JP2004502573A - Core-containing shaped composite structural member and method of manufacturing the same - Google Patents

Abstract

A core-shaped shaped composite structural member (2) and a method for manufacturing the same are provided.
A structural member (2) is a shaped structure, includes an inner material (4) and an outer material (8), and has an intermediate support structure or stabilizing structure (6). The shaping structure of the structural member (2) is such that the inner composite material (4) and the outer composite material (8), and the intermediate support structure (6) are tube-rolled, i.e., rolled, and then if necessary. They can be formed by bonding or connecting them. For shaped structures that are not entirely flat, the applications of the structural member (2) of the present invention are almost endless.
[Selection diagram] Fig. 1

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
This application claims the benefit of US Provisional Patent Application No. 60 / 216,636. By reference to this patent application, the content disclosed in this patent application is incorporated herein.
[0002]
The present invention relates to a structural member and a method for manufacturing the same. In particular, the present invention relates to a cored shaped composite part and a method for producing the same.
[0003]
[Prior art]
In recent years, the use of lightweight composite materials has been increasingly emphasized. One use of such composites is to improve the efficiency of automobiles. To that end, the United States Government and the United States Automobile Research Committee (USCAR), representing DaimlerChrysler, Ford and General Motors, have partnered to form a partnership for the New Generation Vehicle (PNGV). One goal of PNGV is to develop technologies such as hybrid technology, which provide today's affordability, performance, and safety, yet are environmentally friendly vehicles with up to three times the fuel efficiency. Can be used to manufacture For example, PNGV has improved the fuel efficiency of today's vehicles from about 11.90 km / l (28 mpg) to about 35.29 km / l (83 mpg) and has the current vehicle gross weight (1.47 t (3200 pounds)). Is required to be reduced by 40% to 60%.
[0004]
One way to improve fuel efficiency is to reduce the weight of today's vehicles and use lightweight materials. Materials such as steel and aluminum used in today's vehicles are extremely heavy when compared to composite materials, but have tensile, compressive, flexural, interlaminar and in-plane shear strengths, and vehicle design considerations. It was necessary to provide sufficient structural properties, including other mechanical and material properties to meet the requirements.
[0005]
Many other uses for lightweight composites are for assisting in or replacing structural materials such as steel, cast iron, and aluminum. These applications include buildings, bridges, recreational vehicles, aerospace, defense, and sports equipment, as well as many other applications.
[0006]
A composite material is macroscopically a mixture or combination of one or more materials that are solid in their final state, incompatible with each other, and differ in chemical properties. Types of composites include layered, granular, fibrous, flaked, and filled composites. However, composite materials often do not have the structural properties mentioned above and / or the low cost combinations necessary for them to be widely used in the automotive industry and other applications.
[0007]
One way to improve the structural properties of the composite, especially to increase its torsional or flexural strength, is to make the composite structurally more efficient. One form of high structural efficiency is to combine composite materials by sandwiching a support structure, such as a honeycomb or foam structure, between panels of the composite material. Examples of such combinations are described in US Pat. No. 5,006,391, US Pat. No. 5,195,779, US Pat. No. 5,652,039, US Pat. No. 5,834,082, US Pat. See U.S. Patent No. 5,848,767; U.S. Patent No. 5,849,122; and U.S. Patent No. 5,875,609. By reference to these patents, the contents disclosed in these patents are incorporated herein. However, such combinations are generally limited to generally flat structures, which greatly limits the use of such materials.
[0008]
[Problems to be solved by the invention]
The present invention provides a core-shaped shaped composite structural member and a method of manufacturing the same.
[0009]
[Means for Solving the Problems]
The shaped structural member includes a composite material sandwiching a support or stabilizing structure. The shaping structure can be provided by tube-rolling (ie, roll-wrapping) the composite material and the support structure together, and then, if necessary, joining or joining these materials. With a shaped overall non-flat structure, there is almost no limit to the use of the structural member of the present invention.
[0010]
1 to 11 show only some, but not all, of the structural members and their manufacturing method in connection with the following description.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
The following description provides specific details for a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without these specific details. Indeed, the present invention can be practiced by modifying the illustrated structural members and methods, and can be used in connection with equipment and techniques conventionally used in the industry.
[0012]
FIG. 1 shows one shaped structural member according to the invention, a tubular member having a substantially circular cross section. In the description of the present invention, a "shaped" structural member is any shape, size, or configuration, wherein at least a portion of the outer or inner periphery of such a member is not substantially flat, curved, geometric, Including geometric or irregular shapes. Preferably, the shaped components have a closed surface feature, such as a surface, that facilitates manufacturing these shaped components as described below. In the description of the present invention, a "closed" structural member is a structural member having any shape, size, and configuration, wherein at least a portion of the surface (inner and / or outer) of such a member is substantially. , That is, substantially continuous. Examples of closed features include tubular features, spherical features, polygonal features, conical features, or other similar shapes, as well as features shown and described below.
[0013]
The structural member of the present invention may comprise a cylindrical or non-cylindrical shape such as a cone, a pyramid, a pod, a hemisphere, or a sphere. The structural member of the present invention may further have a circular or non-circular cross-section such as a rectangle, square, hexagon, octagon and the like. The structural member of the present invention may further comprise a highly irregular, non-closed, substantially flat surface. Indeed, the structural member of the present invention may include any complex shaped shape or combination of shaped shapes. The structural members of the present invention are characterized in that they are not substantially flat, thereby distinguishing them from the well-known sheet core composites.
[0014]
In FIG. 1, the tubular structural member 2 comprises an inner section or section 4, an intermediate section or section 6, and an outer section or section 8. Inner portion 4 and outer portion 8, and optional core region 10, are formed of any suitable composite material, as described below. The intermediate part 6 is a cored structure, which is attached to, supports and / or stabilizes the inner and outer parts.
