Lightweight, rigid composite structures

• US 20060141232A1
• Filed: 12/27/2004
• Published: 06/29/2006
• Est. Priority Date: 12/27/2004
• Status: Active Grant

• Current Assignee: MKP Structural Design Associates, Inc.
• Original Assignee: MKP Structural Design Associates, Inc.
• Inventors: Ma, Zheng-Dong
• Granted Patent: US 7,563,497 B2
• Time in Patent Office: Days
• US Class Current: 428/292.100
• CPC Class Codes: E04C 2/34 composed of two or more spaced sheet-like parts E04C2/32 takes precedence; spacers for cavity walls E04B2/44
• CPC Class Codes: E04C 2002/3488 spaced apart by frame like structures
• CPC Class Codes: Y10T 428/23914 Interlaminar
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 442/3187 Triaxially woven fabric
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/3203 Multi-planar warp layers
• CPC Class Codes: Y10T 442/3211 Multi-planar weft layers
• CPC Class Codes: Y10T 442/45 Knit fabric is characterized by a particular or differential knit pattern other than open knit fabric or a fabric in which the strand denier is specified
• CPC Class Codes: Y10T 442/456 Including additional strand inserted within knit fabric
• CPC Class Codes: Y10T 442/463 Warp knit insert strand

Abstract

Biomimetic tendon-reinforced” (BTR) composite structures feature improved properties including a very high strength-to-weight ratio. The basic structure includes plurality of parallel, spaced-apart stuffer members, each with an upper end and a lower end, and a plurality of fiber elements, each having one point connected to the upper end of a stuffer member and another point connected to the lower end of a stuffer member such that the elements form criss-crossing joints between the stuffer members. The stuffer members and fiber elements may optionally be embedded in a matrix material such as an epoxy resin. The fiber elements are preferably carbon fibers, though other materials, including natural or synthetic fibers or metal wires may be used. The stuffer members may be rods, tubes, or spheres, and may be constructed of metal, ceramic or plastic. The stuffer members are preferably spaced apart at equal distances. If the members are tubes, the fiber elements may be dressed through the tubes. Alternatively, the fiber elements may tied to the ends of the stuffer members and/or to each other at the joints. Both linear and planar structures are disclosed.

Claims

1. A biomimetic tendon-reinforced”

(BTR) composite structure, comprising;

a plurality of parallel, spaced-apart stuffer members, each with an upper end and a lower end;

a plurality of fiber elements, each having one point connected to the upper end of a stuffer member and another point connected to the lower end of a stuffer member such that the elements form criss-crossing joints between the stuffer members.

2. The structure of claim 1, wherein the stuffer members and fiber elements are embedded in a matrix material.

3. The structure of claim 1, wherein the stuffer members and fiber elements are embedded in an epoxy resin.

4. The structure of claim 1, wherein the stuffer members are rods, tubes, ellipsoids or spheres.

5. The structure of claim 1, wherein the stuffer members are metal, ceramic or plastic.

6. The structure of claim 1, wherein the stuffer members are spaced apart at equal distances or at variable distances determined through optimization.

7. The structure of claim 1, wherein the fiber elements are carbon fibers, nylon, Kevlar, glass fibers, plant fibers, or metal wires.

8. The structure of claim 1, wherein:

the stuffer members are tubes; and

the fiber elements run through the tubes.

9. The structure of claim 1, wherein the fiber elements are tied to the ends of the stuffer members.

10. The structure of claim 1, wherein the fiber elements are tied to one another at the joints.

11. The structure of claim 1, wherein:

the stuffer members are arranged in a two-dimensional plane; and

further including a panel bonded to one or both of the surfaces forming an I-beam structure.

12. The structure of claim 1, wherein:

the stuffer members are arranged in two-dimensional rows such that the ends of the members collectively define an upper and lower surface; and

further including material bonded to one or both of the surfaces.

13. The structure of claim 1, wherein:

the stuffer members are arranged in two-dimensional rows such that the ends of the members collectively define an upper and lower surface; and

further including a solid panel bonded to one or both of the surfaces.

14. The structure of claim 1, wherein:

the stuffer members are arranged in two-dimensional rows such that the ends of the members collectively define an upper and lower surface; and

further including a mesh panel bonded to one or both of the surfaces.

15. The structure of claim 1, wherein:

the stuffer members are arranged in two-dimensional rows such that the ends of the members collectively define an upper and lower surface; and

further including additional fiber elements connecting the ends of the members.

16. The structure of claim 12, wherein the stuffer members and fiber elements are embedded in a matrix material.

17. The structure of claim 12, wherein the stuffer members and fiber elements are embedded in an epoxy resin.

18. The structure of claim 12, wherein the stuffer members are rods, tubes, or spheres.

19. The structure of claim 12, wherein the stuffer members are metal, ceramic or plastic.

20. The structure of claim 12, wherein the stuffer members are spaced apart at equal distances.

21. The structure of claim 12, wherein the fiber elements are carbon fibers.

22. The structure of claim 12, wherein:

the stuffer members are tubes; and

the fiber elements run through the tubes.

23. The structure of claim 12, wherein the fiber elements are tied to the ends of the stuffer members.

24. The structure of claim 12, wherein the fiber elements are tied to one another at the joints.