US5082701A
Expired / Lapsed
US
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Multi-directional, light-weight, high-strength interlaced material and method of making the material
Assignee: Joss Co
•
Filing: 1987-12-09
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Granted: 1992-01-21
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Expires: 2007-12-09
Abstract
Abstract Continuous flat unidirectional flat ribbons, which have been precut from an impregnated fiber reinforced-matrix composite tape so as to have a substantially greater width than thickness, are interlaced in over-and-under relationship in 0 degree and 90 degree directions into the form of a continuous, multi-directional seamless tube. The tube may be cut into tubular sections, which then are subjected to temporary heat and pressure so that the matrix fuses the interlaced ribbons to form an integral tube. The elongated seamless tube also may be cut into planar sections and used to form integral members of planar or contoured construction. The integral members may be formed of a single layer of the interlaced material, or of laminated construction form multiple layers of the interlaced material, with the ribbons of each layer either extending parallel, at an angle other than 0/90 degrees, aligned, or offset, with respect to the ribbons in the other layer(s). The formed members may have interlaced ribbons of different types and/or contain different types of fibers in different sections of the members, to provide the members with different structural characteristics.
Inventors
- 👤 Paul t. Craven
- 👤 Richard A. Fisher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 23:19
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2305/00; B32B2305/07; B32B2307/00; B32B2307/50; B32B2307/536; B32B2307/70; B32B2307/718; B32B2605/00; B32B2605/18; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/13; Y10T428/131; Y10T428/1314; Y10T428/1352; Y10T428/1362; Y10T428/30
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
171 words
A circular-machine-interlaced material of multi-directional, light weight, high-strength construction, which comprises: a plurality of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the material, with the ribbons having sets of respective opposed engaged flat surface portions disposed in the plane of the material and the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons having continuous fibers extending in only longitudinal directions in said at least some 0 degree and 90 degree ribbons, respectively; and at least some of the 0 degree and 90 degree ribbons having been pre-impregnated with a matrix so that substantially all of the continuous fibers of the respective ribbons are encapsulated in the matrix and substantially the entire surface area of each of the opposed engaged flat surface portions of each set of said opposed engaged flat surface portions of the respective ribbons is coated with the matrix.
Claim 2
Dependent Claim
171 words
A circular-machine-interlaced material of multi-directional, light weight, high-strength construction, which comprises: a plurality of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the material, with the ribbons having sets of respective opposed engaged flat surface portions disposed in the plane of the material and the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons having continuous fibers extending in only longitudinal directions in said at least some 0 degree and 90 degree ribbons, respectively; and at least some of the 0 degree and 90 degree ribbons having been pre-impregnated with a matrix so that substantially all of the continuous fibers of the respective ribbons are encapsulated in the matrix and substantially the entire surface area of each of the opposed engaged flat surface portions of each set of said opposed engaged flat surface portions of the respective ribbons is coated with the matrix.
Claim 3
Dependent Claim
13 words
The material as recited in claim 1, wherein the matrix is a thermoplastic.
Claim 4
Dependent Claim
14 words
The material as recited in claim 1, wherein the matrix is a thermosetting plastic.
Claim 5
Dependent Claim
13 words
The material as recited in claim 1, wherein the matrix is a ceramic.
Claim 6
Dependent Claim
36 words
The material as recited in claim 1, wherein the ribbons have a thickness of at least 2 mils and a width of at least 1/8 inch, and the interlaced ribbons have an essentially flat, unkinked configuration.
Claim 7
Dependent Claim
39 words
The material as recited in claim 5, wherein the ribbons have a thickness in a range on the order of 2 to 150 mils and a width in a range on the order of 1/8 inch to 3 inches.
Claim 8
Dependent Claim
22 words
The material as recited in claim 1, wherein at least some of the ribbons include continuous carbon, glass, boron and/or ceramic fibers.
Claim 9
Dependent Claim
18 words
The material as recited in claim 1, wherein at least some of the ribbons include continuous synthetic fibers.
Claim 10
Dependent Claim
18 words
The material as recited in claim 1, wherein at least some of the ribbons are solid metal ribbons.
Claim 11
Dependent Claim
20 words
The material as recited in claim 1, wherein at least some of the ribbons include metal powder and/or metal filaments.
Claim 12
Dependent Claim
70 words
The material as recited in claim 1, wherein a major portion of the 0 degree ribbons are of a first material and a major portion of the 90 degree ribbons are of a second material interlaced in a pattern with a major portion of the first material on one side of the interlaced material and a major portion of the second material on an opposite side of the interlaced material.
Claim 13
Dependent Claim
20 words
The material as recited in claim 11, wherein the first material is metallic and the second material is electrically insulating.
