WO2005030483A2

WO2005030483A2 - High strength composite material geometry and methods of manufacture

Info

Publication number: WO2005030483A2
Application number: PCT/IB2004/003172
Authority: WO
Inventors: Robert D. Hunt
Original assignee: Hunt Robert D
Priority date: 2003-09-29
Filing date: 2004-09-29
Publication date: 2005-04-07
Also published as: WO2005030483A3

Abstract

A flexible or rigid composite material is formed by spirally winding a composite material tape (510) around a composite material core (506) using a spiral winding apparatus (508). Using a flexible composite material core (506) allows the composite material to conform to any shape. Dual plane, dual axis composite material geometry is used in order to strengthen the composite material structure.

Description

HIGH STRENGTH COMPOSITE MATERIAL GEOMETRY AND METHODS OF MANUFACTURE

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of Applicant's U.S. Provisional Application Number 60/507,033 titled, "New Composite Material having a High Strength Internal Framework Geometry and Method of Manufacture" dated September 29, 2003, the entire disclosure of which is incorporated herein by reference. [0002] This application claims the benefit of applicant's U.S. Provisional Application Number 60/512,053, "Composite Material Structure Via Use of a Pressurized Water Molding Process that Forms a Specific Shape and Provides Heat to Cure the Composite Material Via the Circulation of Pressurized Hot Water Through the Mold" dated October 17, 2003, the entire disclosure of which is incorporated herein by reference. [0003] This application claims the benefit of applicant's U.S. Provisional Application Number 60/532,533, "Shape

Conforming Flexible Composite Material Matrix" dated December 26, 2003, the entire disclosure of which is incorporated herein by reference. [0004] This application claims the benefit of applicant's U.S. Provisional Application Number 60/545,267, "Flexible Composite Material or Pipe" dated February 17, 2004, the entire disclosure of which is incorporated herein by reference,

BACKGROUND OF THE INVENTION

[0005] New lightweight strong composite materials offer the possibility of new material geometries and bonding capabilities that are not possible with metal, principally because adjoining layers of fabric simply become a single layer with composite materials after the wetting, baking, and curing process. Using layers of metal materials only periodic bolts or welds join the layers, which are much weaker, plus the materials generally weight much more. [0006] A common construction technique for composite materials is to sandwich a layer of core material, such as a foam board or a honeycomb core material, between two layers of composite material, such as carbon fiber or Kevlar. However, often the core material is weakly bonded to the composite materials and detrimental delamination occurs as the core material separates from the composite material. This problem can become even more severe when the external pressure rapidly changes as gas is present within the space containing the core material between the composite layers. [0007] When composite materials are corrugated, the corrugations are generally on one plane or a single plane corrugation is used that runs in either the X-Axis or the Y- Axis directions, which means that if there is an X-Axis set of corrugations and a Y-Axis set of corrugation that they will intersect with the Y-Axis set of corrugations. Weakness occurs at these intersections and usually either the X-Axis or the Y-Axis is detrimentally cut into sections by the other. Frameworks in buildings and in many other construction techniques resolve this problem in relation to intersections cutting support members into sections by the use of multiple planes, such that one support member rests on the top of another support member that is below it so that neither the X- Axis nor the Y-Axis members are cut at intersections. [0008] A molding process known as the "lost wax" method of forming a mold using wax that is melted out of the structure at the end of the process to create hollow passageways is used in many molding processes. However, the lost wax process has a number of problems, including the need for passageways to remove the melted wax, wax cannot be used in hot curing processes because the wax will prematurely melt, and it may be difficult to mold the wax into the desired shape, and the strength of the wax may be insufficient to withstand the negative pressure of a vacuum as used in many composite material curing processes. In general, the lost wax method of molding is not applicable to modern composite material structure formation. [0009] Often core materials, such as honeycomb or foam board, are used to strengthen composite material structures. These add weight to the structure and are extremely difficult to remove, if not impossible to remove, from the fabricated structure if it is desirable to remove these materials to reduce the weight of the composite material structure formed. [0010] Core materials also affect the curing process by acting as detrimental insulation that prevents the composite material from curing uniformly, especially when heat is only applied externally and interior sections do not receive adequate heat for curing. [0011] New bonding materials for composite materials are now known that provide superior bonds having excellent strength, which in some instances the bonds are stronger than the composite materials that are bonded together. [0012] New lightweight strong composite materials offer the possibility of new material geometries and bonding capabilities that are not possible with metal, principally because adjoining layers of fabric simply become a single 95 layer with composite materials after the wetting, baking, and curing process. Using layers of metal materials only periodic bolts or welds join the layers, which are much weaker, plus the materials generally weight much more. [0013] Pultrusion technology which pulls continuous fiber

100 through a resin bath and then forms it into shapes via guides. The material is then heated to rapidly cure the composite material thus formed that is cut into the desired lengths via a saw. Pultrusion technology is used to make long sections of composite material that may contain intricate shapes,

105 including parallel rows of sealed sectional modulus sections that provide additional strength to the composite material thus formed. The advantage of pultrusion technology is that the process allows low cost automated manufacture of large area panels.

