JP2000153567A - Composite structural member having high bending strength and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite structure having layered arrangement imparting high strength and especially high bending strength. SOLUTION: A composite member 10 has a peculiar layered structure imparting high bending strength and is formed from a plurality of layers and a fiber component 18 arranged in a polymer matrix is contained in the respective layers. An inner layer 16 contains a fiber component comprising fibers stretched in a peripheral direction and an intermediate layer 22 is equipped with the first fibers 24 arranged around the periphery of the composite member and stretched in an axtially direction and the second axial fibers 30 crossing fibers in a spiral direction and embedded in the polymer matrix. An outer layer 38 contains fibers embedded in the polymer matrix and stretched in a pheripheral direction in the same way as the inner layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

FIELD OF THE INVENTION The present invention relates to composite structural members having high flexural strength, and more particularly, to composite structural members having a unique laminar arrangement and structure that provides high flexural strength.

[0002]

2. Description of the Related Art At present, a wide variety of composite materials known to those skilled in the art are used for parts requiring light weight and high strength. Such materials can be single or multi-layered,
At least a portion thereof is comprised of a polymer matrix with embedded fiber components. The arrangement of the fiber components in each layer is a factor that determines properties such as the strength of the final structure.

[0003]

Many composite materials are vulnerable to excessive bending, compression, or torsional forces and easily cause structural damage. Therefore, development of a lightweight structure capable of withstanding a large force is desired.

[0004] Accordingly, it is an object of the present invention to provide a composite structure having a layered arrangement that provides high strength, especially high bending strength. Another object of the present invention is to provide an elongated composite structural member having high strength and light weight. A further object of the present invention is to provide a simple and efficient method for producing such a composite structural member. Another object of the present invention is to
From the following disclosure of the invention, it can be clearly read.

[0005]

The composite structural member of the present invention having a large strength is generally a tubular composite member having various cross-sectional shapes such as an elongated, circular, rectangular, or square shape, that is, a hollow composite structural member. , Wherein each layer includes a fiber component disposed within a polymer matrix. In a composite structure of at least three layers, the inner and outer layers include continuous circumferential fibers arranged at an angle of ± 30 ° to ± 90 ° with respect to the longitudinal axis of the composite structural member. The composite member includes at least one such inner layer and outer layer in the circumferential direction. Circumferential fibers provide crushing strength, reinforce axially extending fibers and prevent buckling failure. The resistance to crush strength is the cosin ² between the fiber direction and the longitudinal axis of the member.
Alternatively, it is shown as a function of (sin) ² . The composite structure further forms a circumferential gap between each pair,
At least one intermediate layer comprising a plurality of circumferentially-spaced, first fibers that are axially elongated and are combined. Also, between each pair of first fibers extending in the axial direction, a set of second fibers extending in the axial direction is arranged. The axial second fiber is:
It is intermingled with helical blade fibers positioned at an angle of ± 5 ° to ± 60 ° with respect to the longitudinal axis of the composite member. Both the first axial fiber and the second fiber are disposed substantially parallel to the longitudinal axis of the member, ie, at an angle of about 0 °. Also,
Each set of the first and second fibers in the axial direction is 2
Desirably, it is configured to include adjacent fibers of a book. The combination of the first fiber and the second fiber extending in the axial direction is configured so that the wall thickness is almost uniform throughout the composite.

[0006] The circumferential fiber and the blade fiber may be formed of a fiber material having a coefficient of 10 million psi or more, for example, aramid, carbon (carbon), graphite (graphite), glass or the like. . In addition, the fiber in the axial direction is a fiber material having a coefficient of 12 million psi or more that can withstand bending stress,
For example, it may be formed of carbon, graphite, ceramic, boron (boron), glass, or the like. The matrix component of the composite, i.e., the structural portion other than the fiber, usually penetrates and binds to the fiber component, and at the same time, firmly bonds between the layers.
It is composed mainly of polymer resin and / or ceramic. In particular, anhydride, polyamide, or using an aliphatic amine as a catalyst, epoxy resin,
A thermosetting material such as a polyester resin is a matrix material that is suitably used for producing a composite. Further, a thermoplastic material, for example, polyphenylene sulfide, polyether sulfone, polyethylene terephthalate, nylon, polypropylene, polycarbonate, acetal, polyether ether ketone, or the like may be used.
The matrix component may include a ceramic material.

That is, among the present invention, the invention according to claim 1 is a composite structural member comprising a plurality of layers, wherein each layer includes a fiber component disposed in a polymer matrix, and the composite member comprises: A . B. at least one inner layer comprising circumferentially extending fibers; B. at least one outer layer comprising circumferentially extending fibers; i) a first fiber extending in the axial direction, which is combined with a plurality of fibers at intervals in the circumferential direction so as to form a circumferential gap between each pair; and ii) disposed in the circumferential gap. At least one intermediate layer comprising: a second fiber that is provided, and is combined with each other at a plurality of circumferentially spaced intervals, and is axially elongated, and is intermingled with a helical fiber. The inner layer,
Forming a rigid, elongated composite structural member such that the outer layer and the intermediate layer have a predetermined wall thickness over the entire length of the member. A second aspect of the present invention is characterized in that, in the first aspect of the present invention, each of the inner layer and the outer layer contributes less than 25% to the total elastic modulus of the composite. According to a third aspect of the present invention, in the second aspect, the intermediate layer includes three layers. According to a fourth aspect of the present invention, in the first aspect, the diameter of the fiber extending in the circumferential direction is:
0.007 inch to 0.040 inch. The invention according to claim 5 is the invention according to claim 4, wherein the diameter of the fiber extending in the axial direction is 0.007 inches to 0.040 inches.
It is characterized by the following. The invention according to claim 6 is the invention according to claim 1.
The diameter of the fiber in the spiral direction is 25% of the diameter of the fiber extending in the axial direction.
Less than. The invention according to claim 7 is the invention according to claim 1, wherein the fiber extending in the circumferential direction has a coefficient of 10 million psi or more, aramid fiber, carbon fiber, graphite fiber, and glass. Selected from fibers. The invention according to claim 8 is the invention according to claim 1, wherein the fiber extending in the axial direction has a coefficient of 12 million psi or more, carbon fiber, graphite fiber, glass fiber, ceramic fiber, Boron fiber,
And aramid fiber. According to a ninth aspect of the present invention, in the first aspect of the present invention, the fiber in the helical direction has 1,000 fibers.
It is selected from aramid fiber, carbon fiber, glass fiber, and graphite fiber having a coefficient of 10,000 psi or more. According to a tenth aspect of the present invention, in the first aspect, the circumferentially extending fibers are arranged at an angle of ± 30 ° to ± 90 ° with respect to a longitudinal axis of the member. , Characterized in that. The invention according to claim 11 is characterized in that, in the invention according to claim 10, the axially extending fibers are arranged at an angle of about 0 ° with respect to the longitudinal axis of the member. And Claim 1
The invention according to claim 2 is the invention according to claim 11,
The helical fibers are arranged at an angle of ± 15 ° to ± 60 ° with respect to the longitudinal axis of the composite member;
It is characterized by the following. According to a thirteenth aspect of the present invention, in the first aspect, the polymer matrix is made of a material selected from epoxy, polyester, and vinyl ester. The invention according to claim 14 is the invention according to claim 1,
The polymer matrix is polyphenylene sulfite, polysulfone, polyethylene terephthalate, polypropylene, polycarbonate, acetal,
It is made of a material selected from nylon and polyetheretherketone. The invention according to claim 15 is the invention according to claim 14, wherein the volume ratio between the polymer matrix resin and the fiber is 50%.
% Or less. According to a sixteenth aspect of the present invention, in the first aspect of the present invention, the semiconductor device has a bending strength of 0.25% or more in maximum stacking strain. According to a seventeenth aspect of the present invention, there is provided a marine sailing mast formed from the composite structural member according to the first aspect.
An eighteenth aspect of the present invention resides in a whip antenna case formed from the composite structural member according to the first aspect. The invention according to claim 19 is a method for manufacturing a composite structural member, comprising: B. Cover the circumference of the elongated mandrel with circumferentially extending fiber and liquid polymer resin to form a first layer; B. placing a plurality of first fibers extending in the axial direction and a liquid polymer resin on the first layer to form a first portion of the intermediate layer; A. placing on said first portion a plurality of second fibers intermingled with helical fibers and extending axially and a liquid polymer resin to form a second portion of the intermediate layer; B. An outer layer is formed by placing fibers extending in the circumferential direction and a liquid polymer resin on the intermediate layer; Covering said outer layer with molding wrap; F. Curing the member at a high temperature. The invention according to claim 20 is the invention according to claim 19, further comprising: After the curing is completed, the molding wrap is removed from the member; After completion of the curing, the mandrel is removed from the member. According to a twenty-first aspect, in the nineteenth aspect, the intermediate layer is formed in three layers.

