GB2423648A - Braided carbon fibre and resin impact resistant conduit - Google Patents

Braided carbon fibre and resin impact resistant conduit Download PDF

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Publication number
GB2423648A
GB2423648A GB0503774A GB0503774A GB2423648A GB 2423648 A GB2423648 A GB 2423648A GB 0503774 A GB0503774 A GB 0503774A GB 0503774 A GB0503774 A GB 0503774A GB 2423648 A GB2423648 A GB 2423648A
Authority
GB
United Kingdom
Prior art keywords
impact resistant
conduit
tube
former
carbon fibre
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0503774A
Other versions
GB2423648B (en
GB0503774D0 (en
Inventor
Derek Andrews
Travis Steel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TT Electronics Fairford Ltd
Original Assignee
New Chapel Electronics Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by New Chapel Electronics Ltd filed Critical New Chapel Electronics Ltd
Priority to GB0503774A priority Critical patent/GB2423648B/en
Publication of GB0503774D0 publication Critical patent/GB0503774D0/en
Priority to AT06250720T priority patent/ATE507601T1/en
Priority to ES06250720T priority patent/ES2365498T3/en
Priority to DE602006021497T priority patent/DE602006021497D1/en
Priority to EP06250720A priority patent/EP1696530B1/en
Priority to US11/358,127 priority patent/US20060211993A1/en
Publication of GB2423648A publication Critical patent/GB2423648A/en
Application granted granted Critical
Publication of GB2423648B publication Critical patent/GB2423648B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/04Protective tubing or conduits, e.g. cable ladders or cable troughs
    • H02G3/0462Tubings, i.e. having a closed section
    • H02G3/0481Tubings, i.e. having a closed section with a circular cross-section
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/02Elements
    • C08K3/04Carbon
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00Use of ingredients characterised by shape
    • C08K7/02Fibres or whiskers
    • C08K7/04Fibres or whiskers inorganic
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/04Protective tubing or conduits, e.g. cable ladders or cable troughs
    • H02G3/0406Details thereof

Abstract

An impact resistant conduit is formed from braided carbon fibre 12 and resin. The braid is made up of a number of strands 10. The use of carbon fibre allows for a conduit of smaller mass. The conduit may have a water or liquid proof coating or an electrical or EMC coating or an abrasion reducing coating on the inner or outer surface. The conduit may be made in a mould which may be inflatable.