110 [0014] In the process of manufacturing composite materials, molds are generally used to form the desired shape. The molds limit the shape of composite structures because it is very difficult to create composite material structures that conform to an irregular shape and contain interior sections, such as

115 corrugations or intentional internal openings within the composite material structure. Blank open faced molds are generally only suited for large smooth flat sections. [0015] For example, in conventional boat construction a boat hull is cast via the use of a mold. Thereafter, a

120 lengthy and expensive process is undertaken. The process involves cutting irregular shaped sections of high density core material, which are bonded together on the inside of the hull. After the interior of the hull is lined with the bonded sections of core material a layer of fiber and resin are 125 applied over the core material to form an interior external layer of the hull. [0016] The above described process has numerous problems other than being expensive and time consuming. The core material is generally flat and the hull is generally curved.

130 Therefore, the core material must be cut into very small irregular sections in order to conform to the curved shape of the hull. Even after cutting the core material into small sections, the flat core material usually forms gaps that do not directly join to the curved hull, creating weakening voids

135 that have detrimental effects, such as filling with water and causing corrosive effects, and most important the promotion of delamination - in general the most critical problem associated with the use of core sandwich composite material construction that is primarily used for airplane and boat construction.

140 [0017] Old boats with fiberglass hulls often have rotten ribs and spars that are made of wood. Decks and bulkheads are often collapsed and transoms are often too weak to support an outboard motor any longer.

145 SUMMARY OF THE INVENTION

[0018] The present inventor has succeeded at designing methods and systems for forming new composite material geometries that provide an internal framework consisting of

150 corrugations running on two planes in both the X-Axis direction and Y-Axis direction to create a new single bond composite material that is very strong. A method of manufacture is herein presented of a new single-bond composite material having an X-Axis corrugated layer bonded

155 to a Y-Axis layer by a bonding layer that separates the plane of the Y-Axis layer from the X-Axis layer; and, the internal sectional modulus of the corrugation on the X and Y plane are closed by the bonding layer. Additional outer layers may be applied if it is desirable to close the outer corrugations to

160 form additional sectional modulus for even greater strength. [0019] Corrugations are important to the strength of the design as they provide substantial stiffness, but the corrugations must run in both the X and Y axis directions to prevent elongation failure. Two drawings of the design are

165 described below that describe the concept. The first drawing is a flat panel that explains the two axis corrugation on separate planes bonded together into a single unit by a bonding layer principal and the second drawing is a cylinder that also uses the two axis corrugation on separate planes

170 bonded together by a bonding layer design. [0020] A flat panel (the bonding panel) bonds an upper corrugated X-axis section to the top of the panel and bonds a lower corrugated Y-Axis section to the bottom of the bonding panel. If the X-Axis and the Y-Axis intersect then a weak

175 area is formed at the junction. By having an axis on each side of the . bonding layer the X-axis and the Y-Axis are on two different planes and do not intersect. The bonding layer flat panel closes the corrugations on both the top and lower corrugated panels forming sectional modulus for

180 strength. Once the entire assembly is baked and cured, it is one single composite structure having X-Axis corrugations on one side of the bonding layer flat panel and having Y-Axis corrugations on the opposite side of the bonding layer flat panel. This process could not be accomplished with metal as

185 only welds would join the layers of metal. The composites materials are internally bonded together by the bonding layer. [0021] To form a cylinder, the rings are corrugated to form the Y-Axis and the layers of material running axially the length of the cylinder are corrugated to form the X-Axis

190 to prevent the bucking failure you described. The layer in the middle between the Y-Axis rings and X-Axis corrugations (that run the full length of the cylinder) bonds the two layers together and closes the corrugations to form sectional modulus. The spiral wrap on the outside of the cylinder

195 closes the corrugations of the X-Axis material and provides a circular outer skin. Four layers are used: (1) the internal Y-Axis corrugated rings (2) the full length bonding layer between the X-Axis and Y-Axis (3) the full length X- Axis corrugated layer (4) the spiral wound layer that forms

200 the outer surface. [0022] The present inventor has succeeded at designing methods and systems for producing a molding and curing process for composite material structures that provides a shape by the use of pressurized water within a suitable container, such as

205 a section of hose, that is made of lightweight strong material having thin walls, including walls with square, rectangular, triangular or any other desired shape. The hose material may be either rigid or flexible, but generally to provide the very lightweight needed in many applications, the material would be

210 flexible and the hose itself would be collapsible when not pressurized. [0023] Hot pressurized water flowing within the hose like shell provides heat internally to the composite material to cure the material uniformly through out. The internal

215 pressure of the water within the hose holds the shape of the hose that acts as a form onto which composite materials are applied. [0024] Composite materials are typically placed in a bag having a vacuum. As a result, negative pressure is applied

220 against the composite material structure by the vacuum bag. The pressurized water provides a greater internal pressure than the negative external pressure of the vacuum, which prevents the collapse of the hose so that the desired shape of the composite material structure is retained.

