Abstract: A braided member has a longitudinal axis and a plurality of braided strands of structural fiber. At least one elongate member having a rigidity greater than that of the strands of structural fiber is intertwined into the braided strands parallel to the longitudinal axis of the braided member. According to the preferred embodiment of the present invention, the structural fibers are selected from the group consisting of aramid, glass, and carbon fibers and the braided member is a triaxially braided tube. According to the preferred embodiment of the present invention, the elongate member is a pultruded rod having compressive strength approaching its tensile strength.

Abstract: A method of forming a pultruded shaped composite material comprising carbon fiber having a diameter not greater than 0.001 inch aligned linearly with a degree of waviness defined by an average amplitude to length (A/L) ratio of less than 0.9 percent in a matrix is formed around the fiber and solidified or cured into a rigid form that will not melt during subsequent processing steps to prevent an increase in waviness during subsequent processing steps. The compressive strength of the composite material approaches the tensile strength of the material. The matrix material consists essentially of a resin present in the range of about 10 to 50 percent by volume of the composite material. The A/L ratio is determined by measuring the distribution of angularity found in the aligned carbon fibers in a selective cross section cut at five degrees to the fiber plane, wherein the standard deviation for a 300 sample angularity measurement is not greater than 0.88 degrees.

Abstract: A pultruded shaped composite material of carbon fiber having a diameter not greater than 0.001 inch aligned linearly with a degree of waviness defined by an average amplitude to length (A/L) ratio of less than 0.9 percent, the matrix formed around the fiber and solidified or cured into a rigid form that will not melt during subsequent processing steps to prevent an increase in waviness during subsequent processing steps. The matrix material consists essentially of a resin present in the range of about 10 to 50 percent by volume of the composite material. The A /L ratio is determined by measuring the distribution of angularity found in the aligned carbon fibers in a selective cross section cut at five degrees to the fiber plane, wherein the standard deviation for a 300 sample angularity measurement is not greater than 0.88 degrees.

Abstract: A method of constructing a fiberglass structure features that enable a gelcoat protective layer to be applied to an article formed in an automatic process. In the process, a web of fiberglass is drawn through a bath of structural resin to impregnate the fiberglass with the structural resin. A web of organic, porous veil material is drawn through a bath of gelcoat resin simultaneously with the structural resin impregnated web of fiberglass. The two webs are squeezed together, and the resin metered to provide a composite web having a layer of resin and a layer of gelcoat. A mold draws the composite web off of the rollers. Once a section has been drawn onto the mold, the web is sheared. Then the mold is moved into an oven for heating and curing the article.

Abstract: A process of fabricating a composite structural member which has opposite sides produced from preformed sheets of thermoplastic material. In carrying out the process, reinforcing material comprising fibers and thermosetting resin in the uncured state is layed on the inside of one of the performed sheets. The two preformed sheets are assembled together with the reinforcing material located there between. The edges of the preformed sheets are sealed and a vacuum drawn. The resin is then allowed to cure to cause the resin and fiber to bond together and to the performed thermoplastic sheets and which become an integral part of the structural member.

Abstract: Following is disclosed structural apparatus and methods of construction of plied filamentary tape including a first ply of impregnated, unidirectional fibers extending along the longitudinal axis of the structural member to form a truss cap. Overlying the first ply are second and third angle plies having fibers transverse to each other and oblique relative to those of the first ply. Portions of the second and third plies may be folded transversely to the plane of the first ply to form one or more shear webs of selected geometry. A portion of each shear web consists of an excess width of ply for attachment to another structural member. The impregnation matrix bonds the plies to each other and to another structural member to form a selected structure. A cart structure embodying the principles of the invention is also disclosed.