Reinforced composite structure

Abstract

A reinforced composite structure ( 29 ) is disclosed. The structure is formed by opposed layers of material extending over a core and continuous bundles stitched in a repeating pattern through the opposed layers ( 30, 32 ) and the intermediate core ( 29 ) to form the reinforced composite structural member ( 29 ).

1. A stiff reinforced composite structure comprising:
 a core;  
 first and second layers of fibrous material, the first and second layers bounding respective first and second opposed surfaces of the core and having respective exterior surfaces;  
 and a first set of continuous fibrous bundles extending in a repeating pattern over the exterior surface of the first layer, through the first layer, through the core; through the second layer, over the exterior surface of the second layer; and  
 a matrix material joining the first and second layers of fibrous material, the fibrous bundles and the core into a stiff reinforced composite structure.  
 
     
     
       2. The reinforced composite structure of  claim 1  wherein the core is a material selected from the group consisting of clay, foam, a honeycomb, metal, paper, plastics rubber, wax and wood. 
     
     
       3. The reinforced composite structure of  claim 1  wherein the layers are a material selected from the group consisting of a fibrous composite layered material, a woven fabric, a unidirectionally oriented fiber and a randomly oriented fiber. 
     
     
       4. The reinforced composite structure of  claim 1  wherein the fibrous bundles are made from a material selected from the group consisting of glass fibers, quartz fibers, graphite fibers, organic fibers and steel fibers. 
     
     
       5. The reinforced composite structure of  claim 4  wherein the steel fibers are joined together by a lower melting point metal matrix. 
     
     
       6. The reinforced composite structure of  claim 1  wherein the matrix material joins the first and second layers and portions of the fibrous bundles extending over the exterior surfaces of the layers. 
     
     
       7. The reinforced composite structure of  claim 6  wherein the matrix material is selected from the group consisting of a thermoset resinous matrix material and a thermoplastic resinous matrix material. 
     
     
       8. The reinforced composite structure of  claim 1  further comprising a protective layer covering the respective exterior surfaces of the first and second layers and portions of the fibrous bundles extending over the respective exterior surfaces. 
     
     
       9. The reinforced composite structure of  claim 8  wherein the protective layer is made from a material selected from the group consisting of a resinous coating, a protective film and a metal. 
     
     
       10. The reinforced composite structure of  claim 1  further comprising an edge layer extending between edges of the first and second layers. 
     
     
       11. The reinforced composite structure of  claim 1  wherein the fibrous bundles extend between the first and second layers in a direction substantially perpendicular to the first and second layers. 
     
     
       12. The reinforced composite structure of  claim 1  wherein the fibrous bundles extend between the first and second layers in a direction oblique to the first and the second layers. 
     
     
       13. A method of making a stiff reinforced composite structure comprising the steps of:
 applying first and second layers of fibrous material over respective first and second opposed surfaces of a core material; and  
 sewing a set of continuous, fibrous bundles in a repeating pattern over the exterior surface of the first layer, through the first layer, through the core material, through the second layer,  
 over the exterior surface of the second layer, and coagulating the first and second layers of fibrous material and the fibrous bundles with a matrix material; and curing the matrix material, thereby joining the fibrous material, the fibrous bundles, the core and the matrix material into a stiff reinforced composite structure.  
 
     
     
       14. The method of  claim 13  wherein the method further comprises sewing the fibrous bundles in a generally perpendicular direction with respect to the first and second layers. 
     
     
       15. The method of  claim 13  wherein the method further comprises sewing the fibrous bundles in an oblique direction with respect to the first and second layers. 
     
     
       16. The method of  claim 13  wherein the method further comprises applying an edge layer extending between edges of the first and second layers. 
     
     
       17. A stiff reinforced composite structure comprising:
   a core;        first and second layers of fibrous material, the first and second layers bounding respective first and second opposed surfaces of the core and having respective exterior surfaces,        internal fibers stitched between the first and second layers and through the core, at least some of the internal fibers extending between the first and second layers in a direction oblique to the first and second layers, and        a matrix material joining the first and second layers of fibrous material, the internal fibers and the core into a stiff reinforced composite structure.     
     
     
       18. The reinforced composite structure of  claim 17  having internal fibers oriented in a crossing substantially perpendicularly intersecting pattern in combination with internal fibers which are arranged at angles other than substantially ninety degrees compared with the substantially perpendicular internal fibers. 
     
     
       19. The reinforced composite structure of  claim 17  wherein said structure has a geometry or shape. 
     
     
       20. The reinforced composite structure of  claim 19  wherein said structure has a complex geometric configuration having multiple plateaus connected by sloping spans. 
     
     
       21. The reinforced composite structure of  claim 17  wherein the core is a material selected from the group consisting of clay, foam, a honeycomb, metal, paper, plastics, rubber and wood. 
     
     
       22. The reinforced composite structure of  claim 17  wherein the layers are a fibrous composite layered material. 
     
     
       23. The reinforced composite structure of  claim 17  wherein the material internal fibers are made from a material selected from the group consisting of glass fibers, quartz fibers, graphite fibers, organic fibers and metallic fibers. 
     
     
       24. The reinforced composite structure of  claim 23  wherein the metallic fibers are joined together by a lower melting point metal matrix. 
     
     
       25. The reinforced composite structure of  claim 17  wherein the matrix material is selected from the group consisting of a thermoset resinous matrix material and a thermoplastic resinous matrix material. 
     
     
       26. The reinforced composite structure of  claim 17  further comprising a protective layer covering respective exterior surfaces of the first and second layers. 
     
     
       27. The reinforced composite structure of  claim 26  wherein the protective layer is made from a material selected from the group consisting of a resinous coating, a protective film and a metal. 
     
     
       28. The reinforced composite structure of  claim 17  further comprising and edge layer extending between edges of the first and second layers. 
     
     
       29. The reinforced composite structure of  claim 17  wherein some of the internal fibers extend between the first and second layers in a direction substantially perpendicular to the first and second layers.