225 [0025] The hose may be made of a method used in inflatable boats that have a diagonal stitching connecting the outer walls of the inflatable boat sections. The stitching retains the desired shape of the flexible material that forms the walls. When pressurized, this method of hose fabrication will

230 retain shapes other than circular. [0026] After the composite material structure has cured and the vacuum bag removed, the water may be removed from the hose and only the lightweight section of hose remains in the interior of the completed composite material structure. Thus,

235 no material having weight occupies the center area of the hose and the final composite material structure then contains hollow interior passageways, without having to remove a mold material, such as wax or core material, (if it can be removed at all) that may be trapped within the interior of the

240 composite material structure. The pressurized water mold process allows a lighter-weight, finished product to be fabricated. [0027] Additionally, these interior passageways may be beneficially used for the transport of pressurized fluids,

245 such as compressed air, water, etc. internally within the composite material structure. [0028] An improved method of manufacture of this novel geometry that uses pultrusion and bonding technologies is herein disclosed. A wide panel of composite material

250 consisting of rows of parallel sealed modulus sections that run in the X-Axis direction is constructed via the pultrusion technique. An identical second panel is constructed in the same manner. The second panel is rotated approximately 90 degrees so that the sealed sectional modulus is turned to the

255 Y-Axis direction, which is perpendicular to the first panel. The second panel is bonded to the second panel via a bonding material to form the X-Axis and Y-Axis geometry of the invention. [0029] The above described manufacturing process provides

260 a method for the large scale production of low cost high strength lightweight composite material panels that employ the novel geometry described herein. [0030] The first and second panel may employ a different geometry as may be desirable in some use applications. For

265 example, the second panel may be thinner and less strong than the first panel in applications where the first panel is used to bridge between two support structures and greater strength is required for the lower sustaining panel. Panel of equal strength are well suited for applications where support for

270 the panels is provided on all four sides and far greater overall strength is accomplished by use of this novel composite material matrix. [0031] The present inventor has succeeded at designing methods and systems for producing composite material

275 structures of complex geometry by the use of a flexible composite material matrix that conforms to any shape, such as the curved shapes used in the manufacture of boats and airplanes. The flexible matrix may be applied to any formed shape, such as a mold, hull of a boat or an airplane section,

280 in order to strengthen the composite material structure. [0032] The flexible composite material matrix is formed by weaving or wrapping a composite material fabric around a core material or inserting the core material within a fabric sleeve that may be either solid, foam, or a gas or liquid filled

285 envelope in order to form corrugations . of the fabric material that provide additional strength. The core material is made into sections, like a link sausage. Therefore, bending may occur at the intersection of each section to create flexibility. The length of the sections may be altered to

290 determine the degree of flexibility or the core material may be flexible. [0033] In the present invention the fabric material may be fiberglass, carbon fiber, Kevlar, etc that may either need the application of a resin to cure the material or may be a

295 prepreg composite material that contains resin within fabric material layers. The prepreg composite material hardens upon the application on heat to cure the prepreg composite material, A length of the desired material is wrapped around a core material, which may be sections as described above or may be

300 long continuous lengths of flexible core material. The material used in the preferred embodiment of the present invention is a lightweight continuous flexible flotation material. [0034] A length of fabric material may corrugate around

305 the core material that is either perpendicular or parallel to the length of the fabric. However, in the preferred embodiment of the present invention, the core material runs parallel to the length of the fabric. This allows very long sections of the flexible composite matrix to be easily

310 manufactured. [0035] After a long section of the flexible composite matrix has been manufactured, it is formed into a roll. The roll then can be placed on a roller. Linear sections of the flexible composite matrix material can be pulled from the

315 roller through a resin bath to apply resin to the flexible composite matrix. Excess resin is removed from the flexible composite matrix by rollers as the flexible composite matrix comes out of the resin bath. Sections of the flexible composite matrix are cut off and are applied then to a mold,

320 the interior of a boat hull, or an airplane section, etc. The flexible composite matrix will conform to the shape of the surface to which it is applied, especially if the flexible composite matrix is vacuum bagged so that external atmospheric pressure is applied to the flexible composite matrix to press

325 it against the surface to which it is applied. [0036] To create additional strength, a second layer of flexible composite matrix may be applied over the first layer of flexible composite matrix in a perpendicular manner such that Dual-Plane X-Axis corrugations and Y-Axis corrugations

330 are formed to provide superior strength characterizes as more fully described in Applicants Provisional Patent titled, "New Composite Material having a High Strength Internal Framework Geometry and Method of Manufacture" dated September 29, 2003. [0037] Advantages of using the flexible composite matrix

