US5401564A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Materials and processes for fabricating formed composite articles and use in shoe arch
Assignee: Hexcel Corp
•
Filing: 1993-03-23
•
Granted: 1995-03-28
•
Expires: 2013-03-23
Abstract
Abstract A strong, lightweight composite material having beneficial flexing characteristics is made using a unique reinforcement material. The reinforcement material comprises a fabric incorporating glass rovings with graphite tows in an architectural combination that retains the properties of both materials. Composite structures made using this reinforcement material with a thermosetting or thermoplastic matrix are extremely lightweight, with desirable anisotropic flexing properties. The finished composite structure is extremely useful as an arch support in a shoe to absorb and distribute the forces generated by walking. In distributing forces on the foot such a support will provide the desired stiffness along the longitudinal axis while allowing increased flexibility along the transverse axis.
Inventors
- 👤 Frank F. W. Lee
- 👤 Thomas K. Owen
- 👤 William J. Swanson
- 👤 James R. Watts
- 👤 Susan M. Brinkerhoff
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 22:56
CPC Classifications
A; A43; A43B; A43B7/00; A43B7/14; A43B7/22; A43B7/226; B; B29; B29C; B29C70/00; B29C70/04; B29C70/06; B29C70/10; B29C70/16; B29C70/22; B29C70/28; B29C70/40; B29C70/42; B29C70/46; B29K; B29K2105/00; B29K2105/06; B29K2105/08; B29K2105/0809; B29K2105/0845; B29K2307/00; B29K2309/00; B29K2309/08; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/24628; Y10T428/24636; Y10T428/24942; Y10T428/29; Y10T428/2913; Y10T428/2915; Y10T442/00; Y10T442/30; Y10T442/3179; Y10T442/322; Y10T442/3228; Y10T442/3236; Y10T442/3301; Y10T442/3309
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
85 words
An anisotropic structural composite comprising: at least one ply of an anisotropic woven fabric reinforcement comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; and, a matrix wetting said at least one woven fabric reinforcement wherein said matrix is hardened to provide an anisotropic structural composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 2
Dependent Claim
85 words
An anisotropic structural composite comprising: at least one ply of an anisotropic woven fabric reinforcement comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; and, a matrix wetting said at least one woven fabric reinforcement wherein said matrix is hardened to provide an anisotropic structural composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 3
Dependent Claim
24 words
The anisotropic structural composite of claim 1 wherein said matrix is selected from the group consisting of thermosetting resins, thermoplastic resins and combinations thereof.
Claim 4
Dependent Claim
34 words
The anisotropic structural composite of claim 2 wherein said matrix is a thermosetting resin and said thermosetting resin is selected from the group consisting of epoxy resins, polyester resins, acrylic resins, and polyurethane resins.
Claim 5
Dependent Claim
30 words
The anisotropic structural composite of claim 2 wherein said matrix is a thermoplastic resin and said thermoplastic resin is selected from the group consisting of polyetherimides, polyurethanes, polycarbonates and acrylics.
Claim 6
Dependent Claim
98 words
A process for forming an anisotropic shaped composite structure comprising; providing at least one ply of anisotropic reinforcement material comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; wetting said at least one ply of anisotropic reinforcement material with a resin matrix; and shaping the anisotropic reinforcement material wetted with the resin matrix to provide an anisotropic shaped composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 7
Dependent Claim
98 words
A process for forming an anisotropic shaped composite structure comprising; providing at least one ply of anisotropic reinforcement material comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; wetting said at least one ply of anisotropic reinforcement material with a resin matrix; and shaping the anisotropic reinforcement material wetted with the resin matrix to provide an anisotropic shaped composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 8
Dependent Claim
17 words
The process of claim 5 wherein said shaping step is accomplished by simultaneously applying heat and pressure.
Claim 9
Dependent Claim
25 words
The process of claim 6 wherein said pressure is applied in a mold having a rigid male face and a compliant female face opposite thereto.
Claim 10
Dependent Claim
27 words
The process of claim 7 wherein the male face is a metal or metal alloy and the female face is silicone or a polyurethane gas pressure bag.
Claim 11
Dependent Claim
22 words
The process of claim 5 wherein said matrix is selected from the group consisting of thermosetting resins, thermoplastic resins, and combinations thereof.
Claim 12
Dependent Claim
32 words
The process of claim 9 wherein said matrix is a thermosetting resin and said thermosetting resin is selected from the group consisting of epoxy resins, polyester resins, acrylic resins, and polyurethane resins.
Claim 13
Dependent Claim
28 words
The process of claim 9 wherein said matrix is a thermoplastic resin and said thermoplastic resin is selected from the group consisting of polyetherimides, polyurethanes, polycarbonates and acrylics.
Claim 14
Dependent Claim
19 words
The process of claim 5 wherein said anisotropic shaped composite structure comprises a single ply of anisotropic reinforcement material.
Claim 15
Dependent Claim
20 words
The process of claim 5 wherein said anisotropic shaped composite structure comprises a plurality of plies of anisotropic reinforcement material.