The present invention also provides a mast member for a wind-powered marine vessel, which is manufactured from a composite material. A hollow elongated upright structural member comprising means for securing a mast to a ship and means for engaging a sail, wherein the upright structure is formed from a plurality of layers containing fiber components disposed within a polymer matrix. A member; B. a boom mounted on the boom portion of the upright member; In order to increase the thickness of the boom part of the upright member,
A reinforcing layer of fibrous material disposed within the polymer matrix of the boom section. Further, in the mast member: At least one inner layer comprising circumferentially extending fibers disposed within a polymer matrix;
B. i) a first fiber extending in the axial direction, which is combined with a plurality of fibers at intervals in the circumferential direction so as to form a circumferential gap between each pair; and ii) disposed in the circumferential gap. At least one intermediate layer including a second fiber that is provided, and is combined with each other at a plurality of circumferentially spaced intervals, and is axially extended with a second fiber that is mixed with the helical fiber. C. And at least one outer layer including circumferentially extending fibers. Additionally, the mast member is characterized in that the reinforcing layer increases the diameter of the boom portion of the upright member by about 0.015 inches.

[0009]

Embodiments of the present invention will be described below with reference to the drawings.

[0010] The composite structural member of the present invention is formed from a plurality of layers including fiber components disposed within a polymer matrix. This unique layer arrangement of the composite
It is a factor that gives a large strength to the member. The composite member is often a tubular structure having various cross-sectional shapes, such as elongated, circular, elliptical, rectangular, square, polygonal, and the like. The composite member according to the present invention is used for a portion required to be lightweight and have high strength, for example, a sailboat mast or boom, an antenna, and the like.

FIG. 1 shows the fiber component arrangement of a plurality of layered structures forming a composite member 10 of the present invention. As shown in FIG. 1, a composite member 10 manufactured on a removable mandrel is formed from a plurality of layers containing fiber components embedded within a polymer matrix. The inner layer 16, also shown in FIGS. 2 to 5, comprises a circumferential fiber component 18 arranged at an angle of ± 30 ° to ± 90 ° with respect to the longitudinal axis 20 of the composite member. This circumferential component provides the composite member with circumferential strength, which is greatest in the 90 ° direction and becomes progressively smaller as the angle decreases. Thus, the orientation angle of the fiber component 18 relative to the longitudinal axis 20 is preferably between ± 60 ° and ± 90 °, and more preferably between ± 80 ° and ± 90 °. Also, the fiber component is preferably configured to include 4 to 10 continuous unidirectional strands. For example, when manufacturing a small sailboat mast, the fiber component 18
It is formed from about eight fiber strands. Furthermore,
A braided or woven fiber component 18 (not shown) may be used to improve circumferential stiffness and buckling strength.

The fiber component may be composed of any of various fibers commonly used in the manufacture of a composite structure, but it is preferable to use a fiber having a coefficient of 10 million psi or more. Desirable fiber materials include aramid, carbon, graphite, and glass, although a particularly preferred material in many applications is glass sold by Owens-Calling under the trademark E-glass. Fiber (glass fiber). Preferred fiber diameters for fiber component 18 range from about 0.007 to 0.040 inches. A smaller diameter can increase the structural strength, but a larger diameter has better workability.

Normally, the innermost layer 16 is constructed as a single inner layer containing a circumferentially extending fiber component 18, but if it is necessary to form a structural member having greater strength and stiffness. The inner layer may be composed of two or more layers having circumferential fibers. If the inner layer is formed from multiple layers, the circumferential fibers of each layer may be arranged at the same angle within the above range with respect to the longitudinal axis 20 and in opposite directions. desirable.

Immediately outside the inner layer 16 in the circumferential direction, one or more intermediate layers are formed. 1 and 3 to 6 show an embodiment including one intermediate layer 22. FIG. Middle layer 2
2 comprises two independent fiber components 24 and 30 that extend axially. The first fiber component 24 extending in the axial direction comprises a plurality of non-braided continuous fibers 2.
4A, the fibers 24A are arranged around the perimeter of the composite 10 for each set 26, separated by a gap 28, as shown in FIG. Individual fibers 24
A extends the entire length of the composite member 10 and is disposed at an angle of about 0 ° with respect to the longitudinal axis 20 of the composite. Each set 26 is comprised of two axial fibers 24A placed circumferentially adjacent to one another. Further, the sets 26 are separated from each other by a circumferential gap 28 and are arranged at equal intervals on the circumference of the composite. Composite member 10
Is defined to have a uniform width, the dimensions of which are selected according to the application site. Often the diameter of the composite structural member according to the invention is wholly or partially tapered, in which case the dimensions of the void 28 vary uniformly over the entire length of the tapered portion.

The second axial fiber component 30 comprises a second axial fiber 32 disposed on the periphery of the composite 10 with a gap 28 therebetween. Like the first axial fiber 24A, the second axial fiber 32 is also arranged in each set 34, each set typically including two independent fibers 32. In a given complex, the number of sets 34 may be the same as the number of sets 26. That is, in this case, the sets 26 and 34 of the first and second axial fibers 24A and 32 are provided.
Are alternately arranged on the circumference of the composite 10 such that each set of fibers is at an angle of approximately 0 ° to the longitudinal axis 20 of the composite member 10.