Description

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IMPACT RESISTANT CONDUIT
The present invention relates to an impact resistant conduit, electrical wiring housed in the conduit, and transport using such a conduit.
Exposed electrical wiring, for example forming part of a wiring harness, is presently protected from damage by being housed or sheathed in metal tubing. A typical metal is stainless steel.
However, metal is relatively heavy and, in the case of stainless steel, extremely expensive.
The present invention seeks to overcome this problem.
In accordance with a first aspect of the present invention, there is provided an impact resistant conduit comprising impact resistant material which includes a composite mixture of resin and carbon fibre.
Preferable and/or optional features are set forth in claims 2 to 20, inclusive.
In accordance with a second aspect of the invention, there is provided a method of forming an impact resistant conduit, in accordance with the first aspect of the invention, comprising the steps of: (a) braiding a plurality of elongate flexible elements formed from the impact resistant material onto a former; (b) heating the braided impact resistant material so that the plurality of elongate elements form a unitary impact resistant conduit; and (c) forming the unitary impact resistant conduit into a desired shape.
The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows part of apparatus used in a method of forming an impact resistant tube, in accordance with the second aspect of the invention; and Figure 2 shows ajig used in the method of forming an impact resistant tube.
One embodiment of an impact resistant tube will now be described, by way of example only, with reference to the drawings. The impact resistant tube, having an uninterrupted circumference, is formed from impact resistant thermoplastic material being a composite mixture of carbon fibre, poly-paraphenylene terephthalamide-based (for example Keviar ) fibre, and resin.
This material is impregnated and available from Schappe Ltd. at B.P. 8901800 Charnoz, France under the trade name TPFL .
The resin is one or more of polyetheretherkeyton (PEEK), polyphenylenesulphide (PPS), polyetherimide (PEL), polyamide (PA) polypropylene (PP), and the fibres are provided in an amount of 40% to 70% fibre volume fraction. No halogens are present.
The impact resistant material is initially formed as an elongate flexible element, for example a yarn, tape or thread. Referring to Figure 1, a plurality of the elongate elements 10 is braided unidirectionally. The braiding is initiated, and then a rigid elongate former (not shown) is coaxially inserted, and braiding is completed on the former.
The flexible braided material 12 and former are placed in an oven and heat treated, so that the elongate elements form a homogenous matrix or unitary tube on the former.
The unitary tube is cooled, and the former is removed. The unitary tube is then post-heated to slightly soften the impact resistant material to allow post-forming.
As shown in Figure 2, a jig 14 is utilised to post-from the unitary tube. Once softened, the unitary tube is placed in a channel 16 of the jig corresponding to a desired shape of impact resistant tube The unitary tube is held in the jig 14 until the material has cooled. Once cooled, the impact resistant tube assumes a rigid hollow structure which retains its shape.
In a second embodiment of a method for forming the impact resistant tube, unidirectional braiding of a plurality of the elongate elements is again initiated. A former is again coaxially inserted However, the former is an inflatable and deflatable bladder-type former. Unidirectional braiding is completed on the deflated former.
The flexible braided material and deflated former are placed in a mould which defines the finished shape of the impact resistant tube. The former is inflated, so that the braided material is pressed against the internal sides of the mould. The mould together with the braided material and inflated former are heated in an oven. The yarns or threads again form a homogenous matrix or unitary tube along the former.
The mould is cooled, and the former is deflated and removed from the unitary tube. The impact resistant conduit is thus formed and shaped simultaneously, or substantially simultaneously, and without the need for a separate jig.
One or both formers, and thus the finished tube, can have a round, oval or substantially quadrilateral cross-section. Other cross-sectional shapes are possible.
The tube typically has diameters which range from 6 mm to 50 mm, and with a wall thickness that ranges from 0.3 mm to 5.0 mm.
Shapes such as two dimensional and three dimensional bends, flairs and belling can be imparted to the tube by the methods described above without reducing structural integrity. Consequently, complex and tortuous paths can be formed without weakening the tube.