Claim 14
Dependent Claim
49 words
The material as recited in claim 11, wherein the material is of elongated tubular seamless construction and at least some of the 90 degree ribbons are ribbon portions formed by a single continuous helically extending ribbon extending at a slightly inclined angle to the axis of the tubular material.
Claim 15
Dependent Claim
15 words
The material as recited in claim 1, wherein the material is of flexible planar construction.
Claim 16
Dependent Claim
22 words
The material as recited in claim 1, wherein the matrix bonds the interlaced ribbons together and forms a material of integral construction.
Claim 17
Dependent Claim
51 words
The material as recited in claim 15, wherein the integral material is of elongated tubular seamless construction and at least some of the 90 degree ribbons are ribbon portions formed by a single respective continuous helically extending ribbon extending at a slightly inclined angle to the axis of the tubular material.
Claim 18
Dependent Claim
15 words
The material as recited in claim 15, wherein the integral material is of planar construction.
Claim 19
Dependent Claim
15 words
The material as recited in claim 15, wherein the integral material is of contoured construction.
Claim 20
Dependent Claim
24 words
The material as recited in claim 15, wherein the integral material includes separate sections having interlaced ribbons formed of different types of continuous fibers.
Claim 21
Dependent Claim
216 words
A multi-directional, light-weight, high-strength laminated material, which comprises: a circular-machine-formed first layer of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the first layer and with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least one additional circular-machine-formed layer of 0 degree and 90 degree flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the at least one additional layer and with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons of each layer comprising continuous unidirectional fibers pre-impregnated with a matrix so that substantially all of the continuous fibers are encapsulated in the matrix, and the elongated 0 degree and 90 degree ribbons of each layer having the continuous fibers extending in only longitudinal directions in said 0 degree and 90 degree ribbons, respectively; the layers of 0 degree and 90 degree ribbons being in superimposed relationship with respect to one another; and the 0 degree and 90 degree ribbons of each layer being integrally bonded to each other and the 0 degree and 90 degree ribbons of each adjacent layer by the matrix.
Claim 22
Dependent Claim
216 words
A multi-directional, light-weight, high-strength laminated material, which comprises: a circular-machine-formed first layer of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the first layer and with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least one additional circular-machine-formed layer of 0 degree and 90 degree flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the at least one additional layer and with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons of each layer comprising continuous unidirectional fibers pre-impregnated with a matrix so that substantially all of the continuous fibers are encapsulated in the matrix, and the elongated 0 degree and 90 degree ribbons of each layer having the continuous fibers extending in only longitudinal directions in said 0 degree and 90 degree ribbons, respectively; the layers of 0 degree and 90 degree ribbons being in superimposed relationship with respect to one another; and the 0 degree and 90 degree ribbons of each layer being integrally bonded to each other and the 0 degree and 90 degree ribbons of each adjacent layer by the matrix.
Claim 23
Dependent Claim
59 words
A multi-directional, light-weight high-strength laminated material, as recited in claim 20, wherein the interlaced ribbons of at least one layer extend at an angle to the interlaced ribbons of at least one other layer which is greater than the slightly inclined angle at which the 90 degree ribbons extend with respect to the 0 degree ribbons in each layer.
Claim 24
Dependent Claim
34 words
A multi-directional, light-weight, high-strength laminated material, as recited in claim 20, wherein the interlaced ribbons of at least one layer are offset with respect to the interlaced ribbons of at least one other layer.
Claim 25
Dependent Claim
44 words
A multi-directional, light-weight, high-strength laminated material, as recited in claim 22, wherein at least some of the interlaced ribbons of at least one layer are of different construction than at least some of the interlaced ribbons of at least one of the other layers.
Claim 26
Dependent Claim
133 words
A circular-machine-interlaced material of multi-directional, light-weight, high-strength, integral flexible construction, which comprises: a plurality of spaced continuous elongated ribbons of continuous unidirectional fibers extending in interlaced over-and-under symmetrical relationship with respect to a plane of the material in approximately 0 degree and 90 degree directions, respectively, with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; said elongated fibers in the 0 degree ribbons extending only in a longitudinal direction in the 0 degree ribbons and the elongated fibers in the 90 degree ribbons extending only in a longitudinal direction in the 90 degree ribbons; and a matrix bonding the ribbons of continuous unidirectional fibers, the matrix also impregnating the fibers of each ribbon and covering exterior surfaces of the ribbons to provide the integral flexible material.
Claim 27
Dependent Claim
133 words
A circular-machine-interlaced material of multi-directional, light-weight, high-strength, integral flexible construction, which comprises: a plurality of spaced continuous elongated ribbons of continuous unidirectional fibers extending in interlaced over-and-under symmetrical relationship with respect to a plane of the material in approximately 0 degree and 90 degree directions, respectively, with the 90 degree ribbons extending at a slightly inclined angle to the 0 degree ribbons; said elongated fibers in the 0 degree ribbons extending only in a longitudinal direction in the 0 degree ribbons and the elongated fibers in the 90 degree ribbons extending only in a longitudinal direction in the 90 degree ribbons; and a matrix bonding the ribbons of continuous unidirectional fibers, the matrix also impregnating the fibers of each ribbon and covering exterior surfaces of the ribbons to provide the integral flexible material.