335 are: A thicker stronger hull, airplane section, or composite structure is created; increased floatation of the material is accomplished due to the low density interior sections formed within the composite structure formed that may be hollow or may be flotation core material. A thicker and stronger 340 composite structure makes it far more difficult to penetrate and thus safer in regards to accidents. Increased floatation also makes the composite structure safer. For example, a boat hull may become unsinkable and an aircraft may float rather than sink in water. The composite material sections may be

345 used for the construction of floating docks and other buoyant structures due to the buoyancy created by the internal low density sections. [0038] Further, the composite material structures are lightweight due to the interior areas containing low density

350 materials, such as cork or envelops filled with air or inert gases contained within envelopes, such as plastic, vinyl, etc. Interior passageways may be formed to be beneficially used for the transport of pressurized fluids, such as compressed air, water, etc. internally within the composite material structure.

355 [0039] The flexible composite material may beneficially be used as a repair material for boats, furniture, or any other apparatus that requires strengthening. The addition of the flexible matrix to old boats with fiberglass hulls can provide structural integrity that can act as a replacement for rotten

360 ribs and spars. Hulls that are repaired with the matrix will become stronger, lighter, and will provide flotation to prevent sinking of the hull. Additionally a strong lightweight transom may be fabricated using the flexible composite material matrix of the present invention.

365 [0040] The present inventor has succeeded at designing methods and systems for producing a flexible composite material beam that has several major advantages over other construction materials: (1) the flexible beam may form many irregular shapes, such as a shape that is twisted along the

370 axis of a beam, curved, round or oval shapes, square or rectangular shapes, tubular or cylindrical shapes, "S" shapes, "U" shapes, or "V" shapes or upside down "V" shapes, etc. that may be used in the construction of many items or may be used to form either the shape conforming or flat panel dual-plane,

375 dual-axis matrix that is described more fully in the four Provisional Patent Applications cited above; and, (2) chemical bonds, such as resins or bonding agents, may be used to attach individual sections of flexi-beam, flexi-pipe, or rigid beam together because the fabric of the beam is not pre-cured as

380 are most construction materials; and, (3) the material is easy to cut into sections because there is no hard cured resin that is difficult to cut through; and, (4) the beams may be made both stronger and lighter than conventional construction materials; and, (5) the composite material may be hollow to

385 form pipe or ducts, such as air ducts, that may also be flexible to curve; and, (6) the process of spiral winding is much faster than conventional spiral winding techniques because a tape having a minimum width of several inches is used instead of single strand roving.

390 [0041] In the present invention, the flexible beam or pipe is formed by spiral wrapping fiber around a flexible core material. The fiber material wrapped around the flexible core is a woven fiber tape having a minimum width of several inches, instead of individual strands of fiber as is used by prior art

395 spiral winding machines. The tape may be overlapped to provide additional fiber thickness. [0042] The flexible core or rigid core material used may vary in density, length, and may be of almost any shape, such as round, rectangular or square, oval, etc. and may also be

400 hollow, to reduce weight or to make an insulated pipe section. [0043] The flexible or rigid composite beam or pipe is produced without the use of resins. The resin that cures the pipe or beam into a rigid structure is applied by the end user after the beam or pipe has been bent to the desired

405 configuration in the case of a flexi-beam or flexi-pipe. [0044] In the process of making complex composite material structures, the individual members are bonded together by a resin or bonding agent that creates a much stronger bond than is produced by fasteners, which allows sections of flexi-beam

410 or flexi-pipe to be bonded to other sections of flexi-beam or flexi-pipe material or to sections of rigid-beam or rigid-pipe merely by placing them firmly together during the bonding process. [0045] The above process allows many different composite

415 products to be made simply by placing individual members together. For example, the letter "A" can be made by making an upside down "V" out of one piece of flexi-beam by bending it into the proper shape. Then the horizontal cross brace of the "A" may be added using another piece of flexi-beam or

420 rigid-beam. Additionally, a saw horse can be made by running another piece of rigid-beam across the top of two "A's". This can be one single bonding process to build the saw horse or it may be constructed making separate bonds for each member. [0046] The dual-plane, dual axis matrix is made by placing

425 on one plane a series of parallel sections of flexi-beam to form a continuous side-by-side layer. Then a second layer of parallel sections of flexi-beam side-by-side are place over the top of the lower layer and the entire assembly is bonded together by resin either at as single bonding application as a

430 series of bonds. [0047] Portions of sections of flexi-beam may have resin applied and cured to a hard finish and the rest of the beam may be left to be cured later in order to make an attaching bond to another member. In the example sawhorse example above

435 the piece of beam that runs across the top of two "A's" could be cured rigid everywhere but on its ends so that it can span the distance between the top of two "A's" in a rigid manner and thereby not need additional support. Or in the alternative, a rigid-beam having a rigid straight interior

440 core may be used to span the distance between the two "A's". Likewise a column post constructed of flexi-beam could be cured lying of the ground everywhere but at the top of the post where an attaching plate will rest at a later time. [0048] Because there is no hard cured resin to cut through,

445 pieces of flexi-beam can be easily cut into smaller sections of beam, usually without the aide of power tools. [0049] Structures of complex geometry may be formed using flexible flexi-beam and flexi-pipe composite material that conforms to any shape, such as the curved shapes used in the

450 manufacture of boats and airplanes. The flexi-beam may be applied to any formed shape, such as a mold, hull of a boat or an airplane section, in order to strengthen the composite material structure and may used in place of conventional spars and ribs on boats and aircraft.