The number of first axial fibers 24A that make up a given composite member is determined by the diameter of the composite and its ultimate use. The number of axial fibers 24A in a given composite may be 5% to 100% of the number of axial braided fibers 32, and more preferably 40% to 100% of the number of axial fibers 32. %. In the tapered composite member 10, the number of fibers in each component 24 and 30 varies over the entire length of the taper to maintain a uniform layer thickness or to achieve the desired layer thickness. .

Each set 26 of axially non-braided fibers 24A is fixed to one another such that, in combination with the axial fibers 32, a wall of substantially uniform thickness is formed over the entire length of the composite. It is arranged on the circumference at a distance. For example,
48 axial fibers 32 (eg BASF G3
When making a 2 inch diameter composite tube, including 0-500 12K fiber), 24 axial fibers 24A are grouped in pairs and spaced equally around the circumference of the composite. The desired spacing between each set of (eg, BASF G30-5012K fiber) is about 0.50 inches. Further, as shown in FIGS. 1 and 4-6, the axial second fiber component 30 engages a braided fiber component 36 consisting of two helical yarns 36A and 36B. Axial second fiber 3
Yarns 36A, 36B are intermixed with second axial fibers 32 such that each of the two is sandwiched between braided yarns 36A, 36B. Knitted yarn 36A, 36B
Does not mix with the first fiber 24A in the axial direction, but passes over the surface of the fiber 24A, as shown in FIGS.

As the second axial fiber 32,
Almost straight, mixed with yarns 36A and 36B,
It is desirable to use one that gives maximum strength without causing folds such as swelling and bending. In response, each braided yarn 36
The radial amplitude of each yarn needs to be large so that A, 36B is twisted around the axial fiber 32 throughout the thickness of the layer.

It is desirable that each of the yarns 36A and 36B be continuous and extend over the entire length of the composite member 10. However, non-continuous knitting yarns may be used by twisting or overlapping. Further, preferably, the yarn 36A,
36B is ± 5 ° to ± 5 ° with respect to the longitudinal axis 20.
It is arranged at an angle of 60 °. As shown in FIG.
The wavelength λ of the wavy axial fiber 32 is equal to the distance between two braided fibers of the same type, for example, two braided fibers 36A. The wavelength of the waveform is determined based on the diameter and elastic modulus of the axial second fiber 32, as well as the modulus and strength of the material of the matrix 14. The longer the optimal wavelength, the more the fiber 32 and matrix 14 can withstand higher strain forces. Desired wavelength λ
Is about 0.10 to 1.00 inches.

In a given composite structure according to the invention,
The first and second axial fibers 24A, 32 have the same diameter and are formed from the same material. The diameter of these axial fibers depends in part on the diameter of the composite structure, with a preferred range of 0.070 to 0.040 inches. The first and second axial fibers 24A, 32 are made of polyethylene, carbon, graphite, ceramic, boron, aramid, glass, or the like.
What is necessary is just to be comprised from any of many fiber materials. If a particularly large strength is required,
A fiber material such as carbon having a coefficient of 4,000,000 psi or more, a maximum stress of 500 ksi, and a minimum strain of 1.4% is preferably used. The number of filaments per yarn is about 12,000, about 615 yd / lb (0.807
g / m) and carbon fibers having a modulus of 30 million psi or more are suitably used in many applications. One example of such a fiber is BASF
From Celion Carbon Fiber G30-5012
Fibers sold under the trademark K.

The diameter of the braided yarns 36A, 36B is
It is smaller than the diameter of the axial fibers 24A, 32, particularly preferably 25% or more. That is, the diameter of the braided yarns 36A and 36B is about 0.005 to 0.0.
The range is 15 inches. Braided yarn 36A, 36
B is aramid, glass, carbon, graphite, etc.
What is necessary is just to be comprised from any one of many fiber materials. Desirable materials for the braided yarns 36A, 36B include, for example, glass fibers sold by Owen Corning under the trademark S-2 glass. Furthermore, a fiber with a modulus of 10 million psi or more and a maximum stress of 600 ksi is desirable.

The composite structural member according to the present invention may include a single intermediate layer 22 in many applications,
It is more desirable to have two or more intermediate layers 22. For example, a sailboat mast typically incorporates three intermediate layers 22. When manufacturing a highly flexible member 10 having three intermediate layers 22, it is preferable to make the outer two layers the same and to reduce the number of fibers 24A, 32 in the axial direction by the innermost layer. With such a configuration, the rigidity in the axial direction, the bending strength, and the breaking strength in the circumferential direction can be increased.

As shown in FIGS. 1 and 5, an outer layer 38 containing fibers is secured immediately adjacent to the intermediate layer 22. The outer layer 38 also includes a circumferential fiber component 40 embedded in a matrix of polymer resin or the like (see FIG. 1). Outer layer fiber component 40
Are arranged at the same angle as the fiber component 18 of the inner layer, but the winding direction is
8 is exactly opposite to the winding direction. With this configuration, the member 10 can be given sufficient strength to withstand the radial load and the crushing load. It is preferable to form the outer-layer fiber component 40 so as to have the same diameter as the inner-layer fiber component 18 and from the same fiber material. Usually, a single outer layer is used, but there can be more than one outer layer depending on the application.

The tensile modulus of the inner layer 16 and the outermost layer 38 are each less than 25% of the total elastic modulus in the axial direction of the composite (measured in the 0 degree direction). The balance is adjusted by the combination with one or more intermediate layers 22.

When exposed to extreme external conditions, for example,
If there is a possibility of impact from broken pieces or other high-speed objects, the fiber component 18 should be replaced by approximately 4,35.
With a coefficient of 100,000 psi and a maximum strain of 1.66%,
A carbon yarn such as BASF G40-700 and a fiber component 38 of 500,000 (500,000)
It is desirable to use an aramid fiber, such as Kevlar HT or Kevlar 29 from Dubon, which has a maximum stress of at least psi and a tensile modulus of at least 12 million psi. Further, by mixing, knitting, or weaving the fibers of the outer layer, a greater impact strength can be given.

As described above, each layer of the composite member 10 is composed of a matrix 14 such as a polymer and a fiber component arranged therein. The matrix is usually the same in all layers and the material is made up of multiple fiber components 1 to provide a strong and reliable composite.
What is necessary is just to be able to penetrate into 8, 24, 30, and 40 sufficiently and to be able to combine with them. Known thermosetting or thermoplastic polymers having high strength can be suitably used as the polymer matrix material. Examples of the thermosetting polymer include epoxy, vinyl ester, polyester, and the like, which can be cured with a well-known curing agent such as anhydride, polyamide, and aliphatic amine. Examples of the thermoplastic polymer include polyphenylene sulfide, polyether sulfone, polyethylene terephthalate, nylon, polypropylene, polycarbonate, acetal, and polyether ether ketone. A particularly preferred polymer matrix material is a low viscosity epoxy resin that is cured with an anhydrous compound. For example, manufactured by Dow Chemical Company and D.C.
E. FIG. An epoxy resin sold under the trademark R330 epoxy resin can be used. Further, methyl tetrahydrophthalate anhydride can be used as an anhydrous curing agent for such an epoxy resin, that is, as a catalyst.