Claim 28
Dependent Claim
11 words
The material of claim 24, wherein the matrix is a thermoplastic.
Claim 29
Dependent Claim
12 words
The material of claim 24, wherein the matrix is a thermosetting plastic.
Claim 30
Dependent Claim
11 words
The material of claim 24, wherein the matrix is a ceramic.
Claim 31
Dependent Claim
170 words
A circular-machine-interlaced material of multi-directional, light-weight, high-strength construction, which comprises: a plurality of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the material so that the ribbons have sets of respective opposed engaged flat surface portions disposed in the plane of the material and the 90 degree ribbons extend at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons having fibers extending in only longitudinal directions in said at least some 0 degree and 90 degree ribbons, respectively; and at least some of the 0 degree and 90 degree ribbons having been being pre-impregnated with a matrix so that substantially all of the fibers of the respective ribbons are encapsulated in the matrix and substantially the entire surface area of each of the opposed engaged flat surface portions of each set of said opposed engaged flat surface portions of the respective ribbons is coated with the matrix.
Claim 32
Dependent Claim
170 words
A circular-machine-interlaced material of multi-directional, light-weight, high-strength construction, which comprises: a plurality of 0 degree and 90 degree elongated flat ribbons interlaced in over-and-under symmetrical relationship with respect to a plane of the material so that the ribbons have sets of respective opposed engaged flat surface portions disposed in the plane of the material and the 90 degree ribbons extend at a slightly inclined angle to the 0 degree ribbons; at least some of the elongated 0 degree and 90 degree ribbons having fibers extending in only longitudinal directions in said at least some 0 degree and 90 degree ribbons, respectively; and at least some of the 0 degree and 90 degree ribbons having been being pre-impregnated with a matrix so that substantially all of the fibers of the respective ribbons are encapsulated in the matrix and substantially the entire surface area of each of the opposed engaged flat surface portions of each set of said opposed engaged flat surface portions of the respective ribbons is coated with the matrix.
Claim 33
Dependent Claim
88 words
A circular-machine-interlaced fabric of flat tapes of polymeric material reinforced with continuous filaments in both the warp and weft directions, said warp and weft tapes being interlaced in over-and-under symmetrical relationship with respect to a plane of the fabric, with the warp and weft tapes having sets of opposed flat surface portions disposed in the plane of the fabric and the weft tapes extending at a slightly inclined angle to the warp tapes, and said warp and weft tapes having edges that are abutting substantially throughout the fabric.
Claim 34
Dependent Claim
88 words
A circular-machine-interlaced fabric of flat tapes of polymeric material reinforced with continuous filaments in both the warp and weft directions, said warp and weft tapes being interlaced in over-and-under symmetrical relationship with respect to a plane of the fabric, with the warp and weft tapes having sets of opposed flat surface portions disposed in the plane of the fabric and the weft tapes extending at a slightly inclined angle to the warp tapes, and said warp and weft tapes having edges that are abutting substantially throughout the fabric.
Claim 35
Dependent Claim
8 words
A composite of the fabric of claim 29.
Claim 36
Dependent Claim
29 words
The material as recited in claim 1, wherein the 0 degree ribbons are disposed in tightly abutted relationship, and the 90 degree ribbons are disposed in tightly abutted relationship.
Claim 37
Dependent Claim
33 words
A multi-directional, light-weight, high-strength laminated material, as recited in claim 20, wherein the 0 degree ribbons are disposed in tightly abutted relationship, and the 90 degree ribbons are disposed in tightly abutted relationship.
Claim 38
Dependent Claim
27 words
The material of claim 24, wherein the 0 degree ribbons are disposed in tightly abutted relationship, and the 90 degree ribbons are disposed in tightly abutted relationship.
Claim 39
Dependent Claim
27 words
The material of claim 28, wherein the 0 degree ribbons are disposed in tightly abutted relationship, and the 90 degree ribbons are disposed in tightly abutted relationship.
Claim 40
Dependent Claim
25 words
The fabric of claim 29, wherein the warp tapes are disposed in tightly abutted relationship, and the weft tapes are disposed in tightly abutted relationship.
Claim 41
Dependent Claim
8 words
A composite of the fabric of claim 35.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-01-20 | 1995-07-22 | 1996-01-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-01-20 | 1999-07-22 | 2000-01-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-01-20 | 2003-07-22 | 2004-01-21 | $7700.00 | Window Closed / Lapsed |