455 [0050] The fabric material used to spiral wind around the core material may be fiberglass, carbon fiber, Kevlar, etc that may either need the application of a resin to cure the material or may be a prepreg composite material that contains resin within fabric material layers. The prepreg composite

460 material is a thermo set that hardens upon the application on heat to cure the prepreg composite material. [0051] The core material may be rigid as well as flexible. Rigid core material rigid-beam loses a lot of capabilities of flexi-beam as far as the ability to conform to shapes, but it

465 still has the advantage of chemical bonding to attach individual members together to make a complex structure. The rigid material does; however, have the advantage of spanning a gap between two supports, which the flexi-beam can only do when the beam is supported along its entire length by a form

470 that it can rest on. [0052] After a long section of the flexi-beam or flexi- pipe has been manufactured, it is formed into a roll. The roll then can be placed on a roller. Linear sections of the flexible composite matrix material can be pulled from the

475 roller through a resin bath to apply resin to the flexible composite matrix. Excess resin is removed from the flexible composite matrix by rollers as the flexible composite matrix comes out of the resin bath. Sections of the flexible composite matrix are cut off and are applied then to a mold,

480 the interior of a boat hull, or an airplane section, etc. The flexible beam will conform to the shape of the surface to which it is applied, especially if the flexible beam is vacuum bagged so that external atmospheric pressure is applied to the flexi-beam to press it against the surface to which it is

485 applied. [0053] Further, the composite flexi-beam members are lightweight if lightweight fabric are used with interior areas having low density materials, such as cork or envelops filled with air or inert gases contained within envelopes, such as

490 plastic, vinyl, etc. Interior passageways may be formed to be beneficially used for the transport of pressurized fluids, such as compressed air, water, etc. internally within the composite material structure. [0054] The flexible beam or flexible pipe may beneficially

495 be used as a repair material for boats, furniture, or any other apparatus that requires strengthening. The addition of the flexible beam to old boats with fiberglass or carbon fiber hulls can provide structural integrity that can act as a replacement for rotten ribs and spars. Hulls that are

500 repaired with flexi-beam will become stronger, lighter, and will provide flotation to prevent sinking of the hull. Additionally a strong lightweight transom may be fabricated using the flexible beam to form the matrix. [0055] Flexi-beam and flexi-pipe may be manufactured using

505 an extrusion machine to extrude a flexible or rigid core material. The core material is spiral wound with a fiber tape, such as Kevlar, carbon fiber, fiberglass, etc. by a spiral winding machine as presented herein and then stapled or bound to prevent the fiber from unwrapping from the core.

510 [0056] Advantages of using the flexible composite matrix are: A thicker stronger hull, airplane section, or composite structure is created; increased floatation of the material is accomplished due to the low density interior sections formed within the composite structure formed that may be hollow or

515 may be flotation core material. A thicker and stronger composite structure makes it far more difficult to penetrate and thus safer in regards to accidents. Increased floatation also makes the composite structure safer. For example, a boat hull may become unsinkable and an aircraft may float rather

520 than sink in water. The composite material sections may be used for the construction of floating docks and other buoyant structures due to the buoyancy created by the internal low density sections. [0057] Further, the composite material structures are

525 lightweight due to the interior areas containing low density materials, such as cork or envelops filled with air or inert gases contained within envelopes, such as plastic, vinyl, etc. Interior passageways may be formed to be beneficially used for the transport of pressurized fluids, such as compressed air,

530 water, etc. internally within the composite material structure. [0058] The flexible composite material may beneficially be used as a repair material for boats, furniture, or any other apparatus that requires strengthening. The addition of the flexible matrix to old boats with fiberglass hulls can provide

535 structural integrity that can act as a replacement for rotten ribs and spars. Hulls that are repaired with the matrix will become stronger, lighter, and will provide flotation to prevent sinking of the hull. Additionally a strong lightweight transom may be fabricated using the flexible

540 composite material matrix of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1. describes a single bond composite 545 material (100) having corrugated layers of composite material that run in both the X-Axis (104) and Y-Axis (108) directions as viewed from a top view. A corrugated layer of composite material running in the X-Axis (104) direction; and, a center bonding layer (102) of composite material that forms a flat 550 panel positioned between the two corrugated layers (104 & 108) that separates the plane of the two corrugated layers (104 & 108) . Sealed modulus (106) are formed by the bonding layer that closes the corrugations that are adjacent to the bonding layer (102) of both the X-Axis corrugated layer (104) and the

555 Y-Axis corrugated layer (108) to create greater strength. The intersections of the three layers (102 & 104 & 108) bond together when the composite material layers are wetted with an epoxy resin and are cured into a single bond composite material (100) .

