Minimal weight composites using open structure

Patent metadata

Field	Value
Publication number	US-9840792-B2
Application number	US-201414512848-A
Country	US
Kind code	B2
Filing date	Oct 13, 2014
Priority date	Apr 16, 2012
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

Preforms for open structured (lattice) composite tubular members manufactured from large (i.e. high filament count) prepreg yarns on a conventional maypole braiding machine, and subsequently cured to produce fiber reinforced composites of high strength and light weight.

First claim

What is claimed is:

1. An open structure composite member comprised of a plurality of jacketed yarns, each comprised of a plurality of tows pre-impregnated with resin and defining a core formed from at least twenty thousand (20,000) axially aligned filaments, the tows packed within a jacket, wherein the plurality of jacketed yarns are combined and cured to form an open structure composite member, and wherein the open structure composite member is formed at a rate of at least one meter per minute.

2. The composite member of claim 1 further comprising jackets formed from tows pre-impregnated with resin.

3. The composite member of claim 1 whereby the jackets are formed from a material selected from the group consisting of aramids, polyethylene, nylon, polyester, polyolefin, and liquid crystal polymer.

4. The composite member of claim 1 whereby the jackets are formed from one of braiding, yarn wrapping, or thermoplastic extrusion.

5. The composite member of claim 1 further comprising axially aligned filaments selected from the group consisting of carbon fiber, para-aramid, liquid crystal polymer, and glass.

6. The composite member of claim 1 comprising jacketed yarns defining a braiding architecture selected from the group consisting of diamond, twill, hercules, biaxial, triaxial, and true triaxial patterns.

7. An open structure composite member comprised of a plurality of jacketed yarns each comprised of a plurality of tows pre-impregnated with resin and defining a core formed from at least twenty thousand (20,000) axially aligned filaments, the tows hexagonally packed within a jacket, wherein the plurality of jacketed yarns are combined and cured to form an open structure composite member.

8. The composite member of claim 7 further comprising jackets formed from tows pre-impregnated with resin.

9. The composite member of claim 7 whereby the jackets are formed from a material selected from the group consisting of aramids, polyethylene, nylon, polyester, polyolefin, and liquid crystal polymer.

10. The composite member of claim 7 whereby the jackets are formed from one of braiding, yarn wrapping, or thermoplastic extrusion.

11. The composite member of claim 7 further comprising axially aligned filaments selected from the group consisting of carbon fiber, para-aramid, liquid crystal polymer, and glass.

12. The composite member of claim 7 comprising jacketed yarns defining a braiding architecture selected from the group consisting of diamond, twill, hercules, biaxial, triaxial, and true triaxial patterns.

13. A method of forming an open structure composite member comprising the steps of:
providing a plurality of jacketed yarns each comprised of a plurality of tows pre-impregnated with resin and that define a core formed from at least twenty thousand (20,000) axially aligned filaments packed within a jacket;
combining the plurality of jacketed yarns; and
curing the combined jacketed yarns to form an open structure composite member.

14. The method of claim 13 wherein providing a plurality of jacketed yarns includes providing jackets formed from tows pre-impregnated with resin.

15. The method of claim 13 wherein providing a plurality of jacketed yarns includes providing jackets formed from a material selected from the group consisting of aramids, polyethylene, nylon, polyester, polyolefin, and liquid crystal polymer.

16. The method of claim 13 further comprising the step of interlacing the open structure composite member with a yarn, the yarn oriented laterally within said open structure composite member.

17. The method of claim 13 further comprising the steps of:
exuding resin from the plurality of pre-impregnated tows;
mechanically interlocking the plurality of tows; and
bonding the plurality of tows that contact the resin at a crossover joint.

18. The method of claim 14 further comprising the steps of:
exuding resin from the plurality of pre-impregnated jackets;
mechanically interlocking the plurality of jackets; and
bonding the plurality of jackets that contact the resin at a crossover joint.

19. The method of claim 15 further comprising the steps of:
partially melting the jackets; and
bonding the jackets at a crossover joint.

20. The method of claim 13 further comprising the steps of:
reinforcing the open structure composite member with a plurality of braided sleeves;
infusing resin into the plurality of sleeves;
adding resin at a crossover joint; and
curing the open structure composite member with a plurality of braided sleeves.

Assignees

• Univ Auburn

Inventors

• Broughton Jr Roy M
• Branscomb David J
• Beale David G

Classifications

• Y10T428/249922

  Embodying intertwined or helical component[s] · CPC title

• D04C1/06

  Braid or lace serving particular purposes · CPC title

• B29K2307/04

  Carbon · CPC title

• D02G3/385 Primary

  using hollow spindles, e.g. making coverspun yarns · CPC title

• E04C3/28 Primary

  of materials not covered by groups E04C3/04 - E04C3/20 · CPC title