Structural element formed of a resin-hardened velour fabric and fabrication method

Abstract

A structure based on velour fabric, having at least a first layer and a second layer and intermediate ribs connecting these layers provides a production-efficient, stable and nevertheless light-weight product. The velour fabric is made of a commercial yarn such as aramid fiber, carbon fiber, ceramic fiber or in particular glass fiber. The velour fabric is resin-hardened, wherein the intermediate ribs for rigid spacing elements between the first layer and the second layer.

We claim: 
     
       1. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element comprising a velour fabric formed of two generally parallel layers and intermediate ribs connected between and separating said layers, said intermediate ribs being formed of threads, said velour fabric being made of aramid fibers, carbon fibers, ceramic fibers or glass fibers, and a hardened resin impregnated within said velour fabric. 
     
     
       2. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, wherein the medium-sized length of said threads is greater than the distance (x) between said layers. 
     
     
       3. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, wherein said threads extend between said layers at an angle other than 90°. 
     
     
       4. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 3, wherein the intermediate threads extend at an angle (alpha) of about 65° with respect to said layers. 
     
     
       5. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 3, wherein the intermediate threads extend at an angle (alpha) of about 85° with respect to said layers. 
     
     
       6. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, wherein said intermediate ribs comprise two slightly twisted single threads. 
     
     
       7. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 6, wherein said intermediate ribs comprise individual ribs twisted in the shape of an 8. 
     
     
       8. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 6, wherein said intermediate ribs are formed of threads which are connected to one another at a crossing-over region. 
     
     
       9. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, wherein the intermediate ribs have prop-like transition regions in the outlet region of the layers. 
     
     
       10. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, wherein the intermediate ribs are arranged alternately at larger and smaller intervals. 
     
     
       11. .[.Structural.]. .Iadd.A rigid structural .Iaddend.element according to claim 1, including intermediate ribs formed of crossed threads.