560 [0060] Figure 2. describes a pressure vessel cylinder (200) made of the composite material having corrugated layers of composite material that run in both the X-Axis (204) and Y-Axis (206) direction as viewed from a top view. A corrugated layer of composite material running in the X-Axis

565 (204) direction the full length of the cylinder (200) ; and, a center bonding layer (202) of composite material that forms a curved flat panel positioned between the two corrugated layers (204 & 206) that separates the plane of the two corrugated layers (204 & 206) ; and, a corrugated layer of

570 composite material running in the Y-Axis (206) direction that is formed into a series of rings. Sealed modulus (208) are formed by the bonding layer (202) that closes the corrugations that are adjacent to the bonding layer (202) of both the X-Axis (204) corrugated layer and the Y-Axis

575 corrugated layer (206) of rings to create greater strength. The final and outer layer is a spiral wound composite material layer (210) that seals the upper corrugations of the X-Axis layer (204) to form additional sealed sectional modulus. The intersections of the layers (202 & 204 & 206 &

580 210) bond together when the composite material is wetted with an epoxy resin, baked and cured into a single bond composite material (200) . [0061] Corrugated Y-Axis rings (206) made of lightweight strong composite may be molded, wetted and cured as a separate 585 process. The rings (206) then may be axially aligned on a single plane to create a cylinder shape. [0062] Figure 3 describes the pressurized water mold (303) method of manufacture of the dual axis, dual plane matrix material (302) geometry. Hot pressurized water (304) flows

590 through thin walled hoses that can be seen in the Side View flowing in the X-Axis direction and in the End View flowing in the Y-Axis direction. [0063] Heat is provided to the layers of composite materials (302) in order to cure the composite materials (302) .

595 Generally, the heat is gradually increased (ramped up) and then gradually decreased (ramped down) by temperature controls (not shown) that regulate the heat source. Having the hoses (304) providing heat internally within the composite material structure allows heat to be uniformly distributed to the

600 composite material (302) from the inside out, which prevents the interior of the composite material structure (300) from ¹ not properly curing due to insufficient heat availability. [0064] Figure 4 describes a method of manufacturing a dual axis, dual plane laminate material (400) that creates a

605 strong composite material geometry that uses pultrusion technology. A pultrusion machine (402) feeds out a rigid panel (406) having a series of sealed sectional modulus (418) that run in the X-Axis direction. The panels (406) are cut into at a pre-determined length that generally would be the

610 same as the width of the panel (406) . [0065] Panels (406) are continuously produced by the pultrusion machine (402) . A second sheet (410) that is produced by the pultrusion machine (402) is rotated ninety degrees (90 Deg.) to form a Y-Axis that is perpendicular to

615 sheet One (408) and is bonded to sheet one (408) by a glue like bonding agent (420) forming a laminate (414 & 416), having both an X-Axis plane panel (408) bonded to a Y-Axis plane panel (410) to form the dual axis, dual plane matrix (400) of the present invention.

620 [0066] The laminate (414 & 416) viewed from the Left Side View shows the sealed section modulus (418) on the bottom layer (408) having an X-Axis when viewed from the top view (not shown) of the laminate. The laminate (414 & 416) viewed from the Right Side View shows the sealed section modulus (4l8)

625 on the top layer (410) having a Y-Axis when viewed from the top view (not shown) of the laminate. [0067] Figure 5 describes the manufacturing method of the preferred embodiment of the present invention, which is a flexible composite material beam or pipe (500) useful in

630 constructing the dual-plane, dual-Axis matrix. [0068] A flexible core material (506) is produced by an extrusion machine (502) from raw chemicals (not shown) . The flexible core material (506) is pulled forward by flexible core material rollers (504) . The core material (506) passes

635 to a spiral winding apparatus (508) that rotates around the core material (506). The spiral winding machine (508) consists of a circular shaped frame that rotates on cylinder rollers (518). A fabric tape (510), such as fiberglass, carbon fiber, or Kevlar, is wrapped around the flexible core

640 material (506) as it passes through the machine (508) . A roll of the fabric tape (510), having a minimum width of several inches, is attached to the rotating spiral winding machine (108) by an axis member (524) and thus also rotates around the flexible core material (506) and the fabric tape (510) is thus

645 spiral wound around the flexible core material (506) . A strand of fiber material (522) , much like a string, is then spiral wound around the exterior of the fiber tape (510) in order to prevent the tape (510) from becoming unwound from the core material (506) . Alternately, stapling, adhesive, straps,