[0015]
The core region 10 is located within the inner section of the structural member 2 and is approximately the same size as the substrate or mandrel used in forming the structural member, as described below. The core region 10 may be of any suitable size, determined primarily by the removable mandrel in the manufacturing process used to form the structural member 2 and the configuration of the structural member 2 and the desired end use of the structural member 2; It may be in shape or form. The core region 10 may be hollow, but may optionally be partially or completely filled with any desired core material, such as foam, plastic, conductors, insulators, metals, and the like. The core region 10 including the core material may be a structural element. The core material may be added after the formation of the structural member 2 or may be integrally formed with the structure. If the core material 12 is added after the formation of the structural member 2, it may be attached to the structural member 2 using an adhesive or other suitable bonding means known in the art.
[0016]
The material for the inner section 4 and the outer section 8 can be the same or different. Preferably, the inner part 4 and the outer part 8 are made of the same material. Suitable materials include any reinforced resin matrix material (PPMM). This material is a resin matrix material (RMM) with embedded continuous or discontinuous reinforcement material. In one aspect of the invention, the RMM is an organic resin matrix material (ORMM). See, for example, U.S. Patent Nos. 5,725,920 and 5,309,620. By reference to these patents, the contents disclosed in these patents are incorporated herein.
[0017]
In one aspect of the invention, the ORMM may be a thermosetting resin. Thermosetting resins are polymeric materials that cure irreversibly when heated. Examples of thermosetting resins include epoxy, bismeleimide, polyester, phenolic resin, polyimide, melamine, xylene, urethane, phenolic resin, furan resin, silicone, vinyl ester, and alkyd resin, or combinations thereof. It is. Thermosetting resins can contain various additives well known in the art, such as crosslinking agents, curing agents, fillers, binders, or UV inhibitors. In the present invention, preferably, an epoxy resin, a vinyl ester resin, or a polyester resin is used as the thermosetting resin.
[0018]
In another aspect of the invention, the ORMM may be a thermoplastic matrix material. Thermoplastics are polymeric materials that do not irreversibly cure when heated and, for example, soften when exposed to heat and then return to their original state when cooled. Examples of the thermoplastic resin include polypropylene, polyethylene, polyamide (nylon), polyester (PET, PBT), polyetherketone (PEK), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), and polyphenylene oxide (PPO). And an alloy thereof, and a polyvinyl resin, or a combination thereof. Thermoplastics can contain various additives known in the art, such as crosslinking agents, curing agents, fillers, binders, or UV inhibitors. In the present invention, preferably, a polyamide (nylon) resin, a polyester resin, a polycarbonate resin, and a polypropylene resin are used as the thermoplastic resin.
[0019]
The material used to reinforce the RMM of the present invention may be any form that reinforces the resin matrix. Examples of reinforcement forms include unidirectional tapes, multidirectional tapes, woven fabrics, roving fabrics, matte fabrics, preforms, fibers, filaments, whiskers, and combinations thereof. The type of material used for strengthening the RMM may be any type that performs such a strengthening function. Preferably, the form of reinforcement material for the resin matrix is a fibrous material, such as continuous or discontinuous fibers. Examples of materials that can be used in the present invention include glass-s, glass-e, aramid, graphite, carbon, ultra high molecular weight polyethylene, boron, silicon carbide, ceramic, quartz, metal, isotropic metals (aluminum, magnesium, And titanium), metal-coated composites, CAMP, and combinations of these fibers. See, for example, U.S. Patent No. 6,117,534. By reference to this patent, the disclosure of that patent is hereby incorporated by reference.
[0020]
In one aspect of the invention, an uncured or partially cured composite material is used as the material for the inner and / or outer sections. A composite material is, macroscopically, a mixture or combination of two or more materials whose final state is a solid, incompatible and of different chemical properties. The present invention can use any composite material known in the art, such as layered, granular, fibrous, flaked, and filled composites. The uncured or partially cured composite is a continuous fiber reinforced ORMM (thermoset or thermoplastic).
[0021]
Preferred composite materials used for the inner section 4 and the outer section 8 include B-stage prepreg materials, typically in the form of sheets or laminates, which comprise a plurality of fiber reinforced tows with a predetermined formulation of resin. It can be formed by impregnation. Methods for producing B-stage prepreg sheets and these sheets themselves are well known. See, for example, the sheet described in U.S. Pat. No. 4,495,017. By reference to this patent, the disclosure of that patent is hereby incorporated by reference. Prepreg materials, when cured, are generally stronger and stiffer than metals and exhibit great resistance to fatigue, chemicals, abrasion, and corrosion. Preferred reinforcements for prepregs include aramid, glass materials, nickel carbide, ceramic, carbon, and ultra high molecular weight polyethylene, or combinations thereof. For example, US Pat. No. 4,968,545, US Pat. No. 5,102,723, US Pat. No. 5,499,661, US Pat. No. 5,579,609, and US Pat. See No. 920. By reference to these patents, the contents disclosed in these patents are incorporated herein. Carbon, glass, metals, and isotropic metals, particularly aluminum, magnesium, and titanium, metal-coated composites, and aramid fibers, or combinations thereof, can also be used as fibers. See, for example, U.S. Patent Nos. 5,601,892 and 5,624,115. The contents disclosed in these patents are incorporated herein. In the present invention, preferably, aramid fibers and more preferably Kevlar 29 or 49 fibers are used.
[0022]
The volume of fibers in the prepreg can be varied to maximize mechanical, electrical, and thermal properties. For example, the disclosure of U.S. Pat. No. 5,848,767 is incorporated herein. A high fiber volume results in rigidity and, in the case of heat-conducting fibers, a high thermal conductivity of the component. The volume of the fibers in the present invention is in the range of about 5% to about 95%, preferably in the range of about 50% to about 65%. The fibers of the prepreg can be oriented within the prepreg material in any desired direction from about 0 ° to 90 °, as is well known in the art, with the same number of fibers being balanced in both directions. See, for example, U.S. Patent No. 4,926,721. By reference to this patent, the disclosure of that patent is hereby incorporated by reference.
