Fiber reinforced hybrid composite winding core

Abstract

A hybrid fiber reinforced polymer winding core consisting of several layers of different materials. The winding core layers are constructed so that structural reinforcing layers are sandwiched between outer protective layers. The outermost protective layer and innermost protective layer define the outer wall surface and inner wall surface of the winding core.

I claim:  
     
         1 . A hybrid, fiber reinforced, polymer, web winding core for use in winding web material, comprising: 
 a cylindrical, hollow winding core wall having two ends, said two ends defining a winding core longitudinal axis, said wall having an exterior surface and an inner surface, said exterior surface and inner surface defining a wall thickness, said wall being comprised of a plurality of layers made from fiber reinforced material, said plurality of layers having a plurality of structural reinforcing layers sandwiched between a plurality of outer protective layers, said plurality of structural reinforcing layers adapted to provide resistance to longitudinal bending and radial crushing, said outer protective layers having an outermost protective layer defining the wall exterior surface and an innermost protective layer defining the wall inner surface.    
     
     
         2 . A winding core as recited in  claim 1 , wherein: 
 a plurality of the plurality of structural reinforcing layers contains material with fibers primarily oriented in a longitudinal direction parallel with the winding core longitudinal axis, said layer adapted to resist longitudinal bending.    
     
     
         3 . A winding core as recited in  claim 2 , wherein: 
 a plurality of the plurality of structural reinforcing layers contains material with fibers primarily oriented in a circumferential direction, said layers adapted to resist crushing.    
     
     
         4 . A winding core as recited in  claim 3 , wherein: 
 said plurality of layers containing material with fibers primarily oriented in a longitudinal direction are located in the center of the wall thickness; and    said plurality of layers containing material with fibers primarily oriented in a circumferential direction are located near to the inner and outer wall surfaces.    
     
     
         5 . A winding core as recited in  claim 4 , further comprising: 
 an end cap slidably positioned over and fastened to each end of the winding core wall.    
     
     
         6 . A winding core as recited in  claim 5 , further comprising: 
 a molded texture formed on said outermost protective layer.    
     
     
         7 . A winding core as recited in  claim 6 , wherein: 
 said fiber reinforced material is held in a matrix formed from the following classes of materials:    thermoset polymers such as epoxy resins, polyester resins, or vinyl ester resins, phenolic resins and thermoplastic resins.    
     
     
         8 . A winding core as recited in  claim 7 , wherein: 
 said fiber reinforced material contain fibers made from the following classes of materials: glass, carbon, Kevlar, polyethylene, basalt, hemp, kenaf, and sisal.    
     
     
         9 . A winding core as recited in  claim 8 , wherein: 
 said plurality of layers containing material with fibers primarily oriented in a longitudinal direction contain glass fibers in a matrix containing twenty to forty percent resin.    
     
     
         10 . A winding core as recited in  claim 9 , wherein: 
 a plurality of layers containing material with fibers primarily oriented in a circumferential direction contain carbon fibers in a matrix containing twenty to forty percent resin.    
     
     
         11 . A winding core as recited in  claim 10 , wherein: 
 a plurality of layers containing material with fibers primarily oriented in a circumferential direction contain glass fibers in a matrix containing twenty to forty percent resin.    
     
     
         12 . A winding core as recited in  claim 11 , wherein: 
 the outermost and innermost protective layers are comprised of a composition with sixty to eighty percent polymer resin, said innermost and outermost protective layers adapted to act as sealers protecting the other layers from fraying damage.    
     
     
         13 . A winding core as recited in  claim 12 , wherein: 
 a plurality of protective layers being comprised of woven fiberglass cloth with approximately equal amounts of fiber in warp and fill directions, said protective layers containing thirty to fifty percent resin.    
     
     
         14 . A winding core as recited in  claim 13 , wherein: 
 a portion of said outer protective layers are removed near the winding core end and said cap positioned over that portion of the winding core wall without the outer protective layers.