650 or other forms of binding may be used instead of the strand material (522) to bind the tape (510) to the core material (506) . [0069] The finished composite material product (512), consisting of a flexible core material (506) spiral wound with

655 fiber tape (510) that is spiral wound with a binding fiber strand (522) is wrapped into a composite flexible material roll (514) . A motor (not shown) provides power to make the composite flexible material roll. [0070] The spiral winding machine (508) is mounted on a

660 stand (516) that supports the cylinder rollers (518) that cause the spiral winding machine (508) to rotate on the cylinder rollers (518) . The rollers (518) are powered by an electric motor (520) connected to a power supply (not shown) .

665

670

675

Claims

CLAIMSWhat is claimed is:

1. Amethod of producing a composite beam or pipe that may be cured into a rigid structure by the application of a resin comprising: providing a fabric material such as carbon fiber, fiberglass, or Kevlar, or prepreg composite material; and, providing a core material selected from such species as fiber board, Styrofoam, sealed cell foam, wood, plastic, honeycomb core material, etc.; and, covering the rigid core material with the fabric material.

2. The fabric material of claim 1 whereby the fabric material is a strip of composite material fabric that is spiral wind around the composite core material.

3. The fabric material of claim 1 whereby the fabric material is sewn, glued, stapled, or otherwise attached to the core material to prevent unwrapping of the fabric from the core material

4. The fabric material of claim 1 whereby the fabric material is sprayed onto the composite core material as chopped fabric material.

5. The fabric material of claim 1 whereby the fabric material is a sleeve that is placed over the composite core material.

6. The core material of claim 1 whereby the core material is a rigid vertical or horizontal member that may be cured into a rigid beam or pipe by the application of a resin to cure the composite material,

7. The core material of claim 1 whereby the core material is a flexible member that may be formed into an irregular shape and cured into a rigid member that retains the irregular shape, such as a "V" shape, "S" shape, "0" shape, the curvature of the hull of a boat or airplane, etc., by the application of a resin to cure the composite material.

8. The flexible composite beam or pipe of claim 8 whereby the flexible core material is a flotation material that may be round, oval, rectangular, square, or any other desired shape to form the shape of the flexible beam or pipe and to provide floatation.

9. The composite flexible beam or pipe of claim 8 whereby a complex shape, such as twisted along the axis of the beam or pipe, curved, round or oval shapes, square or rectangular shapes, "S" shape, "U" shape, or "V" shape or upside down "V" shape, etc may be formed prior to curing the beam or pipe to the rigid state, using a resin or heat.

10. The composite core material of claim 1 whereby the core material may be hollow to allow fluids to flow through the core to function as a pipe or duct, such as a water pipe or an air conditioning air duct.

11. The hollow core material of claim 10 whereby the core material acts as an insulation material.

12. The flexible composite beam or material of claim 8 whereby the material may be used as a repair material for boats, furniture, or any other apparatus that requires strengthening.

13. The beam or pipe of claim 1 whereby chemical bonds, such as resins or bonding agents, or the application of heat in case of thermo set bonds are used to attach individual sections of flexi-beam or rigid beam together to create a much stronger bond than is produced by fasteners, which allows sections of flexi- beam or flexi-pipe to be bonded to other sections of 100 flexi-beam or flexi-pipe material or to sections of rigid-beam or rigid-pipe merely by placing them firmly together during the bonding process.

14. The beam or pipe of claim 1 whereby a dual-plane, dual-axis matrix may be formed by placing on one

105 plane a series of parallel sections of flexi-beam to form a continuous side-by-side layer running in the X-Axis direction. Then placing a second layer of parallel sections of flexi-beam side-by-side over the top of the lower layer running in the Y-Axis

110 direction and bonding the entire assembly together using a resin or heat as either a single bonding application or as a series of bonds. 15. The X-axis and Y-Axis geometry of claim 14 whereby the X-Axis layer is separated from the Y-Axis upper

115 plane layer by a flat layer of composite material that acts as a bonding layer to bond the upper plane X-Axis Layer securely to the lower plane Y-Axis layer to form a complex composite matrix geometry having superior strength.

120 16. The beam or pipe of claim 1 whereby the material may easily be cut into sections of any length prior to the application of a resin because there is no hard cured resin that is difficult to cut through.

17. The beam or pipe of claim 1 whereby the beams or pipe

125 are made of very strong lightweight composite materials that after curing are stronger and lighter than conventional construction materials.