Once cured, the tube maintains structural integrity up to 65% crush resistance, is 75% to 80% lighter by volume than stainless steel; and is heat resistant in the range of- 150 C to 350 C, though more preferable operating parameters are -70 C to 260 C The tube exhibits excellent flame, smoke and toxicity resistance as well as being resilient to fuel, oil, solvent and chemical exposure.
An interior coating can be applied to the former before winding the impact resistant material. The coating can be a abrasion reducing coating, such as PTFE; an electrical and/or EMC screening coating; and/or a fluid impermeable coating. More specifically, the fluid impermeable coating can be a liquid impermeable coating.
An exterior coating may alternatively, or additionally, be provided. The coating can also be an abrasion resistant lining, such as PTFE. Alternatively, the coating can be plating, which easily takes to the impact resistant material. The plating can be, for example, gold, nickel, copper, zinc or any other plating suitable for a given application.
The exterior coating can also provide electrical and/or EMC screening.
The tube can be integrated as part of a Connector adaptor, Backshell, harness boot; and/or primary conduit. This is particularly beneficial in protecting an exposed electrical harness on, for example, the undercarriage of an aeroplane which is especially vulnerable to projectile impact during take-off and landing. Furthermore, due to the light weight of the tube, overall weight is reduced in comparison to traditional metal impact resistant tubing.
The impact resistant tube is stiff, reducing the need for brackets and p' clips supporting the wiring or harness.
The tube can also be utilised, for example, in the masts of ships due to its high rigidity and low weight.
In use, electrical wiring may be fully enclosed by the impact resistant tube, or may enter and exit the tube as required.
Although the impact resistant tube has been described as being applicable to aircraft and ships, it can be utilised on any transport, or indeed in any area, where exposed electrical wiring is subject to projectile damage.
Other types of conduit, as alternatives to a tube, can be formed from the impact resistant material. The conduit may have a non-continuous circumference, for example having a U- or C- shaped cross-section.
Although Kevlar fibres are used in conjunction with the carbon fibres, it may be possible to dispense with the Kevlar fibres, or utilise alternative fibres, such as R- Glass.
It is thus possible to provide an impact resistant conduit which is more cost- effective to produce than a traditional stainless steel protective tube or conduit, which exhibits better impact resistance, and which is lighter.
The embodiment described above is given by way of example only, and modifications will be apparent to persons skilled in the art without departing from the scope of the invention as defined by the appended claims.
CLAJMS
1. An impact resistant conduit comprising impact resistant material which includes a composite mixture of resin and carbon fibre.
2. An impact resistant conduit as claimed in claim 1, wherein the conduit is a hollow tube having an uninterrupted circumference.
3, An impact resistant conduit as claimed in claim I or claim 2, wherein the resin of the impact resistant material is polyetheretherkeyton (PEEK), polyphenylenesuiphide (PPS), polyetherimide (PEI), polyamide (PA), polypropylene (PP), or a combination thereof.
4. An impact resistant conduit as claimed in any one of the preceding claims, wherein the said material further comprises poly-paraphenylene terephthalamide-based fibre.
5. An impact resistant conduit as claimed in any one of the preceding claims, wherein the or both kinds of said fibres of the said material are in an amount of 40% to 70% fibre volume fraction.
6. An impact resistant conduit as claimed in any one of the preceding claims, wherein the conduit is at least in part formed from braided unidirectional elongate flexible elements of the said material which is consolidated to form a homogenous matrix.
7. An impact resistant conduit as claimed in any one of the preceding claims, wherein the conduit is 65% crush resistant.
8. An impact resistant conduit as claimed in any one of the preceding claims, wherein the conduit is 25% lighter than stainless steel by volume.
9. An impact resistant conduit as claimed in any one of the preceding claims, wherein the conduit is heat resistant to in the range of -150 C to 350 C.
10. An impact resistant conduit as claimed in claim 9, wherein the conduit is heat resistant in the range of -.70 C to 260 C.
11. An impact resistant conduit as claimed in any one of the preceding claims, wherein the tube is shape formable.
12. An impact resistant conduit as claimed in any one of the preceding claims, further comprising an interior coating and/or an exterior coating.
13. An impact resistant conduit as claimed in claim 12, wherein the interior coating is an abrasion reducing coating; an electrical and/or EMC screening coating; and/or a fluid impermeable coating.