Claim 16
Dependent Claim
81 words
An anisotropic structural composite comprising: a single ply anisotropic woven fabric reinforcement comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; and a matrix wetting said single ply woven fabric reinforcement wherein said matrix is hardened to provide an anisotropic structural composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 17
Dependent Claim
81 words
An anisotropic structural composite comprising: a single ply anisotropic woven fabric reinforcement comprising a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements; and a matrix wetting said single ply woven fabric reinforcement wherein said matrix is hardened to provide an anisotropic structural composite which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 18
Dependent Claim
84 words
A composite shoe arch comprising: a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements to form at least one ply of a fabric reinforcement, said at least one ply of fabric reinforcement being wetted with a resin matrix and shaped to provide an anisotropic shoe arch which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 19
Dependent Claim
84 words
A composite shoe arch comprising: a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements to form at least one ply of a fabric reinforcement, said at least one ply of fabric reinforcement being wetted with a resin matrix and shaped to provide an anisotropic shoe arch which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 20
Dependent Claim
26 words
The composite shoe arch of claim 15 wherein said first plurality of glass weft elements are selected from the group consisting of rovings, yarns and fibers.
Claim 21
Dependent Claim
26 words
The composite shoe arch of claim 15 wherein said second plurality of graphite warp elements are selected from the group consisting of tows, yarns and fibers.
Claim 22
Dependent Claim
18 words
The composite shoe arch of claim 15 wherein said first plurality of glass weft elements are E-glass rovings.
Claim 23
Dependent Claim
31 words
The composite shoe arch of claim 15 wherein said second plurality of graphite warp elements are selected from the group consisting of standard modulus carbon fibers and intermediate modulus carbon fibers.
Claim 24
Dependent Claim
39 words
The composite shoe arch of claim 19 wherein said second plurality of graphite elements are standard modulus carbon fibers with a tensile modulus of 30 msi to 38 msi and a tensile strength of 500 psi to 600 psi.
Claim 25
Dependent Claim
39 words
The composite shoe arch of claim 19 wherein said second plurality of graphite elements are intermediate modulus carbon fibers with a tensile modulus of 40 msi to 45 msi and a tensile strength of 650 psi to 785 psi.
Claim 26
Dependent Claim
29 words
The composite shoe arch of claim 15 wherein said first plurality of glass weft elements have a yarn count within the range of 5 to 30 strands per inch.
Claim 27
Dependent Claim
29 words
The composite shoe arch of claim 15 wherein said second plurality of graphite warp elements have a yarn count within the range of 5 to 30 strands per inch.
Claim 28
Dependent Claim
27 words
The composite shoe arch of claim 15 wherein said woven reinforcement has a weave selected from the group consisting of plain weave, twill weave and satin weave.
Claim 29
Dependent Claim
25 words
The composite shoe arch of claim 15 wherein said resin matrix is selected from the group consisting of thermosetting resins, thermoplastic resins and combinations thereof.
Claim 30
Dependent Claim
35 words
The composite shoe arch of claim 25 wherein said resin matrix is a thermosetting resin and said thermosetting resin is selected from the group consisting of epoxy resins, polyester resins, acrylic resins, and polyurethane resins.
Claim 31
Dependent Claim
31 words
The composite shoe arch of claim 25 wherein said resin matrix is a thermoplastic resin and said thermoplastic resin is selected from the group consisting of polyetherimides, polyurethanes, polycarbonates and acrylics.
Claim 32
Dependent Claim
15 words
The composite shoe arch of claim 15 comprising a plurality of plies of woven fabric.
Claim 33
Dependent Claim
78 words
A composite shoe arch comprising: a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements to form a single ply fabric reinforcement, said single ply fabric reinforcement being wetted with a resin matrix and shaped to provide an anisotropic shoe arch which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 34
Dependent Claim
78 words
A composite shoe arch comprising: a first plurality of glass weft elements interlaced with a second plurality of graphite warp elements to form a single ply fabric reinforcement, said single ply fabric reinforcement being wetted with a resin matrix and shaped to provide an anisotropic shoe arch which is more flexible along a first axis parallel to said first plurality of glass weft elements than along a second axis parallel to said second plurality of graphite warp elements.
Claim 35
Dependent Claim
17 words
The anisotropic structural composite of claim 1 comprising a plurality of plies of anisotropic woven fabric reinforcements.
References Cited (Backward Citations)
US2653396A
Cited
US4241124A
Cited
US4520581A
Cited
US4439934A
Cited
US4686994A
Cited
US4612713A
Cited
US4611413A
Cited
US4610101A
Cited
US4688338A
Cited
US4668338A
Cited
US4778717A
Cited
US4931345A
Cited
US4881329A
Cited
US5087193A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-03-27 | 1998-09-26 | 1999-03-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-03-27 | 2002-09-26 | 2003-03-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-03-27 | 2006-09-26 | 2007-03-28 | $7700.00 | Window Closed / Lapsed |