Composite structures with embedded veils for anchoring fasteners

Patent metadata

Field	Value
Publication number	US-11807309-B2
Application number	US-202017124610-A
Country	US
Kind code	B2
Filing date	Dec 17, 2020
Priority date	Dec 20, 2019
Publication date	Nov 7, 2023
Grant date	Nov 7, 2023

Abstract

A composite structure of a cargo body and a method of making the same are disclosed. The composite structure includes at least one anchor embedded between fiber-reinforced polymer (FRP) layers. The embedded anchor includes a porous veil of nonwoven fibers in a polymer-rich matrix. Accessories may be coupled to the composite structure by anchoring mechanical fasteners into the embedded anchor.

First claim

What is claimed is:

1. A laminated composite structure of a cargo body, the composite structure comprising:
a core layer including an inner foam core surrounded by a first fiber-reinforced polymer;
an outer skin layer coupled to the core layer and including a second fiber-reinforced polymer;
an inner skin layer coupled to the core layer and including a third fiber-reinforced polymer; and
at least one anchor embedded between the first fiber-reinforced polymer and an adjacent one of the second and third fiber-reinforced polymers, wherein the at least one anchor includes a porous veil of nonwoven fibers.

2. The composite structure of claim 1 , further comprising an accessory coupled to the outer or inner skin layer with a mechanical fastener, wherein the mechanical fastener extends through the outer or inner skin layer and into the at least one anchor.

3. The composite structure of claim 1 , wherein the at least one anchor spans a partial area of the composite structure, whereby the composite structure further comprises at least one anchor-free area outside of the partial area.

4. The composite structure of claim 1 , wherein the fibers of the veil are thermoplastic.

5. The composite structure of claim 1 , wherein the fibers of the veil are polyester, polyethylene, polystyrene, or polypropylene monofilaments or combinations thereof as bi-filaments.

6. The composite structure of claim 1 , wherein the fibers of the veil are spunbond or needle punched.

7. The composite structure of claim 1 , wherein the at least one anchor has a higher resin to fiber weight ratio than the first, second, and third fiber-reinforced polymers.

8. The composite structure of claim 7 , wherein the resin to fiber weight ratio of the at least one anchor is about 5:1 or more.

9. The composite structure of claim 1 , wherein the fibers of the veil are more flexible than the fibers of the first, second, and third fiber-reinforced polymers.

10. The composite structure of claim 1 , wherein the veil has a lower area density than the first, second, and third fiber-reinforced polymers.

11. The composite structure of claim 10 , wherein the area density of the veil is about 500 g/m 2 or less.

12. The composite structure of claim 1 , wherein the veil is thinner than each of the first, second, and third fiber-reinforced polymers.

13. The composite structure of claim 12 , wherein the thickness of the veil is about 0.055 inches or less.

14. The composite structure of claim 12 , wherein the thickness of the veil is about 0.10 inches or more.

15. The composite structure of claim 1 , wherein:
the composite structure is a sidewall of the cargo body;
the core layer includes a plurality of preforms, each preform including the inner foam core surrounded by the first fiber-reinforced polymer;
the outer skin layer further includes an outer gel-coat covering the second fiber-reinforced polymer;
the inner skin layer further includes an inner gel-coat covering the third fiber-reinforced polymer.

16. A method of manufacturing a composite structure of a cargo body as claimed in claim 1 , the method comprising the steps of:
applying a gel-coat resin onto a mold surface to form a first gel coat;
applying a first reinforcing fiber layer onto the first gel coat;
arranging a core layer including a plurality of preforms on the first reinforcing fiber layer;
applying at least one porous veil of nonwoven fibers adjacent to the preforms;
applying a second reinforcing fiber layer onto the preforms;
applying a laminating resin to wet-out the first reinforcing fiber layer, the second
reinforcing fiber layer, and the veil; and
curing the gel-coat and laminating resins.

17. The method of claim 16 , further comprising coupling an accessory to the composite structure by anchoring a mechanical fastener into the veil.

18. The method of claim 16 , wherein the veil soaks up more of the laminating resin per area than each of the first and second reinforcing fiber layers.

19. The method of claim 16 , wherein the veil covers only a portion of the core layer.

20. A laminated composite structure of a cargo body, the composite structure comprising:
a core layer;
an outer skin layer coupled to the core layer;
an inner skin layer coupled to the core layer;
an accessory coupled to the outer or inner skin layer with a mechanical fastener; and
at least one anchor completely embedded between the core layer and the outer or inner skin layer and receiving the mechanical fastener.

21. The composite structure of claim 20 , wherein the accessory is a logistics track having a length, the at least one anchor spanning the length of the accessory.

22. The composite structure of claim 20 , further comprising:
a second accessory coupled to the outer or inner skin layer with a second mechanical fastener;
at least one second anchor embedded between the core layer and the outer or inner skin layer and receiving the second mechanical fastener; and
an anchor-free area between the first and second anchors.

Assignees

• Wabash National Lp

Inventors

• Mccloud Travis Smith
• Lewit Scott M

Classifications

• B62D29/043 Primary

  Superstructures (B62D25/161 takes precedence) · CPC title

• B29C41/20

  incorporating preformed parts or layers, e.g. moulding inserts or for coating articles · CPC title

• B29C41/22

  Making multilayered or multicoloured articles · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B5/06

  characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper · CPC title