[0023]
In yet another aspect of the present invention, sheet molding compounds (SMCs) can be used as the material for the inner or outer portion. The SMCs area sheet is made of a B-stage thermoset resin reinforced with discontinuous fibers. SMCs are fully compounded ORMM compounds, typically comprising discontinuous fiber reinforced materials formed into sheets, plies, or laminates, and require no further preparation. See, for example, U.S. Patent No. 6,103,032. By reference to this patent, the disclosure of that patent is hereby incorporated by reference. Resins that can be used in the SMCs of the present invention include any of the thermosetting resins listed above. Preferably, polyester resins or vinyl esters are used as the resin of the SMCs of the present invention. Fibers that can be used in the SMCs of the present invention include any of the fibers listed above. Preferably, glass fibers, carbon fibers or aramid fibers, preferably Kevlar 29 or 49 fibers, can be used as fibers of the SMCs. The fiber volume of the SMC may also be varied to maximize mechanical and thermal properties.
[0024]
When unsaturated resin is used as the base material, SMCs must have the desired physical properties and mechanical properties such as mechanical strength, impact resistance, rigidity, and dimensional stability. Other materials are incorporated to obtain. Incorporated materials include polymers, reinforcing fibers, resins, fillers, initiators that promote polymerization, viscosity agents, lubricants, release agents, catalysts, thickeners, pigments, polyethylene powder, flame retardants, ultraviolet light Absorbents and other additives are included. Each of these additives imparts important properties to the SMC, either during the processing or molding steps, or in the finished part, and can be incorporated into the SMCs of the present invention.
[0025]
Inner section 4 and outer section 8 include at least one such ORMM material. One layer is sufficient to form each of the inner or outer sections and to provide the desired structural properties to the structural member 2. By adding additional layers, the strength, stiffness, or other physical properties of the structural member 2 can be improved. A single layer containing fibers of complementary orientation can be used. However, it is preferred to use a plurality of layers of complementary orientation to balance the intrinsic stresses of the layers comprising the sections obtained when the B-stage material is fully cured, as described below. In order to be complementary, the fibers of successive layers must be symmetric and balanced as shown in FIG. 2 (for example, the fibers of the overlapping layers may be offset from the axis of the sheet By shifting by an equal and opposite amount). The fibers can be further oriented to match the design parameters of the components into which they are incorporated, for example, to optimize the structural strength for expected loads. The fibers can be at any suitable angle ranging from about 0 ° to about 90 °, including ± 15 °, ± 30 °, ± 45 °, ± 60 °, and ± 75 °, or as known in the art. Orientation. For example, U.S. Reissue Patent Re. See 35,081 and U.S. Patent 5,061,583. By reference to these patents, the contents disclosed in these patents are incorporated herein.
[0026]
The configuration of the inner part 4 and the outer part 8 can be varied within the structural member 2. For example, the materials used (both fibers and resins), the orientation of the fibers, and the curvature, thickness, shape and other characteristics of the inner and / or outer parts (4, 8) may be determined by the length of the structural member 2 It may vary along its length and width. See, for example, U.S. Patent No. 5,718,212. By reference to this patent, the disclosure of that patent is hereby incorporated by reference.
[0027]
The intermediate portion 6 of the structural member 2 of the present invention separates and / or supports the inner portion 4 and the outer portion 8 and any that enhances the structural properties of these two portions when disposed therebetween. Having a structure. Further, the intermediate section 6 may be formed of any suitable material that separates, supports, stabilizes, connects and attaches the inner portion 4 with respect to the outer portion 8. By arranging the intermediate section 6 between the inner section 4 and the outer section 8, the structural properties are improved according to well-known principles of mechanical engineering, and the mechanical structural properties of the structural member 2 are substantially the same, joined together. It is higher than the characteristics of a member consisting only of the inner section 4 and the outer section 8 of the shape. Preferably, as shown in FIG. 1, the intermediate portion is substantially in contact with the outer surface of the inner section 4 and the inner surface of the outer section 8, for example, the intermediate section 6 has most (but not all) of its surface. And at a point separate from the inner section 4 and / or the outer section 8.
[0028]
In one aspect of the invention, the intermediate portion 6 comprises a rib structure (RS), or an outer (or inner) portion, from where a single member (rib) of the structure is adjacent to the inner (or outer) portion. It has a structure that extends continuously to a close location. In another aspect of the invention, the RS has a structure in which one end of the rib is connected to a position close to at least one inner (or outer) layer and the other end is in contact with or connected to another rib. is there. Examples of these RSs include corrugated materials, posts, curved materials, honeycomb cones, and the like. These structures, as well as other RSs, are shown in FIG.
[0029]
RS is advantageous because the added weight NITUITE, the structural properties of the structural member, is often greatly improved. The RS contains a large volume of "ribs" and voids. The “ribs” of the RS enhance the structural characteristics of the structural member, where cavities are provided to minimize the weight of the RS. The respective amounts of ribs and voids present in the RS used in the present invention will depend on the configuration of the selected RS, for example, the configuration shown in FIG. Preferably, if the required (or desired) structural strength of the RS or structural member is obtained, the amount of void space should be maximized and the amount of ribs minimized to provide maximum strength with minimum weight. Must.
[0030]
The RS used in the present invention can be incorporated into a structural member in any suitable manner. In one aspect of the invention, the RS may be incorporated as a stand-alone "rib" extending from at least one inner layer to at least one outer layer, such as the configuration shown in FIG. In another aspect of the invention, the ribs can be connected to a support sheet or other ribs, where the sheet or other ribs themselves are connected to at least one inner and outer layer.
[0031]
If desired, additional materials can be incorporated into the rib structure. Examples of additional materials that can be incorporated and filled into the RS include, besides air, materials such as resins, foams, insulators, or NVH (noise, vibration, or roughness) reducing materials.
[0032]
RS is not necessarily a uniform structural member. In one feature of this embodiment, the type of RS rib may vary from position to position. Further, multiple types of RSs can be incorporated into at least one intermediate layer. In another aspect of the invention, the periodicity and / or thickness of the ribs can be varied in different regions of the at least one intermediate layer. In another aspect of the invention, the strength and other physical properties of the ribs can be varied with location.
