Composite structure and method of manufacture

Abstract

A fiberglass laminate used in fabricating a composite pile comprising a plurality of fiberglass type layers and an impervious tube array. A tubular composite pile construction includes the laminate as well as plastic inner and outer skins and a resin injected into the laminate. A method of fabrication includes providing a mandrel, wrapping a plastic inner sleeve about a bladder on the mandrel, wrapping the fiberglass laminate and wrapping a plastic outer skin about the laminate. Lastly, a resin is injected into the laminate to substantially fill between the inner and outer skins.

1 . A fiberglass laminate used in fabricating a composite pile comprising:
 first and second layers of a fiberglass material;   a plurality of fiberglass strands extending in a spaced unidirectional matrix and disposed between said respective first and second layers; and   a plurality of pervious tube members extending between respective first and second layers and uniformly arranged so as to enable injection on a resin material therethrough.   
     
     
         2 . The fiberglass laminate of  claim 1  wherein said first layer comprises a woven roving fiberglass cloth. 
     
     
         3 . The fiberglass laminate of  claim 2  wherein the fiberglass cloth has a density of from 12 oz. per square yard to 48 oz. per square yard. 
     
     
         4 . The fiberglass laminate of  claim 1  wherein said second layer comprises at least one of a continuous strand fiberglass mat and distributed random fiberglass filaments. 
     
     
         5 . The fiberglass laminate of  claim 4  wherein said second layer has a density of from 12 oz. per square yard to 48 oz. per square yard. 
     
     
         6 . The fiberglass laminate of  claim 1  wherein the fiberglass strands comprise continuous fiberglass rovings with a per bundle yield between 53 yards per pound and 625 yards per pound. 
     
     
         7 . The fiberglass laminate of  claim 6  wherein the strands are grouped, spread and controlled to yield between 30 oz. per square yard and 250 oz. per square yard of unidirectional reinforcement. 
     
     
         8 . The fiberglass laminate of  claim 1  wherein the tube members comprise spiral slotted members from which the resin can escape therealong. 
     
     
         9 . The fiberglass laminate of  claim 1  wherein the laminate is subjected to passage through a needle loom to form orthogonal fiberglass filaments for binding the layers together. 
     
     
         10 . The fiberglass laminate of  claim 2  wherein the woven roving cloth is heavier in the hoop direction, greater than 50% and lighter in the vertical direction, less than 50%. 
     
     
         11 . The fiberglass laminate of  claim 10  wherein the hoop or annular strands are preferably about 80% in number and the vertical about 20% in number. 
     
     
         12 . The fiberglass laminate of  claim 1  wherein the laminate is subjected to passage through a sewing head. 
     
     
         13 . A tubular composite pile construction comprising:
 a pre-formed laminate of a plurality of fiberglass layers that are bound together;   a plastic inner skin on one side of the laminate and constructed and arranged to form an inner surface of the tubular pile;   a plastic outer skin on an opposite side of the laminate and constructed and arranged to form an outer surface of the tubular pile; and   a resin injected into said laminate with the skins forming a mold for retaining the resin while also forming the respective inner and outer pile surfaces.   
     
     
         14 . The construction of  claim 13  wherein the pre-formed laminate comprises:
 first and second layers of a fiberglass material; 
 a plurality of fiberglass strands extending in a spaced unidirectional matrix and disposed between said respective first and second layers; and 
 a plurality of pervious tube members extending between respective first and second layers and uniformly arranged so as to enable injection on the resin material therethrough. 
 
     
     
         15 . The construction of  claim 14  wherein the pervious tube members receive the resin and inject the resin between the first and second layers. 
     
     
         16 . The construction of  claim 13  wherein at least one of the skins is made of PET. 
     
     
         17 . The construction of  claim 13  wherein the resin is injected with a vacuum. 
     
     
         18 . A method of fabricating a tubular composite pile, comprising the steps of:
 providing a mandrel having a bladder thereabout that can be inflated;   wrapping a plastic inner sleeve about the bladder;   wrapping a fiberglass laminate, that is comprised of a plurality fiberglass layers that are at least loosely bound together, about the plastic inner sleeve;   wrapping a plastic outer skin about the laminate; and   injecting a resin into the laminate to substantially fill between the inner sleeve and outer skin.   
     
     
         19 . The method of  claim 18  including inflating the bladder prior to injecting the resin. 
     
     
         20 . The method of  claim 19  wherein the bladder is inflated to a pressure between 2 and 50 pounds per square inch. 
     
     
         21 . The method of  claim 18  wherein the resin is injected using vacuum. 
     
     
         22 . The method of  claim 21  wherein the vacuum is between 24 and 29 inches of mercury. 
     
     
         23 . The method of  claim 22  wherein the resin is injected at a pressure between 2 and 50 pounds per square inch. 
     
     
         24 . The method of  claim 18  wherein the resin is injected through a flow channel within the laminate. 
     
     
         25 . The method of  claim 18  wherein the resin is injected through a flow channel disposed outside of the laminate.