 2, further comprising an interior region defined by an inner surface of the at least one inner layer.

4. The structural member of claim 3, wherein the interior region is hollow, partially filled, or completely filled.

5. The structural member of claim 3, wherein the at least one of the composite materials is formed from a prepreg material.

6. The structural member of claim 5, wherein the prepreg material comprises a plurality of layers.

7. The structural member of claim 6, wherein the plurality of layers have a plurality of fibers with an orientation ranging from 0 to about 90 degrees.

8. The structural member of claim 1, wherein the structural member has at least one end with the at least one initiator not located near the at least one end.

9. The structural member of claim 1, further comprising a composite overwrap on a portion of the outer surface of the structural member.

10. 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; and

a composite overwrap on a portion of the at least one contoured outer layer;

wherein an outer surface of the structural member has a polygonal shape.

11. 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

wherein an outer surface of the structural member has a polygonal shape.

12. The structural member of claim 11, further comprising a composite overwrap on a portion of the outer surface of the structural member.

14. The structural member of claim 13, further comprising a composite overwrap on a portion of the outer surface of the structural member.

16. The method of claim 15, including providing the at least one inner layer by roll wrapping the at least one inner layer over a substrate.

17. The method of claim 16, including providing the at least one outer layer by roll wrapping the at least one outer layer over the at least one inner layer.

18. The method of claim 17, further including removing the substrate.

19. The method of claim 18, including partially or completely filling the interior created by removing the substrate.

20. The method of claim 19, further including constraining the at least one outer layer and reacting any reactable material of the at least one inner or outer layers prior to removing the substrate.

21. The method of claim 20, including constraining the at least one outer layer by roll wrapping at least one layer of a shrink-wrap material over the at least one outer layer.

22. The method of claim 21, including removing the at least one layer of the shrink-wrap material after the reaction.

23. The method of claim 20, further including providing a plurality of pressure distributors over the at least one outer layer while constraining the outer layer.

24. The method of claim 23, wherein the plurality of pressure distributors provides the outer surface with the polygonal shape.

25. The method of claim 15, further including providing an overwrap over a portion of the at least one outer layer.

26. The method of claim 25, including providing the overwrap by roll wrapping a composite material over said portion.

27. The method of claim 25, further including radially cutting the structural member along the portion containing the overwrap.

13. 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

a composite overwrap on a portion of the at least one contoured outer layer;

wherein an outer surface of the structural member has a polygonal shape.

15. A method for making a contoured structural member, comprising:

providing at least one inner layer comprising a composite material;

providing at least one outer layer over the at least one inner layer, the at least one outer layer comprising a composite material;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.

28. A method of making a contoured structural member, comprising

providing at least one inner layer comprising a reinforced resin matrix material;

providing at least one outer layer over the at least one inner layer, the at least one outer layer comprising a reinforced resin matrix material;

providing an overwrap over a portion of the at least one outer layer;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.

29. A method of 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 outer layer over the at least one inner layer, the at least one outer layer comprising a reinforced resin matrix material;

roll wrapping an overwrap over a portion of the at least one outer layer;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.

30. A contoured structural member made by the method comprising:

providing at least one inner layer comprising a composite material;

providing at least one outer layer over the at least one inner layer, the at least one outer layer comprising a composite material;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.

31. A contoured structural member made by the method comprising:

providing at least one inner layer comprising a reinforced resin matrix material;

providing at least one outer layer over the at least one inner layer, the at least one outer layer comprising a reinforced resin matrix material;

providing an overwrap over a portion of the at least one outer layer;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.

32. 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 outer layer over the at least one inner layer, the at least one outer layer comprising a reinforced resin matrix material;

roll wrapping an overwrap over a portion of the at least one outer layer;

connecting the at least one inner and outer layer to the at least one inner layer; and

providing an outer surface of the structural member with a polygonal shape.