[0033]
The RS ribs can be formed of any suitable material that exhibits the desired structural properties. Any material known in the art that provides such a function includes materials having individual compartments such as beads, corrugated materials, thermoplastic molding materials, honeycomb materials, wood (balsa), and rigid foam plastics. Foams, polymer foams, metallic components, or any combination of these materials are included. For example, US Pat. No. 5,344,038, US Pat. No. 4,573,707, US Pat. No. 5,562,981, US Pat. No. 4,128,963, US Pat. No. 4,968,545. And U.S. Patent No. 5,894,054. By reference to these patents, the contents disclosed in these patents are incorporated herein.
[0034]
The preferred intermediate portion 6 can be formed using honeycomb materials (known as honeycomb cores), such as paper or aluminum foil, typically formed in various random or geometric compartment shapes. Made of one or more thin sheets of the same material. See U.S. Patent No. 5,876,654. By reference to this patent, the disclosure of that patent is hereby incorporated by reference. It is well known that honeycomb cores with geometric compartment features have better structural properties than many foams or solid cores of relatively high density. Honeycomb cores can be of various shapes, aluminum, aramid materials such as Corex (Korex is a registered trademark), nylon materials such as Nomex (Nomex is a registered trademark), plastics, reinforced phenolic resin, It can be formed of a material such as carbon, glass fiber, or a combination of these materials. Preferably, a Nomex honeycomb is used as the material for the intermediate part 6.
[0035]
The material and shape (width, length, and geometry) of the compartment can be optimized to provide the desired support and / or stability for the inner and outer portions. For example, the size of the compartment is in the range of about 1/8 inch to about 3/4 inch, and preferably about 3/16 inch. It is.
[0036]
The honeycomb core compartment can be filled with a material other than air, such as resin, insulator, or NVH (noise, vibration, or roughness) reducing material. The type of material, thickness, compartment configuration, and “fill material” used for the intermediate portion 6 can vary along the length of the structural member 2.
[0037]
The structural member of the present invention may include additional layers or portions on the outside of the outer portion 8, if desired. In one example, one layer of metal material, insulator, additional composite material, or honeycomb core material may be disposed on outer portion 8. Many additional parts or layers, including similar or different composite materials, can be added in a similar manner. Furthermore, at least one structural component such as a bracket, a joint, a cap or the like can be arranged at the end of the structural member 2.
[0038]
The structural member of the present invention comprises any profile or feature that is not substantially flat. FIG. 4 illustrates some of such features. The structural member shown in FIG. 4 differs from the structural member shown in FIG. 1 in that the cross section of the tube is not substantially circular.
[0039]
The present invention can be formed by any suitable process that provides the structure of the structural member 2. Suitable processes for forming the composite layer include US Pat. No. 5,225,016, US Pat. No. 5,192,384, US Pat. No. 5,569,508, US Pat. No. 952, US Pat. No. 5,225,016, US Pat. No. 5,624,519, US Pat. No. 5,567,499, and US Pat. No. 5,851,336. Any process known in the art, such as thermoforming, bag or resin transfer molding, or an inflatable mandrel process is included. By reference to these patents, the contents disclosed in these patents are incorporated herein. Another suitable process is the vacuum bagging process described in US Pat. No. 5,848,767. By reference to this patent, the disclosure of that patent is hereby incorporated by reference. Other suitable processes are filament winding processes, or sheet or tube rolls (also known as roll winding). For example, US Pat. No. 5,632,940, US Pat. No. 5,437,450, US Pat. No. 4,365,952, US Pat. No. 5,624,529, US Pat. No. 5,755,558. No. 4,885,865; U.S. Pat. No. 5,332,606; U.S. Pat. No. 5,540,877; U.S. Pat. No. 5,840,347; and U.S. Pat. See No. 163. By reference to these patents, the contents disclosed in these patents are incorporated herein.
[0040]
In the filament winding process, the filaments of the desired material are dispersed in a matrix of binder material and wound onto any suitable substrate, such as a mandrel assembly shaped to correspond to the desired shape (core region 10) of the structural member 2 as a whole. In the present invention, US Pat. No. 5,795,524, US Pat. No. 5,645,668, US Pat. No. 5,192,384, US Pat. No. 5,780,075, US Pat. Any suitable mandrel described in U.S. Pat. No. 5,940,163, U.S. Pat. No. 5,817,203, and U.S. Pat. No. 5,914,163 may be used. By reference to these patents, the contents disclosed in these patents are incorporated herein. The substrate or mandrel must have sufficient strength and the desired shape, and must be able to withstand the process conditions for manufacturing the structural member. Suitable mandrels include those made of metals such as steel and aluminum, polycarbonates, thermoplastics, or RRMM materials. The mandrel may be solid or hollow.
[0041]
The filament is wrapped around the mandrel and reciprocally displaced relative to the mandrel along the longitudinal or winding axis of the mandrel to form portion 4. Additional portions, structures, or layers, such as additional metal layers or composite layers, can be added as described above or as is known in the art.
[0042]
Preferably, the present invention uses a tube roll (also known as roll wrapping) process to produce the structural members of the present invention. One exemplary tube roll process is shown in FIG. The tube roll process uses separate plies or laminates of the desired composite or polymeric material rather than filaments. The plies or laminates are alternately stacked, wound, or rolled onto at least one mandrel assembly, such as mandrel 20. If desired, a release film can be applied to the mandrel before winding the material around the mandrel. If one or more laminates are used, prior to or during the winding process, the laminates may be oriented manually or by any suitable mechanical device, with the fibers oriented as desired. As shown in FIG. After the formation of the inner part 4, the material comprising the intermediate part 6 is placed on the inner part 4, preferably by winding or roll winding, by any suitable human or by mechanical devices. The roll winding process is then restarted and the material of the outer part 8 is applied. Further details on the roll winding process can be found in ASM International's Handbook of Industrial Materials published in 1987, Volume 1, pages 569-574, Composites. By touching the document, the contents disclosed in the document are included in the present specification. If desired, additional layers or materials can be applied to outer portion 8 in a manner similar to those known in the art.
