Toecap made from woven layers of continuous strands aligned in layer-specific orientation

Abstract

A toecap comprises woven layers each composed of continuous strands of prepreg material. In a particular embodiment, the continuous strands in each layer are aligned in a layer-specific orientation. In a preferred embodiment, the layer specific orientation of a first of said layer is orthogonal to an orientation of a second layer. In another preferred embodiment, the layer specific orientation of a first layer is oriented at forty-five degrees from an orientation of a second layer. In another preferred embodiment, the woven layers further comprise a hybrid layer having a sheet-molding compound (SMC) layer.

I claim:  
     
         1 . A toecap comprising: 
 woven layers each composed of continuous strands of prepreg material.    
     
     
         2 . The toecap of  claim 1  wherein: 
 said continuous strands of prepreg material for each of said woven layers are aligned in a layer-specific orientation.  
 
     
     
         3 . The toecap of  claim 2  wherein: 
 the layer specific orientation of a first of said layer is orthogonal to an orientation of a second layer.  
 
     
     
         4 . The toecap of  claim 2  wherein: 
 the layer specific orientation of a first layer is oriented at forty-five degrees from an orientation of a second layer.  
 
     
     
         5 . The toecap of  claim 1  wherein: 
 the woven layers further comprise a hybrid layer having a sheet-molding compound (SMC) layer.  
 
     
     
         6 . The toecap of  claim 1  further comprising: 
 a resin between said woven layers.  
 
     
     
         7 . The toecap of  claim 1  further comprising: 
 a resin comprising vinyl ester between said woven layers.  
 
     
     
         8 . The toecap of  claim 1  further comprising: 
 a resin comprising polyester between said woven layers.  
 
     
     
         9 . The toecap of  claim 1  further comprising: 
 a resin comprising epoxy between said woven layers.  
 
     
     
         10 . The toecap of  claim 1  further comprising: 
 a resin comprising polyurethance between said woven layers.  
 
     
     
         11 . The toecap of  claim 1  wherein: 
 said continuous strands of prepreg material for each of said woven layers comprising directional continuous reinforcing roving.  
 
     
     
         12 . The toecap of  claim 1  wherein: 
 said continuous strands of prepreg material comprising directional continuous glass fiber.  
 
     
     
         13 . The toecap of  claim 1  wherein: 
 said continuous strands of prepreg material comprising directional continuous woven cloth made out of yarns.  
 
     
     
         14 . A method for manufacturing a toecap comprising: 
 laying up a plurality of layers wherein each layer composed of continuous strands of prepreg material.    
     
     
         15 . The method for manufacturing a toecap of  claim 14  wherein: 
 said step of laying up said plurality of layers further comprising a step of laying up said plurality of layers by aligning each of said of continuous strands of prepreg material in a layer-specific orientation.