One of the advantages of the layered structure of the composite structural member of the present invention is that the layer arrangement of the intermediate layer 22 allows for a uniform wall thickness throughout the composite 10. The first axial fiber component 24 effectively fills the voids formed between each set 34 of the second axial fibers 32. The presence of such voids results in a non-uniform surface and thickness, which results in reduced flexural, torsional, and radial strength of the composite. The graph of FIG. 9 shows the relationship between the composite length and the maximum strain in the composite manufactured according to the present invention and other structures. Curve A shows the flexural strength of a composite made according to the present invention, which also clearly shows that the configuration of the present invention improves the flexural strength. Curve B shows the flexural strength of a similarly constructed composite, but without the first axial fiber component 24. Curve C illustrates the flexural strength of a composite constructed similarly to the composite of Curve A, except that it does not include the circumferential fiber components 18, 38 and the axial fiber component 24.

The composites produced according to the invention have a high wall thickness uniformity and consequently a high flexural strength. Furthermore, the braided fiber component 36, which is a component in the Z direction, that is, the radial direction and the thickness direction, makes the bonding between the layers stronger and greatly contributes to the increase in the strength of the composite. Also, by reducing the plication of axial fibers with large coefficients, the stress on the matrix is reduced as compared to other hybrid or braided composite structures. As described above, the configuration of the present invention can increase the bending strength of the composite member without increasing the weight, and the lightweight and high-strength composites manufactured according to the present invention can be variously modified. Applicable to the site.

The composite of the present invention is particularly suitable for sites where it is necessary to withstand a bending strain of 0.25% or more (defined by a change in the ratio of the total length to the original length and usually measured by a strain gauge). Suitable for. For example, the composite structural members of the present invention include ski poles, yacht spars, golf club shafts, pole vault rods, fishing rods, fishing boat overhangs, oar shafts, paddle shafts, hockey stick shafts, baseball bats. It is suitably used for parts requiring light weight and high strength, particularly high bending strength, such as glider structural members. Further, such a composite material can be used for structural piping, and can be used for manufacturing structural members of aircraft and aerospace vehicles, structural members of automobiles, tubular containers, torsion springs, leaf springs, robots, and the like. Can also. Further, it can be used for communication antennas, marine structures, and medical accessories such as wheelchairs, canes, stretchers, and prostheses. Particularly preferred applications of the composite of the present invention include mast structures for sailboats and small sailboats.

FIG. 7 shows a spar 42 manufactured in accordance with the teachings of the present invention and used in the construction of sail columns such as sailboat masts. The spar 42 includes an upright tubular post 44 that supports a sail (not shown). The spar 42 is formed of the above-described composite including a single inner layer, a three-layer intermediate layer, and a single outer layer. The diameter of the post 44 is the same for about half of the overall spar length and tapers at a uniform rate over the other half.
The diameter of the taper of the spar varies from about 2.0 to 0.85 inches. In addition to the layers and the matrix constituting the posts 44, the spar 42 may be further covered with an environmental protection paint made of polyurethane or the like. In this case, an ultraviolet absorber may be added to the paint in order to prevent deterioration of the matrix material due to direct sunlight.

The spar 4 is provided so as to withstand an excessive bending force applied locally such as mounting a boom (not shown).
2 is provided with a reinforced intermediate boom section 46. The post 44 is reinforced over a length of about 40 inches to accommodate various boom positions and sail designs (see FIG. 7). Reinforced boom section 46, the resin is impregnated, it is adhered in the molding tape spar, of about 8.75 oz / yd ² glass fabric (Example: E
-Glass) on the outside. The diameter of the boom portion 46 is about 0.065 inches when not reinforced, and reinforced increases the wall thickness by about 0.015 inches. By reinforcing the boom portion, the rigidity of the spar in the circumferential direction is increased, and it is possible to withstand the local load caused by the attachment of the boom to the spar. Further, the reinforcing woven fabric used for the boom portion 46 has an advantage that it can withstand a larger local load because the load is distributed as compared with a nonwoven mixed fiber layer having the same layer thickness and the same type. However, while the reinforcing boom portion 46 shown in FIG. 7 may be useful in some applications, it is not necessary for all sailboat masts manufactured from the composite according to the present invention.

FIG. 8 shows a composite assembly apparatus 49 for producing a composite structural member according to the present invention. The various layers forming the composite structural member of the present invention are wound around a mandrel or mold 50 to produce the member, the shape of the mandrel being determined by the composite. The mandrel 50 used in the manufacturing process of the present invention may or may not be tapered, and is made of a material such as aluminum, steel, plastic, rubber, and the like. It may be hollow or solid, but a hollow mandrel is preferred.

As shown in FIG. 8, the mandrel 50 is positioned within the composite manufacturing line so as to traverse a series of stations for applying and winding various fiber and polymer matrix layers around the mandrel 50. I do. First, the fiber 52 of the inner layer 16 is wound around the mandrel 50 by the station 52. Station 52 includes a device that holds a plurality of fiber packages 54 (eg, four to eight packages) that rotate about an axis parallel to transverse direction 56 of mandrel 50. The ratio of the traversal speed of the mandrel 50 to the rotational speed (rpm) of the fiber package 54 at the station 52 determines the amount and direction of fiber in the inner layer 16. For example, when manufacturing a sailboat mast, the mandrel 50 traverses the assembly device 49 at approximately 4 feet per minute, and the rotational speed of the eight yarn packages at station 52 is determined by certain design requirements and complex requirements. 40 to 175, depending on the diameter of a given part of the body
rpm. Immediately after station 52,
A liquid polymer resin such as epoxy is poured from the device 58A, and is permeated and impregnated into the entire inner layer fiber component 18. In this case, the volume ratio between the resin and the fiber is 50%.
It is desirable that:

When the mandrel 50 moves further laterally in the manufacturing apparatus 49, the filament winding station 6
With 0, the fiber component of the first intermediate layer is wound. The first fiber 24 in the axial direction is provided by the yarn package 62A and the yarn package 62B.
Thereby, the second fiber 32 in the axial direction is wound. Further, at the station 60 (not shown)
The mixing device winds the braided yarn components 36A, 36B. Here, the yarn package 62A,
62B is the number of axial fibers 2 present in each layer.
It is desirable to match the number of 4,43. At this time,
Resin coating device 58B forming a part of station 60
The resin is poured from above to form a matrix of the first intermediate layer.

In the same manner as described above, the second and third intermediate layers are formed at the filament winding stations 61 and 64, respectively. Station 6
Resin coating devices 58C, 58 forming a part of 1 and 64
By D, the polymer resin forming the matrix is poured.

Next, the mandrel 50 is connected to the station 5
2 through the same filament winding station 66. Station 66 winds the fiber component of outer layer 38 in a manner similar to station 52. However, in this case, the station 66 is the station 52
And rotate in the opposite direction. After winding the circumferential fiber layer, the resin material is poured by the device 58E. If necessary, a station (not shown) may be added here, and the circumferential fiber layer may be further wound and coated with resin.