[0043]
The layers of the individual parts (the inner part, the intermediate part and the outer part) are cut such that the ends of the individual plies substantially abut when the roll is wound, thereby forming a butt joint 30. And / or be patterned. Preferably, the butt joints formed by the ends of any single ply are offset from the butt joints formed by the ends of adjacent plies, as shown in FIG.
[0044]
The inner part 4 and the outer part 8 may be formed using different methods. For example, the inner part 4 can be formed by filament winding, the outer part 8 can be formed by roll winding, or vice versa. In this aspect of the invention, the inner part 4 may be completely cured before the intermediate part 6 is applied. Similarly, before attaching the outer part 8, the inner part 4 and the intermediate part 6 may be bonded together and cured. Structural members can be formed by combining other methods known in the art, as described above, with roll winding and performing separate steps in different ways. For example, the inner portion 4 can be formed using a filament winding process, and the intermediate portion 6 and the outer portion 8 can be formed using a roll winding process, where the intermediate structure uses a vacuum bag process. Be restrained.
[0045]
If desired, a binder can be placed between successive layers of portions 4 and / or 8. The binder may be placed only in selected areas, or in a pattern such as rows and / or columns, or may be placed over the entire area of the layer / portion. Any suitable binder may be used that assists in bonding the layers and is compatible with all processes used in the manufacture of structural member 2, such as glue, hardener, adhesive, or a combination thereof. Is included. See, for example, U.S. Patent No. 5,635,306. By reference to this patent, the disclosure of that patent is hereby incorporated by reference. The binder can be applied to the substrate before assembly, during assembly, after assembly, manually, or by mechanical means.
[0046]
If the parts 4, 6, and 8 are successively laminated in an uncured state (for example, in the B-stage state), the structure consists of an inner part 4 superimposed on a mandrel, an intermediate part superposed on this inner part 4. 6 and an outer part 8 superimposed on this intermediate part 6. If necessary, the intermediate structure formed by the inner part 4, the intermediate part 6 and the outer part 8 may be constrained if necessary to better connect and connect them together. . The intermediate structure can be restrained by applying a suitable compressive force. This may be achieved by using any suitable means, including a compression die or mold, a vacuum bag, or by using suitable restraining means, such as by placing it in a plastic or metal mold, or by appropriate shrinkage. This can be done by attaching a wrapping tape 22 or a tube made of nylon, silicone, or polypropylene. During the curing process described below, a compressing means (eg, shrink wrap tape or tube) applies an appropriate compressive force by physical or chemical changes so that the materials of the structural member 2 come into contact with each other. If RMM is used in the inner / outer part of the present invention, excess resin will be squeezed out by compression during this curing process. See, for example, U.S. Patent Nos. 5,600,912 and 5,698,055. By reference to these patents, the contents disclosed in these patents are incorporated herein.
[0047]
In addition, if it is necessary that the materials be well bonded and contacted in the intermediate structure, appropriate chemical reactions can be applied to these materials. For example, if the inner portion 4 and / or outer portion 8 comprises a curable material (eg, a B-stage epoxy prepreg), any suitable such as oven curing or UV curing or microwave curing by applying heat and / or pressure. Means 24 can cure the intermediate structure. The required heat and / or pressure depends on the size of the mandrel assembly and the material used for the structural member 2. During the curing process, the shrink wrap tape or tube applies a suitable compressive force. If RMM is used in the inner / outer part of the present invention, the excess resin is squeezed out by the compressive force during this curing process.
[0048]
The process described above can be modified for structural members that are not substantially circular in cross-section, provided with at least one flat on the outer diameter whose degree of curvature is significantly different from the other surfaces of the structural member 2. An example of such a structural member is shown in FIG. As shown in FIG. 7, if at least one relatively flat area is provided on the outer diameter, the shrink wrap (and the associated compressive force) applied to the intermediate structure may not be uniform. . Thus, the connection and connection of the materials to one another is not uniform, and thus the integrity of the structural member 2 is compromised. In order to more evenly bond and connect such materials, at least one pressure distributor 26 is placed in a relatively flat area of the outer part 8 before applying the shrink wrap. These pressure distributors can "distribute" the applied compressive force more evenly over such flat areas and apply the compressive force more evenly over all areas of the intermediate structure.
[0049]
In the present invention, any suitable shape of the pressure distributor that evenly distributes the applied compressive force to the intermediate structure can be used. Exemplary shapes of the pressure distributor include a substantially semi-circular shape (which provides a substantially circular outer surface), and the flat end of the "T" corresponds to the flat area of the intermediate structure. Includes a T-shaped distributor that abuts (and is sized), with the long end of the “T” extending outward. Other shapes and configurations that include a single component rather than multiple components may be used, provided that the compressive force is evenly distributed over the flat area. For a structural member 2 such as the structural member shown in FIG. 4, a substantially semicircular pressure distributor 26 is shown in FIG. The pressure distributor of the present invention can be formed of any suitable material, such as aluminum, steel, and silicone, that retains its shape when subjected to a compressive force. Preferably, aluminum is used as the material for the pressure distributor.
[0050]
Shrink wrap may be placed above and / or below the pressure distributor. Shrink wrap placed under the pressure distributor presses the corners as well as keeps the pressure distributor from sticking to the intermediate structure. Shrink wrap over the pressure distributor presses the flat area.
[0051]
The above process can be modified for structural members as shown in FIG. 11 having different shapes of the inner part and the outer part. The present invention can use any suitable process modification that produces inner and outer portions of different shapes. The following two changes to the process described above illustrate this idea. Although not specifically described below, other changes are possible.
[0052]
First, the inner portion may have a substantially circular cross section and the outer portion may have a non-circular cross section. In such a case, as shown in FIG. 8, a process for forming a circular structural member is performed as described above. To change the shape of the external part, many pressure distributors are placed on the circular outer part before the restraining and curing steps. The number of pressure distributors used corresponds to the desired number of flat sides, for example four for a square and six for a hexagon. The above process is then continued to perform the restraining and curing steps. During the restraining and curing steps, the circular outer shape is changed by applying pressure via a pressure distributor to the desired polygonal flat sides.
