Integrally-reinforced braided tubular structure and method of producing the same

• US 6,510,961 B1
• Filed: 04/14/1999
• Issued: 01/28/2003
• Est. Priority Date: 04/14/1999
• Status: Active Grant

• Current Assignee: A & P Technology Inc.
• Original Assignee: A & P Technology Inc.
• Inventors: Head, Andrew Atkins, Peter, John William
• Primary Examiner(s): POLLARD, STEVEN M
• Application Number:
  US09/292,070
• Time in Patent Office: 1,385 Days
• Field of Search: 220/645, 220/592, 220/590, 220/62.19
• US Class Current: 220/645
• CPC Class Codes: B29C 53/587 having a non-uniform wall-structure, e.g. with inserts, perforations, locally concentrated reinforcements
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/222 the structure being shaped to form a three dimensional configuration
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: B29L 2031/7156 Pressure vessels
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D04C 3/48 Auxiliary devices
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs

Abstract

A method of producing a generally tubular, reinforced, structure including an inner layer of braided material having a predefined indentation configuration, the method including the steps of providing a mandrel having a shape and configuration of indentations corresponding to the shape and indentation configuration of the inner layer, providing a plurality of support members in the vicinity of at least some of the indentations on the mandrel, the support members protruding a predetermined distance radially outwardly from the mandrel, depositing the inner layer over the mandrel and the support members, and removing the support members to a position in which the support members do not protrude the surface of the mandrel.

Claims

1. A braid-reinforced, generally tubular, structure comprising:

an interior;

at least one reinforcement layer, said reinforcement layer including braided material and at least one indentation, said indentation including a recess in the direction of the interior of the structure and said braided material contacting said recess; and

a plurality of reinforcement members in said indentation.

2. A vessel adapted to endure pressure and including a braid-reinforced structure according to claim 1.

3. A fuel tank including a braid-reinforced structure according to claim 1.

4. An airplane fuselage including a braid-reinforced structure according to claim 1.

5. A jet engine part including a braid-reinforced structure according to claim 1.

6. An exhaust shroud including a braid-reinforced structure according to claim 1.

7. A braid-reinforced structure according to claim 1 wherein said indentation includes one of a generally axial indentation, a generally circumferential indentation and a Generally angled indentation.

8. The braid-reinforced structure according to claim 1 further including an outer layer.

45. The braid-reinforced structure according to claim 1 further comprising said structure having one of a conical, generally tubular with a varying radii, non-conical and non-tubular shape.

46. An duct including a braid-reinforced structure according to claim 1.

9. A braid-reinforced, generally tubular, structure comprising:

an interior; and

at feast one reinforcement layer, said reinforcement layer including braided material and at least one indentation, said indentation including a recess in the direction of the interior of the structure and said braided material contacting said recess.

10. The braid-reinforced structure according to claim 9 further including an outer layer.

11. The braid-reinforced structure according to claim 9 further comprising said braided material being seamless.

12. The braid-reinforced structure according to claim 11 further comprising said reinforcement layer being seamless.

13. The braid-reinforced structure according to claim 11 further comprising said braided material being manufactured to conform to said recess.

14. The braid-reinforced structure according to claim 11 further comprising said braided material being a triaxial braid.

25. The braid-reinforced structure according to claim 9 further comprising said braided material being manufactured to conform to said recess.

26. The braid-reinforced structure according to claim 25 further comprising a plurality of indentations, said indentations including a generally axial indentation and a generally circumferential indentation.

27. The braid-reinforced structure according to claim 9 further comprising said recess including walls and a surface area of said walls, the gap between opposing sides of the recess at the level of said reinforcement layer which is non-recessed having an area, and said recess walls surface area being larger than said non-recessed area.

28. The braid-reinforced structure according to claim 27 further comprising said braided material being inextensible.

29. The braid-reinforced structure according to claim 9 further comprising said braided material being inextensible.

30. The braid-reinforced structure according to claim 9 wherein said indentation includes one of a generally axial indentation, a portion of a generally axial indentation, a generally circumferential indentation, a portion of a generally circumferential indentation, a generally angled indentation and a portion of a generally angled indentation.

31. The braid-reinforced structure according to claim 30 further comprising a plurality of indentations, said indentations including at least a generally axial indentation and a generally circumferential indentation.

44. The braid-reinforced structure according to claim 9 further comprising said braided material being a triaxial braid.

15. A braid-reinforced, generally tubular, structure comprising:

an interior; and

at least one reinforcement layer, said reinforcement layer including braided material and a plurality of indentations, each of said indentations including a recess in the direction of the interior of the structure and said braided material contacting said recess.

16. The braid-reinforced structure according to claim 15 wherein said plurality of indentations includes one of at least two generally axial indentations, at least two generally circumferential indentations and at least two generally, angled indentations.

17. The braid-reinforced structure according to claim 15 wherein said plurality of indentations includes at least two generally axial indentations and at least two generally circumferential indentations.

18. The braid-reinforced structure according to claim 15 further including an outer layer.

19. A vessel adapted to endure pressure and including a braid-reinforced structure according to claim 15.

20. A fuel tank including a braid-reinforced structure according to claim 15.

21. An airplane fuselage including a braid-reinforced structure according to claim 15.

22. A jet engine part including a braid-reinforced structure according to claim 15.

23. An exhaust shroud including a braid-reinforced structure according to claim 15.

24. An duct including a braid-reinforced structure according to claim 15.

32. A braid reinforced, generally tubular structure comprising:

a mandrel including at least one indentation, said indentation including a recess in the direction of the interior of the mandrel; and

at least one reinforcement layer deposited on said mandrel, said reinforcement layer including a braided material contacting said recess.

33. The braid-reinforced structure according to claim 32 further comprising said reinforcement layer being seamless.

34. The braid-reinforced structure according to claim 32 further comprising said braided material being manufactured to conform to said recess.

35. The braid-reinforced structure according to claim 32 further comprising said braided material being a triaxial braid.

36. The braid-reinforced structure according to claim 32 further comprising said recess including walls and a surface area of said walls, the gap between opposing sides of the recess at the level of said reinforcement layer which is non-recessed having an area, and said recess walls surface area being larger than said non-recessed area.

37. The braid-reinforced structure according to claim 32 further comprising said braided material being inextensible.

38. The braid-reinforced structure according to claim 32 wherein said indentation includes one of a generally axial indentation, a portion of a generally axial indentation, a generally circumferential indentation, a portion of a generally circumferential indentation, a generally angled indentation and a portion of a generally angled indentation.

39. The braid-reinforced structure according to claim 32 further comprising a plurality of indentations, said indentations including at least a generally axial indentation and a generally circumferential indentation.

40. A braid reinforced generally tubular structure having an inner layer constructed according to the following process:

providing a mandrel having a shape and configuration of indentations corresponding to the shape and indentation configuration of said inner layer;

providing a plurality of support members in the vicinity of at least some of the indentations on said mandrel, the support members protruding a predetermined distance radially outwardly from said mandrel;

depositing said inner layer over said mandrel and said support members; and

removing said support members to a position in which the support members do not protrude above the surface of the mandrel.

41. A braid reinforced generally tubular structure according to claim 40 wherein the process of construction further comprises after depositing said inner layer, installing a plurality of reinforcement members over said inner layer along the indentations of said mandrel.

42. A braid reinforced generally tubular structure according to claim 41 wherein the process of construction further comprises after installing said plurality of reinforcement members, depositing an outer layer over both the inner layer and the reinforcement layers.

43. A braid reinforced generally tubular structure according to claim 40 wherein said indentation configuration includes a plurality of generally axial indentations and a plurality of generally circumferential indentations.