NZ725978A - Thermoplastic composite tension member and method of manufacturing of the latter - Google Patents

Abstract

Disclosed is a tension member for supporting a mast on a yacht or sailboat where a more even or uniform load distribution on the composite fibres forming the tension member is desired. The tension member comprises a plurality of resin/fiber composite rods, fibres, tow, or tape arranged as a bundle have a first end and a second end where at least one of the first end and the second end have the form of a consolidated shaped terminal. The consolidated shaped terminal is substantially uniform and solid in structure, with an inner end and an outer end where the outer end having a dimension greater than a dimension of the inner end. The consolidated shaped terminal is formed by placing at least one of the first end and the second end into a die, or wrapping at least one of the first end and the second end with heat-shrink tape, and applying heat and/or pressure; then the consolidated shaped terminal is formed by the addition of thermoplastic or composite material by: drilling the consolidated end axially; splitting the drilled consolidated end axially; and incorporating the additional thermoplastic material into the void that was created by drilling and splitting by plunging a spiked plunger axially into the consolidated end while it is within a die. The consolidated shaped terminal has a geometry that is a frustum, a concave head, a convex spherical head, a conical taper, an eye, threaded, or an overlap joint, unidirectional tube overlap joint, laminate, flatten and overlap, two-into-one butt-joint, or diagonal-into-vertical joint.