At each filament winding station, the tension of the fiber is adjusted so that the fiber does not loosen or move after being wound and is taut. The tension of the braided fiber 36 is adjusted by using a mixing device that maintains a pulling force of about 11 b / fiber or less.

Finally, the mandrel 50 passes through a tape wrapping device 68 which wraps the thermoplastic tape 41 about 1/2 to 3/4 inch wide around the mandrel 50, ie, the layer. 3 to 1
It is desirable to keep the value between 5 bonds. The pulling force of the tape forms the filament and resin wrapped around the mandrel, removing excess resin and expelling air trapped between the filament and resin. An example of a tape that is particularly useful for making sailboat masts is a silicone-coated polyester film that is 1/2 inch wide and 2 mm thick.

A drive mechanism 70 is used to move the mandrel 50 along the manufacturing apparatus 49. As such a mechanism, a mechanism capable of changing the traversing speed of the mandrel 50 is desirable.

After the thermoplastic tape has been applied, the structure is placed in a vertical convection oven at a temperature of about 300 ° F. for about 2 hours to cure the resin. After removal from the oven and cooling of the structure, the mandrel 50 is removed from the cured composite. When removing the mandrel, the complex shrinks as the resin changes from a liquid to a solid.
It is necessary to pull with a force of 00 lbs or more. Next, the thermoplastic molding tape 41 is rewound and removed from the layered structure.

After removing the tape, the cured resin may be treated with a sand polisher to remove the glass from the cured resin and make the outer diameter of the composite uniform so that the polyurethane coating can be applied. In particular, when a sailboat mast is manufactured, it is desirable to polish the layered structure.

The structure and manufacturing process of the present invention are described in more detail in the following examples, but the present invention is not limited to the following examples.

In this embodiment, a sailboat mast having the above-described structure will be described in detail. The structure of the sailboat mast is as follows.

[0044]

[Table 1]

The following materials were used for the production of the mast of this example.

[0046]

[Table 2]

[0047]

[Table 3]

[0048]

[Table 4]

[0049]

[Table 5]

[0050]

[Table 6]

[0051]

[Table 7]

[0052]

[Table 8]

When manufacturing the mast of this embodiment, FIG.
The mandrel is moved at a speed of 4 ft / min in the apparatus shown in Fig. 1. The mandrel is made from anodized aluminum and has six tapers as shown in Table 9 below.

[0054]

[Table 9]

At station 58A, the mixture of liquid epoxy resin and catalyst described above is poured onto the mandrel where the inner circumferential fiber component 18 is wound. By changing the winding speed of the fiber 18 around the mandrel, the circumferential rigidity and crushing strength can be adjusted. Also, by varying the amount of fiber 18, the circumferential stiffness can be adjusted according to various structure diameters and design load requirements. Next, eight distribution packages are attached to the fiber winding device 52 and rotated about the mandrel. Table 10 below shows the change in the amount of fiber 18 wrapped around the mandrel in this step.

[0056]

[Table 10]

As the mandrel traverses the braid 60, the following fiber components are wound: (1) Twelve fibers 32 equally spaced around the braid
(2) 24 fibers 36A rotating clockwise on the braid; (3) rotating counterclockwise on the braid; 2
Four fibers 36B. Fiber 36A, 36B
Rotates at 3.85 rpm. At the same time, at station 58B, the liquid epoxy resin is poured into the fibers that are assembled around the mandrel.

As the mandrel traverses the braid 61, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The fibers 36A and 36B are 3.8
It rotates at a constant speed of 5 rpm. At the same time, station 58
At C, the liquid epoxy resin is poured into the fibers that are assembled around the mandrel.

As the mandrel traverses the braid 64, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The rotation speed of the device holding the fibers 36A and 36B is 3.85 rpm. At the same time, station 5
In 8D, a liquid epoxy resin is poured into the fibers that are assembled around the mandrel.

Thereafter, the fiber component 40 is set at a speed set so as to give appropriate circumferential rigidity and crushing strength.
Wrap around the mandrel. By varying the amount of fiber 40, the circumferential stiffness can be adjusted according to the diameter and the design load of the structure. The fiber wrapping device 66 is fitted with eight dispensing packages and rotated around the mandrel as the mandrel traverses the device. Table 11 shows the change in the amount of fiber 40 that is wrapped around the mandrel in this process.

[0061]

[Table 11]

At station 58E, a mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 40 is wound. The fiber layer impregnated with the mandrel and the uncured liquid epoxy resin then passes through a tape former 68. Two 1/2 inch wide cellophane tapes (sold by Century Design Inc. of San Diego, CA) are wrapped around a mandrel at a speed of 60 rpm. After removing the mandrel and uncured layer from the traversing device 70, it is suspended vertically in a hot air convection oven and cured at 140 ° C. for 8 hours. After curing is complete, the mandrel is removed from the structure and cellophane tape is wound as described above, according to mandrel removal techniques well known to those skilled in the art.

Next, the finishing process is started, and the mast is cut to a length of 4.6 meters (however, in this case, cut off by 1 inch from the bottom of the structure, and cut off from the tip for the remaining extra length). ). The structure is polished with an 80 grit finishing paper file using a coreless wet polisher. After polishing, a 40 inch long, 14 inch wide glass fiber plain fabric (8.75 oz / yard ² E-
Glass) impregnated with an epoxy resin and a catalyst is wound around the composite structure. The cloth covers the mast from 30 inches away from the base to 70 inches from the base. After spirally wrapping the tape around the reinforced glass fiber, the composite structure is cured at 140 ° C. After curing, the tape is removed and the structure is polished again. In the final step, the structure is coated with a polyurethane paint mixed with 2% by weight of iron oxide pigment. The properties of the obtained structure were as follows.

[0064]

[Table 12]

Embodiment 2 In this embodiment, a sailboat mast having the above-described structure will be described in detail. The structure of the sailboat mast is as follows.

[0066]

[Table 13]

The following materials were used for manufacturing the structure of this embodiment.

[0068]

[Table 14]

[0069]

[Table 15]

[0070]

[Table 16]

[0071]

[Table 17]

[0072]

[Table 18]

[0073]

[Table 19]

[0074]

[Table 20]

In the sailboat mast of this embodiment, the fibers 24A and 32 are composed of a combination of two types of fiber materials. Improved resistance as well as overall flexural strength. Although the first embodiment has a five-layer structure, the present embodiment has a six-layer structure. The mandrel is made of Teflon anodized aluminum and has six tapers to have the desired stiffness distribution as well as profile (see Table 21).

