Composite structural member with high bending strength

Abstract

A composite member (10) features a unique ply geometry which contributes to improved bending strength. The composite is constructed of a plurality of plies, each comprising a fiber component disposed within a polymer matrix. An inner ply (16) has a fiber component (18) which has fibers which are circumferentially extending. An intermediate ply (22) has first axially extending fibers (24) which are disposed about the circumference of the composite, as well as second axial fibers (30) which are interwoven with helically oriented fibers (36) and embedded in a polymer matrix (14). An outer layer (38) is similar to the inner layer as it features circumferentially extending fibers (40) which are embedded in a polymer matrix. The composite materials may be used to manufacture a wide range of items which require light weight combined with high strength.

Having described the invention, what is claimed as new and secured by Letters Patent is: 
     
       1. A tubular composite structural member having a plurality of plies, each ply being defined by a fiber component disposed within a polymer matrix, said composite member having the improvement comprising A. at least one inner ply having circumferentially extending fibers,   B. at least one outer ply having circumferentially extending fibers, and   C. at least one intermediate ply having i) first axially extending fibers in circumferentially-spaced sets with circumferential gaps between each set of the first fibers, and   ii) second axially extending fibers in circumferentially-spaced sets disposed in said circumferential gaps, each said second fiber being interwoven with helically oriented fibers,   said inner, outer and intermdiate plies forming a tubular, elongate composite structural member.     
     
     
       2. A composite structural member according to claim 1 wherein the inner ply and the outer ply each contribute less than twenty-five percent to the total modulus of elasticity of the composite. 
     
     
       3. A composite structural member according to claim 2 having three said intermediate plies. 
     
     
       4. A composite structural member according to claim 1 wherein the diameter of the circumferentially extending fibers ranges between 0.007 inch and 0.040 inch. 
     
     
       5. A composite structural member according to claim 4 wherein the diameter of the axial fibers ranges between 0.007 inch and 0.040 inch. 
     
     
       6. A composite structural member according to claim 1 wherein the diameter of said helically oriented fibers is less than 25% that of said axially extending fibers. 
     
     
       7. A composite structural member according to claim 1 wherein said circumferential fibers are of a material selected from the group consisting of aramid fibers, carbon fibers, and glass fibers having a modulus of at least 10 million psi. 
     
     
       8. A composite structural member according to claim 1 wherein said axially extending fibers are of a material selected from the group consisting of carbon fiber, glass fiber, ceramic fiber, boron fiber and aramid fiber having a modulus of at least 12 million psi. 
     
     
       9. A composite structural member according to claim 1 wherein said helically oriented fibers are of a material selected from the group consisting of aramid fibers, carbon fibers and glass fibers having a modulus of at least 10 million psi. 
     
     
       10. A composite structural member according to claim 1 having a longitudinal axis and wherein said circumferential fibers are oriented at an angle of approximately ±30° to ±90° relative to the longitudinal axis of the member. 
     
     
       11. A composite structural member according to claim 10, wherein said axial fibers are oriented at an angle of approximately 0° to the longitudinal axis of the member. 
     
     
       12. The composite structural member according to claim 11 wherein said helically oriented fibers are oriented at an angle of approximately ±5° to ±60° relative to the longitudinal axis of the member. 
     
     
       13. A composite structural member according to claim 1 wherein the polymer matrix is of a material selected from the group consisting of epoxy, polyester and vinyl ester. 
     
     
       14. A composite structural member according to claim 1 wherein the polymer matrix is of a material selected from the group consisting of polyphenylene sulfide, polysulfone, polyethylene terephthalate, polypropylene, polycarbonate, acetal, nylon and polyetheretherketone. 
     
     
       15. A composite structural member according to claim 14 wherein the ratio by volume of resin in the polymer matrix to fiber is 1:1 or less. 
     
     
       16. A composite structural member according to claim 1 having a bending strength of at least 0.25% maximum laminate strain. 
     
     
       17. A nautical sail mast consisting of a composite structural member according to claim 1. 
     
     
       18. A whip antenna housing consisting of a composite structural member according to claim 1. .Iadd. 
     
     
       19.  A composite structure according to claim 1 wherein said intermediate ply is helically oriented in that said first and second axially extending fibers are helically oriented and said helically oriented fibers interwoven with said second fibers are helically oriented relative to said first and second fibers..Iaddend. .Iadd.20. In a tubular composite member having a plurality of plies, wherein each ply has a fiber component disposed within a polymer matrix, the improvement comprising (A) at least a first clockwise helically oriented ply having (i) first clockwise helically oriented fibers in circumferentially-spaced sets with first circumferential gaps between each set of the first fibers, (ii) second helically oriented fibers in circumferentially-spaced sets disposed in said first circumferential gaps, and (iii) third fibers interwoven with said second fibers, and   (B) at least a second counter-clockwise helically oriented ply having (i) fourth counter-clockwise helically oriented fibers in circumferentially-spaced sets with second circumferential gaps between each set of the fourth fibers, (ii) fifth helically oriented fibers in circumferentially-spaced sets disposed in said second circumferential gaps, and (iii) sixth fibers interwoven with said fifth fibers..Iaddend.   
     
     
        .Iadd.21.  In a tubular composite member according to claim 20, the further improvement comprising at least one inner ply having circumferentially extending fibers, said inner ply being interior to said first and second plies..Iaddend. .Iadd.22. In a tubular composite member according to claim 20, the further improvement comprising at least one outer ply having circumferentially extending fibers, said outer ply being exterior to said first and second plies..Iaddend. .Iadd.23. In a tubular composite member according to claim 20, the further improvement comprising at least one axially oriented further ply disposed interior to one of said first and second plies and exterior to the other of said first and second 
     
     
        plies..Iaddend. .Iadd.24.  An elongated tubular composite member having the improvement comprising a ply having an axially extending first fiber component helically oriented relative to the elongation of the composite member and having a clockwise extending second fiber component interwoven with a counterclockwise extending third fiber component, both of which are helically oriented relative to the first fiber component..Iaddend. .Iadd.25. An elongated tubular composite member having the improvement comprising a ply having axially extending first fibers helically oriented relative to the elongation of the composite member and having clockwise extending second fibers interwoven with counterclockwise extending third fibers, both of which are symmetrically helically oriented relative to the first fibers..Iaddend.