18. A method of constructing a single bond composite material having an internal framework consisting of

130 corrugations running in both the X-Axis and Y-Axis directions that are positioned on two different planes and are bonded together into a single section of composite material by a bonding layer that is positioned between the X-Axis corrugation layer and

135 , the Y-Axis corrugation layer, the method comprising: providing a composite bonding layer, such as carbon fiber or Kevlar that is positioned in the center of a corrugated layer of composite material running in the X-Axis direction and a corrugated layer of composite

140 material running in the Y-Axis direction such that the two corrugated layers do not intersect and such that both the X-Axis corrugations and the Y-Axis corrugations are closed by the bonding layer to form sealed sectional modulus;

145 introducing an epoxy resin; and, curing the baked composite material to create a single bond composite material of high strength.

19. Outer layers may be applied to the single bond composite material of claim 18 for even greater

150 strength.

20. The application of outer layers of claim 19 whereby additional closed modulus sections are created to provide even greater strength.

21. The single bond composite material of claim 18

155 whereby a flat panel having a dual plane, dual axis geometry is produced.

22. The single bond composite material of claim 18 whereby a cylinder having a dual plane, dual axis geometry is produced.

160 23. The cylinder of claim 22 whereby the cylinder is formed by corrugated rings running in the Y-Axis layer having a bonding layer between the corrugated rings and a second corrugated running in the X-Axis direction the entire length of the cylinder.

165 24. The cylinder of claim 2 whereby a -spiral wound layer of composite material is wrapped around the cylinder as an outer layer of the cylinder to provide additional strength prior to application of the epoxy resin and baking and curing.

170 25. The cylinder of claim 22 whereby the cylinder has conical ends and is used as a pressure vessel or is used as the pontoon of a boat or an aircraft.

26. A method of molding and curing a composite material structure, the method comprising:

175 providing hoses that run through the center of layers of composite materials; introducing pressurized hot water that flows through the center of the thin walled hoses; the pressurized water applying a force against the

180 hoses and thereby causing the hoses to form a fixed shape; the flowing hot water providing heat to the surrounding layers of composite materials; the heat curing the layers of composite materials.

185 27. The method of claim 26 whereby the hoses are thin walled hoses.

28. The method of claim 26 whereby the hoses are thermally conductive.

29. The method of claim 26 whereby the hoses run in the 190 X-Axis direction.

30. The method of claim 26 whereby the hoses run in the Y-Axis direction.

31. The method of claim 26 whereby the hoses run in both the X-Axis and the Y-Axis directions.

195 32. The method of claim 26 whereby the hoses form corrugations within the composite materials in the X- Axis direction.

33. The method of claim 26 whereby the hoses form corrugations within the composite materials in the Y-

200 Axis direction.

34. The method of claim 26 whereby the hoses form corrugations within the composite materials in the X- Axis and Y-Axis directions.

35. The method of claim 26 whereby the water is removed 205 from the hoses within the composite material structure after the layers of composite materials have been cured to reduce the weight of the composite material structure.

36. The method of claim 26 whereby the hoses are removed 210 from the composite material structure after the layers of composite materials have been cured to reduce the weight of the composite material structure 37. A method of constructing a extrusion or pultruded composite material having an internal framework

215 consisting of corrugations running in both the X-Axis and Y-Axis directions that are positioned on two different planes and are bonded together into a single section of composite material by a bonding agent that is positioned between the X-Axis

220 corrugation layer forming sealed sectional modulus and the Y-Axis corrugation layer forming sealed sectional modulus, the method comprising: producing an X-Axis layer of composite material using an extrusion using a liquid composite material or

225 pultrusion machine using a fiber, such as fiberglass, carbon fiber or Kevlar; producing an Y-Axis layer of composite material using an extrusion or pultrusion machine using a fiber, such as fiberglass, carbon fiber or Kevlar;

230 rotating the Y-Axis layer to approximately perpendicular to the X-Axis Layer; and, bonding the X-_Axis layer and Y-Axis layers together with a bonding agent to form a very strong new composite material.

235 38. Amethod of claim 18 whereby a flexible composite material matrix structure of complex geometry that conforms to any shape, such as the curved shapes of a boat hull or an airplane section or any other irregular of curving shape is formed

240 39. The flexible composite material matrix of claim 38 is formed by weaving, spiral wrapping or spraying, etc. a composite material fabric or prepreg composite material around a core material that may be either solid, foam, or a gas filled or liquid filled

245 envelope in order to form corrugations of the fabric material that provide additional strength. The core material is made into sections, like a link sausage or may be lengths of continuous flexible flotation material. Therefore, bending may occur at the

250 intersection of each section to create flexibility and the length of the sections may be altered to determine the degree of flexibility. Alternately the core material may be continuous lengths of lightweight flexible flotation material that is round, 255 square, or any other desired shape. 40. The flexible matrix of claim 38 may be applied to any formed shape, such as a mold; and, 41. The flexible matrix of claim 38 whereby a length of fabric material is spiral wound around the core

260 material that is either perpendicular or parallel to the length of the fabric in order to produce long sections of the flexible composite matrix. 42. The long sections of material of claim 41 whereby the long sections are formed into a roll.

265

270

275

280

285