[0076]

[Table 21]

By passing the mandrel through the apparatus shown in FIG. 8, a sailboat mast is manufactured. Mandrel 50
Moves through the assembly at a speed of 4 feet / minute. At station 58A, a mixture of liquid epoxy resin and catalyst is applied to the fiber component 18 on a mandrel.
Is poured where it is wound. At a speed adjusted to give adequate circumferential stiffness and crushing strength,
The fiber component 18 is wrapped around a mandrel.
By changing the amount of the fiber 18 according to the variation of the diameter or the design load of the structure, the rigidity in the circumferential direction can be maintained at an appropriate value. Fiber winding device 5
Attach 8 dispensing packages to 2 and rotate them around a mandrel that moves laterally through the device. Table 22 below
Fiber 18 wrapped around the mandrel
Shows the change in the amount of

[0078]

[Table 22]

The mandrel then passes through four building stations having the same yarn components and fiber arrangement. Hereinafter, the braiding unit 61 of FIG. 8 will be described in detail, but the braiding units 60, 62, and 63 have the same configuration. At station 58C, the fibers are assembled around the mandrel and the liquid matrix component is poured into the fibers. As the mandrel traverses the braid 61, the following fiber components are wound:
(1) A total of 24 fibers 24A paired and equally spaced around the mandrel: 18 E-glass 450 type 30 lobing and 6 carbon fibers of 12k G30500 (2) Around braid A total of 48 fibers 32: 450 type 30 lobing E-glass and 12k G305 equally spaced.
12 carbon fibers of 00 (3) 24 fibers 36A rotating clockwise on the braid, 24 fibers 36A rotating counterclockwise on the braid
B. The rotation speed of the fibers 36A and 36B is 3.85.
It is set to a constant speed of rpm.

Next, at station 58D, the fibers are assembled around the mandrel, and the liquid matrix component is poured into the fibers. Thereafter, the fiber component 40 is wound around the mandrel at a speed set to provide appropriate circumferential stiffness and crushing strength. By varying the amount of fiber 40, the circumferential stiffness can be adjusted according to the diameter and the design load of the structure. The fiber winding device 66 has 8
Install the base dispensing package and rotate it around the mandrel as it traverses the device. In Table 23,
5 illustrates a change in the amount of fiber 40 wrapped around a mandrel.

[0081]

[Table 23]

At station 58E, the mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 40 is wound. The fiber layer impregnated with the mandrel and the uncured liquid epoxy resin then passes through a tape former 68. Two 1/2 inch wide cellophane tapes (sold by Century Design Inc. of San Diego, CA) are wrapped around a mandrel at a speed of 60 rpm. After removing the mandrel and uncured layer from the traversing device 70, it is suspended vertically in a hot air convection oven and cured at 140 ° C. for 8 hours. Using a mandrel removal device, remove the mandrel from the structure and wind the cellophane tape as described above. The resulting mast is cut to a length of 480 centimeters (however, in this case cut off one inch from the bottom of the structure and the remaining excess length from the tip). Using a coreless wet polishing machine, the mast is
Polish with a grit finishing paper file. After polishing, 2
Polyurethane paint mixed with black iron oxide pigment by weight
Cover the mast. The properties of the obtained structure were as follows.

[0083]

[Table 24]

Embodiment 3 Curved Structural Member: Sailing Boom This embodiment describes a method of manufacturing and designing a circular pipe having a curved cross section. The dimensions of the tube manufactured in this embodiment are as follows. Tube length: 180 cm Tube inner diameter: 2.67 cm The tube is composed of the following three integrally molded parts. (1) Straight shim = length 42 cm (2) Curve shim = radius 16 inches: angle 41 角度 (3) Straight part = length 12 inches The structure of this embodiment is made of the same material as the structure of the first embodiment. It is configured. The mandrel used in this embodiment is 8
Made from 0 durometer silicone rubber cord,
It has a constant outer diameter of 1.05 inches.

When manufacturing a curved tube such as a sailboat boom, the mandrel moves in a device similar to that of FIG. 8 except that only two braiding devices 61 and 64 are incorporated. The mandrel 50 moves through the assembly at a speed of 4 feet / minute. At station 58A, the mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 18 is to be wound. The fiber component 18 is wound clockwise around the mandrel at a speed of 50 rpm. Attach eight dispensing packages to the fiber winding device 52 and rotate them around a mandrel that moves laterally through the device.

As the mandrel traverses the braid 61, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. In this case, the rotation speed of the fibers 36A and 36B is set to a constant speed of 3.85 rpm. at the same time,
At station 58C, the liquid matrix component is poured into the assembling fibers around the mandrel.

As the mandrel traverses the braid 64, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The rotation speed of the fibers 36A and 36B is 3.85.
It is set to a constant speed of rpm. At the same time, at station 58D, the liquid matrix material is poured into the fibers that are assembled around the mandrel.
Thereafter, the fiber component 40 is fed at a speed of 50 rpm.
Wind counterclockwise around the mandrel.

At station 58E, the mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 40 is wound. The fiber layer impregnated with the mandrel and the uncured liquid epoxy resin then passes through a tape former 68. Two 1/2 inch wide cellophane tapes (sold by Century Design Inc. of San Diego, CA) are wrapped around a mandrel at a speed of 60 rpm. After removing the mandrel and the uncured layer from the traversing device 70, the mandrel and the uncured layer are fixed to a jig or a mold that determines the contour of the curved portion. The jig is placed in a hot air convection oven and cured at 140 ° C. for 8 hours. Using a mandrel removal device well known to those skilled in the art, remove the silicone mandrel from the structure and wind the cellophane tape as described above. The properties of the obtained structure were as follows.

[0089]

[Table 25]

Embodiment 4 Hereinafter, an example of a composite structural member designed to withstand a combination of bending load and torsional load will be described. The dimensions of the final composite structure are as follows.

[0091]

[Table 26]

The structure of this embodiment is made of the same material as the structure of the first embodiment. Also in this embodiment, FIG.
The same manufacturing equipment as shown in is used,
It has been changed as follows. (1) Four braids are used instead of three braids. (2) Except for the braid 60 and the packages 62B and 62A, the two braids and yarn packages are rotatable about the axis 100 up to a 56 degree angle. The manufacturing method of the structure of this embodiment will be described in detail with reference to FIG.
The mandrel used in this example is made of Teflon anodized aluminum, whose diameter is constant,
1.00 inches. The mandrel 50 moves through the assembly at a rate of 2 feet / minute. At station 58A, the mixture of liquid epoxy resin and catalyst is
It is poured onto the mandrel where the fiber component 18 is to be wound. Fiber component 18 is 7.5
At a speed of rpm, the mandrel is wound counterclockwise. Attach 16 dispensing packages to the fiber winding device 52 and rotate them around a mandrel that moves laterally through the device.

As the mandrel traverses the braid 60, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The rotation speed of the fibers 36A and 36B is 1.9r
pm. At the same time, station 5
At 8B, the liquid matrix component is poured into the fibers that are assembled around the mandrel.

As the mandrel traverses the braid 61, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The rotation speed of the fibers 36A and 36B is 1.9r
pm is set. Furthermore, the whole braid
Rotate clockwise at a speed of 7.5 rpm. at the same time,
At station 58C, the liquid matrix component is poured into the assembling fibers around the mandrel.