[0053]
Second, the inner portion may have a substantially polygonal shape (ie, hexagonal) and the outer portion may have a substantially circular shape. In this aspect of the invention, as shown in FIG. 9, a method for forming a square shaped structural member is performed as described above. In order to change the shape of the outer part, there is no pressure distributor normally placed on the outer part before the restraining and curing steps. Thus, the outer part of the square shape is only wrapped by the restraining means. The process then proceeds as described above to perform the restraining and curing steps. During the constraining and curing steps, the pressure exerted via the constraining means changes the outer shape to a substantially circular shape.
[0054]
When used, the restraint is then removed from the intermediate structure. For plastic or metal molds, open the mold and remove. The shrink wrap tape or tube reacts during the curing process, forming a thin shell, which can be removed manually or by mechanical means, if desired. When used, the pressure distributor is also removed.
[0055]
In another aspect of the invention, the restraining means can be temporarily or permanently left on the outer part. For example, the shrink wrap tape can be left on the structural member in the form of a thin shell for protection during transport and then later removed. In another example, the shrink wrap tape can be permanently left on the structural member as a protective coating.
[0056]
During the restraining and curing steps described above, the inner and outer parts are chemically attached and / or connected to the intermediate part. Preferably, both the inner and outer portions of the material are chemically bonded to the material of the intermediate portion, thus forming a substantially permanent physical bond.
[0057]
Next, the substrate or mandrel is removed from the structural member 2 to form the core region 10. Mandrels are well known in the art for safely removing a mandrel without adversely affecting the structural member 2, as disclosed in US Pat. Nos. 5,900,194 and 5,306,371. It can be removed by any suitable process, including any process. By reference to these patents, the contents disclosed in these patents are incorporated herein. If desired, core region 10 can be filled with any desired material known in the art.
[0058]
The mandrel may be a detachable mandrel or an integral mandrel. The removable mandrel is used in a roll wrapping process and then removed to form interior 10 as described above. The integral mandrel is a mandrel that is part of the structural member 2 and is not removed. Thus, the mandrel remains in the core region 10 and becomes part of the structural member 2.
[0059]
If an integral mandrel is used, the manufacturing process for the structural member 2 and the structural member is changed from the process described above. In this aspect of the invention, the intermediate portion is provided on an integral mandrel, and then the outer portion is provided on the intermediate portion. In this case, the structural member is machined as described above, except that the integral mandrel has not been removed. Thus, an integral mandrel serves as the inner part. If desired, an inner portion may be further provided on the integral mandrel to provide a structural member having an integral mandrel, an inner portion, an intermediate portion, and an outer portion.
[0060]
After formation, the structural members of the present invention can be modified or cut for any desired use. For example, the structural member shown in FIGS. 5, 7, 8, and 9 was cut in half along its length to provide two structural members. Similarly, a structural member can be cut along its length to provide any number of members of a desired length. By cutting the structural member along arbitrary dimensions, many shapes and features can be formed, especially when combined with the broad features of the process of the present invention. Some examples of such shapes and configurations are shown in FIG. If desired, at least one structural component such as a bracket, fastener, joint, cap or the like can be provided on the structural member 2, for example at one end of the structural member.
[0061]
A preferred method for forming the structural member of the present invention is roll winding. However, the other methods described above can be used in the manufacture of structural members in combination with roll winding. This is done, in one aspect of the invention, by performing separate steps in various ways. For example, the inner portion 4 can be formed using a filament winding process, and the intermediate portion 6 and the outer portion 8 can be formed using a roll winding process. In this case, the intermediate structure can be restrained using a vacuum bag process.
[0062]
The structural member of the present invention has many uses such as tie rods, torsion bars, tubes, beams, columns, cylinders, etc., and can be used in many industries. Primarily, the structural members can be used in all applications where lightweight, strong cylindrical objects are required. The structural members of the present invention may be used in the automotive, transportation, aerospace, and defense industries, such as aircraft components, vehicle components such as trucks, trains, shipping containers, defense related applications, motorcycles, sail masts, It can be used in entertainment applications such as golf club shafts and rackets, and in commercial applications such as bridges and buildings.
[0063]
Example 1
A hollow cylindrical structural member having a circular cross section is manufactured according to the following process. A thin coating of release material (Frecoat 700NC or Axel EM606SL / SP) is applied to an aluminum cylindrical mandrel having a circular outer diameter of 2.4 inches and a length of 48 inches.
[0064]
Eight B-stage prepreg laminate sheets containing anisotropic glass fibers in an epoxy-based B-stage resin with a width of 7.5 inches to 8.6 inches (19.05 cm to 21.844 cm). Cut to a length of about 121.92 cm (48 inches). Each of these sheets has a different width according to their position on the mandrel. Preferably, each layer is wide enough to form a close butt joint when the layer is wound on a mandrel.
[0065]
The four individual laminate sheets are then combined such that the fibers of the continuous sheet are symmetric and balanced at an angle of ± 15 ° from the longitudinal axis of the mandrel, and the butt joint of the continuous layers Over the plies so that they do not overlap. Air between the stacked sheets is removed by using rollers or other suitable devices. The stacked prepreg sheets are then manually rolled in a butt joint onto an aluminum mandrel to form the inner portion 4.
[0066]
Next, an intermediate portion including the honeycomb of a hexel Nomex (Hexcel Nomex is a registered trademark) core having a hexagonally shaped compartment and having a thickness of about 0.15 inches (about 3.81 mm). 6 is measured and cut to a size of about 20 inches (about 8 inches) × about 121.92 cm (about 48 inches). The honeycomb core is then manually rolled onto a first set of stacked prepreg sheets (inner portion 4). The remaining four prepreg sheets are stacked on a honeycomb core as described above and then roll wound to form an outer portion 8.
[0067]
Next, the resulting intermediate uncured structure is shrink wrapped. A layer of polyethylene-based 150 gauge shrink wrap tape about 1 inch wide is roll wound on a shrink wrapping machine. An additional layer, including a 200 gauge nylon based shrink wrap tape, is then roll wound on a shrink wrap machine.