14. An impact resistant conduit as claimed in claim 13, wherein the fluid impermeable coating is a liquid impermeable coating.
15. An impact resistant conduit as claimed in any one of claims 12 to 14, wherein the exterior coating is plating.
16. An impact resistant conduit as claimed in any one of claims 12 to 15, wherein the exterior coating provides electrical and/or EMC screening.
17. Electrical wiring, at least part of which is in an impact resistant conduit as claimed in any one of the preceding claims.
18. A wiring harness having an impact resistant conduit as claimed in any one of the preceding claims.
19. Transport having electrical wiring, at least part of which is in an impact resistant conduit as claimed in any one of claims 1 to 16.
20. Transport as claimed in claim 18 or claim 19, wherein the transport is an aircraft.
21. A method of forming an impact resistant conduit as claimed in any one of claims 1 to 16, comprising the steps of: a. braiding a plurality of elongate flexible elements formed from the impact resistant material onto a former; b. heating the braided impact resistant material so that the plurality of elongate elements form a unitary impact resistant conduit; and c. forming the unitary impact resistant conduit into a desired shape.
22. A method as claimed in claim 21, wherein the former is a rigid former, and further comprising a step (d), between steps (b) and (c), of cooling the unitary conduit, removing the rigid former, and then post-heating the unitary conduit.
23. A method as claimed in claim 21, wherein the former is an inflatable and deflatable former, and, in step (b), the braided impact resistant material and former are positioned in a mould, so that steps (b) and (c) occur simultaneously or substantially simultaneously.
24. A method as claimed in claim 23, wherein, in step (a), the former is deflated, and in steps (b) and (c), the former is inflated.
S Thc
Office U
INVESTOR IN PEOPLE I, -
Application No: GB0503774.2 Examiner: Jason Clee Claims searched: 1-24 Date of search: 16 June 2005 Patents Act 1977: Search Report under Section 17 Documents considered to be relevant: Category Relevant Identity of document and passage or figure of particular relevance to claims X 1-5,7GB 2254967 A 11,17 MAUNSELL STRUCTURAL PLASTICS (See references on page 2 lines 3&4 and page 4 lines 11&12 regarding materials of construction for conduits, eg those shown in fig 11.) X 1-5,7, 11- GB2222653A 21 TI CORPORATE SERVICES (See fig 1, conduit formed of resin and carbon fibre 1 over light weight metal/alloy 2; see also reference to method of production including woven fibres and application of heat.) X 1-11,17GB2106073A 21 SCHJAPPARELLI GIOVANNI (See claim 1 in particular.) X 1-5,7-11 JP2005014449A NIPPON STEEL COMPOSITE CO LTD (See WPI abstract accession number 2005-105154 [12]; tube made of carbon fibre and resin mixture, which by the nature of the materials used will be impact resistant.) X 1- 11,21 JP06297590A NITTO BOSEKI CO LTD (See WPI abstract accession number 1995- 011397 [03]; Braided carbon fibre and resin used to make impact resistant conduit.) A - GB 1388721 A POLYGEST AG (Use of PTFE coatings in and on pipes.) A - W02004/020887A2 FEDERAL MOGUL POWERTRA1N INC (Use of materials PEEK, PPS, polypropylene; Use of braided tubes.) A - US 2004/165357 Al SIEMENS AG (See reference to EMC protection.) A - US 2004/109965 Al SOFANOU SA (Note use of polyamides in braiding.) Categories: X Document indicating lack of novelty or inventive A Document indicating technological background and/or state step of the art An Executive Agency of the Department of Trade and Industry <s. i ?Patt , Office iNVESTOR iN PEOPLE * Y Document indicating lack of inventive step if P Document published on or after the declared pnority date but combined with one or more other documents of before the filing date of this invention.
same category & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application
Field of Search:
Search of GB, EP, WO & US patent documents classified in the following areas of the UKCX C3K; C3V; F2P; H2C Worldwide search of patent documents classified in the following areas of the IPC 7 L6L; HO2G The following online and other databases have been used in the preparation of this search report Online: WPI & EPODOC; Internet: Google and Gigablast.
An Executive Agency of the Department of Trade and Industry
GB0503774A 2005-02-24 2005-02-24 Impact resistant conduit Expired - Fee Related GB2423648B (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
GB0503774A GB2423648B (en) 2005-02-24 2005-02-24 Impact resistant conduit
EP06250720A EP1696530B1 (en) 2005-02-24 2006-02-10 Impact resistant conduit
ES06250720T ES2365498T3 (en) 2005-02-24 2006-02-10 IMPACT RESISTANT DRIVING.
DE602006021497T DE602006021497D1 (en) 2005-02-24 2006-02-10 Impact resistant tube
AT06250720T ATE507601T1 (en) 2005-02-24 2006-02-10 IMPACT RESISTANT TUBE
US11/358,127 US20060211993A1 (en) 2005-02-24 2006-02-22 Impact resistant conduit