As the mandrel crosses the second braid 61, the following fiber components are re-wound:
(1) 24 fibers 24A equally spaced in pairs around the mandrel (2) 48 fibers 32 (3) equally spaced around the braid
24 fibers 3 rotating clockwise on the braid
6A (4) 24 fibers 36B rotating counterclockwise on the braid. The rotation speed of the fibers 36A and 36B is set at a constant distance of 1.9 rpm. at the same time,
At a second station 58C, the liquid matrix component is poured into the fibers that are assembled around the mandrel.

As the mandrel traverses the braid 64, the following fiber components are wound: (1) 24 fibers 24A equally spaced in pairs around the mandrel; (2) 48 fibers 32 equally spaced around the braid; and (3) clockwise on the braid. 24 fibers 36A rotating counterclockwise on the braider (4)
B. The rotation speed of the device holding the fibers 36A and 36B is set to a constant speed of 1.9 rpm. Further, the entire braid rotates counterclockwise at a speed of 7.5 rpm.

The second assembling device 61 added to the apparatus of this embodiment is not shown in FIG. 8, but is the same as the assembling device 60. Further, at station 58D, the liquid matrix component is poured into the fibers that are assembled around the mandrel. Thereafter, the fiber component 40 is wound clockwise around the mandrel at a speed of 1.9 rpm. At station 58E, the mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 40 is wound. The fiber layer impregnated with the mandrel and the uncured liquid epoxy resin then passes through a tape former 68.
Two 1/2 inch wide cellophane tapes (sold by Century Design Inc. of San Diego, CA) are wrapped around a mandrel at a speed of 30 rpm. After removing the mandrel and uncured layer from the traversing device 70, it is suspended vertically in a hot air convection oven and cured at 140 ° C. for 8 hours.
Remove the mandrel from the structure using the mandrel removal device. Next, the tape is wound by the method described above. The properties of the obtained structure were as follows.

[0098]

[Table 27]

Embodiment 5 This embodiment is an example of a composite structural member designed to withstand a combination of bending load and torsional load. The structure is manufactured continuously. The following materials were used for manufacturing the structure of this example.

[0100]

[Table 28]

[0101]

[Table 29]

[0102]

[Table 30]

[0103]

[Table 31]

[0104]

[Table 32]

[0105]

[Table 33]

In the present embodiment, a curing accelerator is added as a catalyst so that the matrix can be sufficiently cured while the composite moves in the die assembling apparatus. The resins used in this example are as follows. Epoxy resin: Der 330 (manufactured by Dow Chemical Company) Catalyst: AC-DP-1 (manufactured by Anhydrides & Chemicals Company) The die used in this example is made of tool steel and has an inner diameter of 3.1 cm. . The inner surface of the die is chrome plated and finished to 25 RMS. The length of the die is 75 cm and is heated and maintained at a temperature of 150 ° C. throughout the manufacturing process. The dimensions of the composite structure manufactured in this example are as follows.

[0107]

[Table 34]

In the present embodiment, the same apparatus as that shown in FIG. 8 is used, but modified as follows. (1) One braiding device is disposed in front of the winding station 52. (2) One braid installed after the station 52 rotates clockwise at a speed of 7.5 rpm. Thereafter, the third and fourth braiding devices are installed. (3) Braider # 5 rotates counterclockwise at a speed of 7.5 rpm. (4) A filament winding station similar to the station 66 shown in FIG. 8 is incorporated. (5) Instead of the tape forming machine 68, a heating die having a length of 75 cm is used. (6) A chop saw for cutting the composite portion into a desired length is incorporated. The composite structure of the present invention is manufactured as follows. The mandrel used in this example is made of Teflon anodized aluminum, whose diameter is constant,
1.00 inches. The mandrel is supported by a cantilever in front of the first braiding device. The composite material moves through the heating die at a rate of 2 feet / minute.
The mixture of the liquid epoxy resin and the catalyst, on the mandrel,
It is poured where the fiber components 24A, 32, 36A, 36B are wound.

As the mandrel traverses the first braid # 1, the following fiber components are wound: (1) 2 equally spaced pairs around the mandrel
24 fibers 36A rotating clockwise on the 48 fibers 32 (3) braids equally spaced around the four fibers 24A (2) braid.
(4) 24 fibers 36B rotating counterclockwise on the braid. The rotation speed of the fibers 36A and 36B is set to a constant speed of 1.9 rpm. Further, the whole braider # 1 rotates clockwise at a speed of 7.5 rpm. At station 58A, the mixture of liquid epoxy resin and catalyst is mixed with fiber component 1 on a mandrel.
8 is poured where it is wound. The fiber component 18 is wound around the mandrel at a speed of 7.5 rpm in a counterclockwise direction. Fiber winding device 52
Attach 16 dispensing packages and rotate them around a mandrel that moves laterally through the device.

As the mandrel traverses the second braid # 2, the following fiber components are wrapped: (1) 2 equally spaced pairs around the mandrel
Twenty-four fibers 36A (4) rotating clockwise on 48 fibers 32 (3) braids equally spaced around the four fibers 24A (2) braid.
Twenty-four fibers 36B rotating counterclockwise on the braid. The rotation speed of the fibers 36A, 36B is 1.
It is set to a constant speed of 9 rpm. At the same time, the liquid epoxy resin is poured into the fibers that are assembled around the mandrel by the braiding device.

As the mandrel traverses braids # 3 and # 4, the following fiber components are wound: (1)
Twenty-four fibers 24A (2) equally spaced around the mandrel in pairs and 48 fibers 32 (3) equally spaced around the braid, rotating clockwise on the braid. , 24 fibers 36A
(4) 24 fibers 36B rotating counterclockwise on the braid. The rotation speed of the fibers 36A and 36B is set to a constant speed of 1.9 rpm. At the same time, the liquid epoxy resin is poured into the fibers assembled around the mandrel by the assemblers # 3 and # 4.

As the mandrel crosses braider # 5, the following fiber components are re-wound: (1) 24 pairs equally spaced around the mandrel
24 fibers 36A (4) rotating clockwise on 48 fibers 32 (3) braids equally spaced around fibre 24A (2) braid
Twenty-four fibers 36B rotating counterclockwise on the braid. The rotation speed of the fibers 36A, 36B is 1.
It is set to a fixed distance of 9 rpm. Further, the whole braider # 5 rotates counterclockwise at a speed of 7.5 rpm.
At the same time, the liquid epoxy resin is poured into the fiber assembled around the mandrel by the fifth assembler # 5. Then, the fiber component 40 was changed to 7.5 rp.
Wind clockwise around the mandrel at a speed of m. At station 58E, the mixture of liquid epoxy resin and catalyst is poured onto the mandrel where the fiber component 40 is wound.

The fiber layer impregnated with the mandrel and the uncured liquid epoxy resin then passes through a steel die well known to those skilled in the art. The die has a 3.2 cm diameter hole and is heated to 150 ° C. The layered composite is sufficiently cured while moving through the die. After confirming that the structure has been sufficiently integrated, it is cut to a desired length with a cut-off saw well known to those skilled in the art. Further, it is placed in a heating oven and heated at 150 ° C. for 2 hours so as to give a sufficient catalytic effect to the matrix material. The properties of the obtained structure were as follows.