[0068]
After the winding process, about 121.1 ° C. in the final structure the curing process (about ²⁵⁰ 0 F) for about 120 minutes added. At this time, when the shrink wrapping tape is cured, a compressive pressure is applied to the intermediate structure. After this curing process, the shell (formed by the shrink wrap tape during the curing process) is manually removed using a knife. The mandrel is then manually removed from the center of the tube and the tube is cut to the desired length.
[0069]
Example 2
A cylindrical hollow structural member having a square cross section is manufactured according to the following process. A thin coating of release material (Frecoat 700NC or Axel EM606SL / SP) is applied to a square aluminum mandrel measuring 7.64 cm (3.0 inches) long and 182.88 cm (72 inches) long.
[0070]
Eight B-stage prepreg laminate sheets (eight individual sheets) containing anisotropic glass fibers in an epoxy-based B-stage resin are 30.48 cm (about 12 inches) wide and 12 inches long Cut to a length of about 64 inches. Four of the individual laminate sheets or plies were then symmetrically and balanced with the fibers of the continuous sheet at an angle of ± 15 ° from the longitudinal axis of the mandrel, and continuous. Lay the layers so that the butt joints do not overlap. Air between the stacked sheets is removed by using rollers or other suitable devices. The stacked prepreg sheets are then manually rolled in a butt joint onto an aluminum mandrel to form the inner portion 4.
[0071]
Next, a hexel (Hexcel is a registered trademark) having a hexagonally shaped compartment and a thickness of about 5.08 mm (about 0.2 inches) Nomex (Nomex is a registered trademark) The intermediate portion 6 containing the honeycomb of the core is measured and cut to dimensions of about 12 inches by about 64 inches. The honeycomb core is then manually rolled around the first set of stacked prepreg sheets (inner portion 4). The remaining four prepreg sheets are stacked on a honeycomb core as described above and then roll wound to form an outer portion 8.
[0072]
Next, the resulting intermediate structure is shrink wrapped. One layer of a 150 gauge polyethylene based shrink wrap tape is roll wound onto the resulting structure in a shrink wrap machine. An additional layer, including a 200 gauge nylon based shrink wrap tape, is then roll wound on a shrink wrap machine. Four aluminum semicircular pressure distributors with a diameter of 10.16 cm (4 inches) are placed on the four sides of the resulting device. Next, the outer layer containing a 200-gauge shrink wrap tape based on nylon is roll-wound around a pressure distributor with a shrink wrap machine.
[0073]
After the winding process, about 121.1 ° C. in the final structure the curing process (about ²⁵⁰ 0 F) for about 120 minutes added. At this time, the shrink wrapping tape applies a compressive pressure to the intermediate structure during its curing. After this curing process, the outer shell (formed by the shrink wrap tape during the curing process), the pressure distributor, and the inner shell (formed by the "inner" shrink wrap tape during the curing process) are manually knife knives. Remove with. The mandrel is then manually removed from the center of the tube and the tube is cut to the desired length.
[0074]
Having described preferred embodiments of the invention, the invention as defined in the appended claims is not to be limited to the specific details set forth in the foregoing description without departing from the spirit and scope thereof. It will be appreciated that many changes can obviously be made.
[Brief description of the drawings]
FIG.
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 2
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 3
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 4
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 5
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 6
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 7
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 8
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 9
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 10
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
FIG. 11
FIG. 3 is a view showing a structural member and a method of manufacturing the same according to the present invention.
[Explanation of symbols]
2 tubular structural member 4 inner section or inner section 6 intermediate section or intermediate section 8 outer section or outer section 10 core region

Claims (36)

In the shaping structural member (2),
At least one shaped inner layer (4) comprising a reinforced resin matrix material,
At least one shaped outer layer (8) comprising a reinforced resin matrix material and at least one intermediate layer (6) having a rib structure connecting said at least one inner layer (4) and said at least one outer layer (8). ). The structural member according to claim 1, wherein the structural member has a closed configuration. Structural member according to claim 2, further comprising an interior region (10) defined by an inner surface of the at least one inner layer (4). Structural component according to claim 3, wherein the interior region (10) is hollow, partially filled or completely filled. The structural member according to claim 3, wherein at least one of the reinforced resin matrix materials is formed from a prepreg material. The structural member according to claim 5, wherein the prepreg material includes a plurality of layers. The structural member according to claim 6, wherein the plurality of layers include a plurality of fibers oriented in a range from 0 ° to 90 °. The structural member according to claim 5, wherein the prepreg material includes an epoxy-based resin containing aramid fibers. The structural member according to claim 1, wherein at least one of the reinforced resin matrix materials is a sheet forming compound. The structural member according to claim 7, wherein the rib structure of the at least one intermediate layer includes a honeycomb structure. Structural member according to claim 7, further comprising at least one layer or part covering at least a part of the at least one outer layer (8). In the shaping structural member (2),
At least one shaped inner layer (4) comprising prepreg material,
At least one shaped outer layer (8) comprising prepreg material and at least one intermediate layer (6) having a rib structure connecting said at least one inner layer (4) and said at least one outer layer (8). Including, structural members. The structural member according to claim 12, wherein the rib structure of the at least one intermediate layer (6) comprises a honeycomb structure. In the shaping structural member (2),
At least one shaped inner layer (4) comprising a sheet-forming compound material,
At least one shaped outer layer (8) comprising a sheet-forming compound material and at least one intermediate layer (6) having a rib structure connecting said at least one inner layer (4) and said at least one outer layer (8). ). The structural member according to claim 14, wherein the rib structure of the at least one intermediate layer (6) comprises a honeycomb structure. In the shaping structural member (2),
At least one shaped inner layer (4) comprising a reinforced resin matrix material,
At least one shaped outer layer (8) comprising a reinforced resin matrix material and at least one intermediate layer (6) having a honeycomb structure connecting said at least one inner layer (4) and said at least one outer layer (8) And a structural member. Structural member according to claim 16, further comprising an inner region (1) defined by an inner surface of the at least one inner layer (4). In the shaping structural member (2),