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0503774A GB2423648B (en) 2005-02-24 2005-02-24 Impact resistant conduit

Publications (3)

Publication Number Publication Date
GB0503774D0 GB0503774D0 (en) 2005-03-30
GB2423648A true GB2423648A (en) 2006-08-30
GB2423648B GB2423648B (en) 2009-06-17

Family

ID=34401205

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0503774A Expired - Fee Related GB2423648B (en) 2005-02-24 2005-02-24 Impact resistant conduit

Country Status (6)

Country Link
US (1) US20060211993A1 (en)
EP (1) EP1696530B1 (en)
AT (1) ATE507601T1 (en)
DE (1) DE602006021497D1 (en)
ES (1) ES2365498T3 (en)
GB (1) GB2423648B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102876040A (en) * 2012-10-08 2013-01-16 合肥杰事杰新材料股份有限公司 Polyphenylene sulfide composite material and preparation method thereof
GB2523204B (en) 2014-02-18 2018-02-07 Sigma Prec Components Uk Limited Fibre reinforced thermoplastic composite rigid pipe

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GB1388721A (en) * 1971-04-29 1975-03-26 Polygest Ag Method of manufacturing hollow bodies and coatings of polytetrafluorethylene and the products obtained by said method
GB2106073A (en) * 1981-09-10 1983-04-07 Giovanni Schiapparelli Protective tubing
GB2222653A (en) * 1988-09-07 1990-03-14 Ti Corporate Services Hollow tubular structures of fibre reinforced plastics material and method for their production
GB2254967A (en) * 1989-11-07 1992-10-21 Maunsell Structural Plastics Modular services support system
JPH06297590A (en) * 1993-04-12 1994-10-25 Nitto Boseki Co Ltd Fiber reinforced thermoplastic resin hollow molded object
WO2004020887A2 (en) * 2002-08-28 2004-03-11 Federal-Mogul Powertrain, Inc. Sleeve assembly for receiving elongated items within a duct
US20040109965A1 (en) * 2002-03-18 2004-06-10 Emmanuel Klinklin Protective sleeving and manufacturing process for producing this type of sleeving
US20040165357A1 (en) * 2002-11-27 2004-08-26 Siemens Aktiengesellschaft Mounting device and apparatus for mounting device
JP2005014449A (en) * 2003-06-26 2005-01-20 Nippon Steel Composite Co Ltd Member for vehicle

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US4774043A (en) * 1985-05-23 1988-09-27 Volkswagen Aktiengesellschaft Method for production of a hollow shaft of fiber-reinforced plastic
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Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388721A (en) * 1971-04-29 1975-03-26 Polygest Ag Method of manufacturing hollow bodies and coatings of polytetrafluorethylene and the products obtained by said method
GB2106073A (en) * 1981-09-10 1983-04-07 Giovanni Schiapparelli Protective tubing
GB2222653A (en) * 1988-09-07 1990-03-14 Ti Corporate Services Hollow tubular structures of fibre reinforced plastics material and method for their production
GB2254967A (en) * 1989-11-07 1992-10-21 Maunsell Structural Plastics Modular services support system
JPH06297590A (en) * 1993-04-12 1994-10-25 Nitto Boseki Co Ltd Fiber reinforced thermoplastic resin hollow molded object
US20040109965A1 (en) * 2002-03-18 2004-06-10 Emmanuel Klinklin Protective sleeving and manufacturing process for producing this type of sleeving
WO2004020887A2 (en) * 2002-08-28 2004-03-11 Federal-Mogul Powertrain, Inc. Sleeve assembly for receiving elongated items within a duct
US20040165357A1 (en) * 2002-11-27 2004-08-26 Siemens Aktiengesellschaft Mounting device and apparatus for mounting device
JP2005014449A (en) * 2003-06-26 2005-01-20 Nippon Steel Composite Co Ltd Member for vehicle

Also Published As

Publication number Publication date
US20060211993A1 (en) 2006-09-21
GB2423648B (en) 2009-06-17
EP1696530A1 (en) 2006-08-30
EP1696530B1 (en) 2011-04-27
ATE507601T1 (en) 2011-05-15
DE602006021497D1 (en) 2011-06-09
GB0503774D0 (en) 2005-03-30
ES2365498T3 (en) 2011-10-06

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Effective date: 20190224