[0114]

[Table 35]

As is clear from the above description, the above-mentioned object (including those that are clearly described and those that can be read from the detailed description of the invention) is achieved by the structure of the present invention.
Achieved. Further, it is a matter of course that the above-described manufacturing process and the configuration of the composite structure can be variously changed without departing from the gist of the present invention, and the above-described embodiments and the accompanying drawings do not limit the present invention in any way. Rather, they are merely illustrative of the present invention. The following claims describe the general as well as certain features of the present invention, from which the gist of the present invention may be read.

[0116]

According to the present invention, it is possible to provide a composite structure having a layered arrangement giving a large strength, particularly a large bending strength. Further, according to the present invention, it is possible to provide an elongated composite structure member having high strength and light weight. Further, according to the present invention, a simple and efficient method for manufacturing such a composite structural member can be provided.

[Brief description of the drawings]

FIG. 1 is a partially broken side view of a composite member according to the present invention manufactured using a removable mandrel.

FIG. 2 is a cross-sectional view showing an innermost layer of the composite in the process of forming the composite member of the present invention.

FIG. 3 is a cross-sectional view showing an axial first fiber constituting a part of the innermost layer and the intermediate layer in the process of forming the composite member of the present invention.

FIG. 4 is a cross-sectional view showing an innermost layer and a middle layer in the process of forming the composite member of the present invention.

FIG. 5 is a cross-sectional view of the composite member of the present invention comprising an inner layer, an intermediate layer, and an outer layer.

FIG. 6 is a partial detailed sectional view of the intermediate layer of FIG. 4;

FIG. 7 is a schematic view of a sailboat mast manufactured from the composite member of the present invention.

FIG. 8 is a schematic view showing a method for manufacturing a composite structural member according to the present invention.

FIG. 9 is a graph showing the relationship between composite member length and maximum bending strain for various composite structures.

FIG. 10 is a cross-sectional view showing one of the axial braided filaments obtained by rotating the cross-section of the composite member of FIG. 6 by 90 °.

[Explanation of symbols]

10. composite member, 14 matrix, 16 inner layer, 18 fiber component, 20 shaft, 22 intermediate layer, 24 fiber component, 26 set, 28
Air gap, 30 fiber component, 32 fiber
34 pairs, 36 fibers components, 38 outer layers,
40 fiber component, 41 thermoplastic tape, 4
2. Spar, 43. Fiber, 44. Tubular post, 46. Boom part, 49 .. Composite assembly device, 50
..Mandrels (models), 52. Stations, 54.
· Fiber package, 56 · · transverse direction, 58A
~ E ... Resin coating device (station), 60 ~ 64,
66 station, 68 tape winding device,
70 .. transverse feeder, 100 .. axis.

Claims (21)

[Claims] 1. A composite structural member comprising a plurality of layers, each layer including a fiber component disposed within a polymer matrix, said composite member comprising: B. at least one inner layer comprising circumferentially extending fibers; B. at least one outer layer comprising circumferentially extending fibers; i) a first fiber extending in the axial direction, which is combined with a plurality of fibers at intervals in the circumferential direction so as to form a circumferential gap between each pair; and ii) disposed in the circumferential gap. At least one intermediate layer comprising: a second fiber that is provided, and is combined with each other at a plurality of circumferentially spaced intervals, and is axially elongated, and is intermingled with a helical fiber. The inner layer,
A composite structural member, wherein the outer layer and the intermediate layer form a rigid and elongated composite structural member such that the outer layer and the intermediate layer have a predetermined wall thickness over the entire length of the member. 2. The composite structural member according to claim 1, wherein a contribution rate of each of the inner layer and the outer layer to the total elastic modulus of the composite is less than 25%. 3. The composite structural member according to claim 2, wherein the intermediate layer includes three layers. 4. The composite structural member of claim 1, wherein the diameter of the circumferentially extending fiber is between 0.007 inches and 0.040 inches. 5. The composite structural member of claim 4, wherein the diameter of the axially extending fiber is between 0.007 inches and 0.040 inches. 6. The composite structural member of claim 1, wherein the diameter of the helical fiber is less than 25% of the diameter of the axially extending fiber. 7. The fiber extending in the circumferential direction,
Aramid fiber, carbon fiber, graphite fiber with a coefficient of more than 10 million psi,
The composite structural member according to claim 1, wherein the composite structural member is selected from the group consisting of glass fiber. 8. The fiber extending in the axial direction,
The composite structural member according to claim 1, wherein the composite structural member is selected from carbon fiber, graphite fiber, glass fiber, ceramic fiber, boron fiber, and aramid fiber having a coefficient of 12 million psi or more. 9. The helical fiber according to claim 1, wherein
The composite structural member according to claim 1, wherein the composite structural member is selected from an aramid fiber, a carbon fiber, a glass fiber, and a graphite fiber having a coefficient of 100,000 psi or more. 10. The fiber extending in the circumferential direction,
The composite structural member according to claim 1, wherein the composite structural member is disposed at an angle of ± 30 ° to ± 90 ° with respect to the longitudinal axis of the member. 11. The fiber extending in the axial direction,
The composite structural member according to claim 10, wherein the composite structural member is disposed at an angle of about 0 ° with respect to the longitudinal axis of the member. 12. The composite structural member according to claim 11, wherein the helical fibers are arranged at an angle of ± 15 ° to ± 60 ° with respect to a longitudinal axis of the composite member. 13. The composite structural member according to claim 1, wherein said polymer matrix comprises a material selected from epoxy, polyester, and vinyl ester. 14. The polymer matrix according to claim 1, wherein the polymer matrix comprises a material selected from the group consisting of polyphenylene sulfide, polysulfone, polyethylene terephthalate, polypropylene, polycarbonate, acetal, nylon, and polyetheretherketone. 2. The composite structural member according to 1. 15. The composite structural member according to claim 14, wherein a volume ratio between the polymer matrix resin and the fiber is 50% or less. 16. The composite structural member according to claim 1, wherein the composite structural member has a bending strength of not less than 0.25% of maximum lamination strain. 17. A sailing mast formed from the composite structural member of claim 1. 18. A whip antenna case formed from the composite structural member according to claim 1. 19. A method for manufacturing a composite structural member, comprising: B. Cover the circumference of the elongated mandrel with circumferentially extending fiber and liquid polymer resin to form a first layer; B. placing a plurality of first fibers extending in the axial direction and a liquid polymer resin on the first layer to form a first portion of the intermediate layer; A. placing on said first portion a plurality of second fibers intermingled with helical fibers and extending axially and a liquid polymer resin to form a second portion of the intermediate layer; B. An outer layer is formed by placing fibers extending in the circumferential direction and a liquid polymer resin on the intermediate layer; Covering said outer layer with molding wrap; F. A method of curing a member at a high temperature. 20. Further, A. After the curing is completed, the molding wrap is removed from the member; 20. The method according to claim 19, wherein the mandrel is removed from the member after the completion of the curing. 21. The method according to claim 19, wherein the intermediate layer is formed in three layers.