At least one shaped inner layer (4) comprising a reinforced resin matrix material,
At least one shaped outer layer (8) comprising a reinforced resin matrix material,
At least one intermediate layer (6) having a honeycomb structure connecting the at least one inner layer (6) and the at least one outer layer (8), and an interior defined by an inner surface of the at least one inner layer (4). A structural member including a region (10). In the closed shaping structural member (2),
At least one shaped inner layer (4) comprising a reinforced resin matrix material,
At least one shaped outer layer (8) comprising a reinforced resin matrix material,
At least one intermediate layer (6) having a honeycomb structure connecting the at least one inner layer (4) and the at least one outer layer (8); and an inner region (10) defined by an inner surface of the at least one inner layer. ). In the closed shaping structural member (2),
At least one shaped inner layer (4) comprising a reinforced resin matrix material,
At least one shaped outer layer (8) comprising a reinforced resin matrix material,
At least one intermediate layer (6) having a honeycomb structure substantially in contact with the at least one inner layer (4) and the at least one outer layer (8); and an inner area defined by an inner surface of the at least one inner layer. A structural member including (10). In the method of manufacturing a shaped structural member,
Providing at least one inner layer (4) comprising a reinforced resin matrix material;
Roll winding at least one intermediate layer (6) having a rib structure on said at least one inner layer (4);
Providing at least one outer layer (8) comprising a reinforced resin matrix material on said at least one intermediate layer (6); and providing said at least one inner layer (4) and said at least one outer layer (8) with said at least one A method comprising the step of coupling to an intermediate layer (6). The method of claim 21,
Providing the at least one inner layer (4) by rolling the at least one inner layer (4) around a substrate (20). 23. The method according to claim 22, comprising providing the at least one outer layer (8) by rolling the at least one outer layer (8) around the at least one intermediate layer (6). 24. The method according to claim 23, further comprising removing the substrate (20). 25. The method according to claim 24, comprising partially or completely filling the interior (10) formed by removing the substrate (20). 26. The method according to claim 25, wherein the at least one outer layer (8) is restrained and the reaction of the at least one inner layer (4) or the at least one outer layer (8) before removing the substrate (20). The method further comprising the step of reacting a conductive material. 27. The method according to claim 26, comprising constraining the at least one outer layer by rolling at least one layer of shrink wrapping material (22) around the at least one outer layer (8). 28. The method according to claim 27, comprising removing the at least one layer of shrink wrap after reaction. 28. The method according to claim 27, further comprising the step of providing at least one pressure distributor (26) on said at least one outer layer (8). 30. The method according to claim 29, comprising providing at least one pressure distributor (26) to a plurality of layers of shrink wrap material (22) between two of the layers. In the method for producing a shaped structural member (2),
Rolling at least one inner layer (4) containing a reinforced resin matrix material around a substrate (20);
Roll winding at least one intermediate layer (6) having a rib structure on said at least one inner layer (4);
Rolling and covering at least one outer layer (8) comprising a reinforced resin matrix material around said at least one intermediate layer (6);
A method comprising connecting the at least one inner layer (4) and the at least one outer layer (8) to the at least one intermediate layer (6), and removing the substrate (20). In the method for producing a shaped structural member (2),
Rolling at least one inner layer (4) containing a reinforced resin matrix material around a substrate (20);
Roll winding at least one intermediate layer (6) having a rib structure on said at least one inner layer (4);
Rolling and covering at least one outer layer (8) comprising a reinforced resin matrix material around said at least one intermediate layer (6);
Constraining said at least one outer layer (8) with shrink wrap (22);
Connecting said at least one inner layer (4) and said at least one outer layer (8) to said at least one intermediate layer (6); and removing said shrink wrap material (22) and said substrate (20). Including, methods. In the method for producing a shaped structural member (2),
Rolling at least one inner layer (4) containing a reinforced resin matrix material around a substrate (20);
Roll wrapping at least one intermediate layer (6) having a honeycomb structure so as to substantially contact said at least one inner layer (4);
Roll wrapping at least one outer layer (8) comprising a reinforced resin matrix material to substantially contact said at least one intermediate layer (6);
Constraining said at least one outer layer (8) with shrink wrap (22);
Connecting said at least one inner layer (4) and said at least one outer layer (8) to said at least one intermediate layer (6); and removing said shrink wrap material (22) and said substrate (20). Including, methods. In the shaping structural member (2),
Forming at least one inner layer (4) comprising a reinforced resin matrix material;
Roll winding at least one intermediate layer (6) having a rib structure on said at least one inner layer (4);
Forming at least one outer layer (8) comprising a reinforced resin matrix material on said at least one intermediate layer (6);
A shaped structural member manufactured by a method including a step of connecting the at least one inner layer (4) and the at least one outer layer (8) to the at least one intermediate layer (6). Rolling at least one inner layer (4) containing a reinforced resin matrix material around a substrate (20);
Roll winding at least one intermediate layer (6) having a rib structure on said at least one inner layer (4);
Rolling and covering at least one outer layer (8) comprising a reinforced resin matrix material around said at least one intermediate layer (6);
Constraining said at least one outer layer (8) with shrink wrap (22);
Connecting said at least one inner layer (4) and said at least one outer layer (8) to said at least one intermediate layer (6); and removing said shrink wrap material (22) and said substrate (20). A shaped structural member manufactured by a method comprising: Rolling at least one inner layer (4) containing a reinforced resin matrix material around a substrate (20);
Roll wrapping at least one intermediate layer (6) having a honeycomb structure so as to substantially contact said at least one inner layer (4);
Roll wrapping at least one outer layer (8) comprising a reinforced resin matrix material to substantially contact said at least one intermediate layer (6);
Constraining said at least one outer layer (8) with shrink wrapping material;
Connecting said at least one inner layer (4) and said at least one outer layer (8) to said at least one intermediate layer (6); and removing said shrink wrap material (22) and said substrate (20). A shaped structural member manufactured by a method comprising: