Abstract: A system for sequential circumferential deposition of thermoplastic composite prepreg material to layer plies of prepreg tape, allowing the continuous processing of tubular shapes and rods, comprising a floating mandrel; a first heatable folding shoe configured to heat and wrap a first prepreg tape onto the floating mandrel; a first forming tube configured to heat and pultrude the first prepreg tape so as to form a first layer ply of prepreg tape on the floating mandrel; a second heatable folding shoe configured to heat and wrap a second prepreg tape onto the first layer ply of prepreg tape on the floating mandrel; a second forming tube configured to heat and pultrude the second prepreg tape so as to form a second layer ply of prepreg tape over the first layer ply of prepreg tape on the floating mandrel.

Abstract: A system for sequential circumferential deposition of thermoplastic composite prepreg material to layer plies of prepreg tape, allowing the continuous processing of tubular shapes and rods, comprising a floating mandrel; a first heatable folding shoe configured to heat and wrap a first prepreg tape onto the floating mandrel; a first forming tube configured to heat and pultrude the first prepreg tape so as to form a first layer ply of prepreg tape on the floating mandrel; a second heatable folding shoe configured to heat and wrap a second prepreg tape onto the first layer ply of prepreg tape on the floating mandrel; a second forming tube configured to heat and pultrude the second prepreg tape so as to form a second layer ply of prepreg tape over the first layer ply of prepreg tape on the floating mandrel.

Abstract: A composite structure (10) includes a first outer skin (12); a second outer skin (14); and a core (16) sandwiched between the first outer skin (12) and the second outer skin (14). The core (16) includes a plurality of spaced apart ridges (18) between the first outer skin (12) and the second outer skin (14), each of the spaced apart ridges (18) extending from one end (20) of the composite structure (10) to an opposite end (22); and a plurality of connecting elements (24) between the first outer skin (12) and the second outer skin (14) configured to intersect with the ridges (18) to form open channels (26) within the core (16).

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A composite structure (10) includes a first outer skin (12); a second outer skin (14); and a core (16) sandwiched between the first outer skin (12) and the second outer skin (14). The core (16) includes a plurality of spaced apart ridges (18) between the first outer skin (12) and the second outer skin (14), each of the spaced apart ridges (18) extending from one end (20) of the composite structure (10) to an opposite end (22); and a plurality of connecting elements (24) between the first outer skin (12) and the second outer skin (14) configured to intersect with the ridges (18) to form open channels (26) within the core (16).

Abstract: A composite laminate comprises a plurality of composite plies including at least a first composite ply and a second composite ply. The first composite ply and the second composite ply each comprises a plurality of fibers in a thermoplastic matrix comprising polyethylene. The plurality of composite plies are bonded together to form the composite laminate.

Abstract: A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.

Abstract: A hybrid leaf spring includes an elongated primary leaf having a compression surface, an opposite tension surface, and a first modulus of elasticity. At least one composite material layer is provided having a second modulus of elasticity different from the first modulus of elasticity. An adhesive layer is interposed between and bonds the at least one composite material layer to and in substantially parallel relationship with a respective one of the tension and compression surfaces of the elongated primary leaf. A reinforcing layer of natural, synthetic or metallic sheet material extends within the adhesive layer, preferably in spaced relation to opposing surfaces of the primary leaf and the composite material layer to strengthen the bond formed by the adhesive layer.

Abstract: In a method for making a hybrid leaf spring, at least one layer of composite material is molded onto a primary leaf using a mold with an interior cavity having a curvature for receiving the primary leaf at a depressed camber relative to its initial camber. The depressed camber is between unloaded and curb load cambers of the hybrid leaf spring. The primary leaf and the layer of composite material are positioned in the mold adjacent to one another and with a layer of adhesive therebetween. The layer of adhesive is cured for bonding together the primary leaf and the layer of composite material at the depressed camber so as to generally eliminate bond line shear stress when the camber of the hybrid leaf spring is at the curb height.

Abstract: A hybrid leaf spring includes an elongated primary leaf having a compression surface, an opposite tension surface, and a first modulus of elasticity. At least one composite material layer is provided having a second modulus of elasticity different from the first modulus of elasticity. An adhesive layer is interposed between and bonds the at least one composite material layer to and in substantially parallel relationship with a respective one of the tension and compression surfaces of the elongated primary leaf. A reinforcing layer of natural, synthetic or metallic sheet material extends within the adhesive layer, preferably in spaced relation to opposing surfaces of the primary leaf and the composite material layer to strengthen the bond formed by the adhesive layer.

Abstract: In a method for making a hybrid leaf spring at least one layer of composite material is provided and a metal primary leaf. The layer of composite material and metal primary leaf are positioned adjacent one another in a mold having an interior cavity defined by at least one cavity wall. A layer of adhesive material is located between and in engagement with the layer of composite material and the metal primary leaf. The adhesive is cured by controllably heating the metal primary leaf so that energy in the form of heat is conducted therefrom into the adhesive layer bonding said metal primary leaf and layer of composite material together.

Abstract: In a method for making a hybrid leaf spring, at least one layer of composite material is molded onto a primary leaf using a mold with an interior cavity having a curvature for receiving the primary leaf at a depressed camber relative to its initial camber. The depressed camber is between unloaded and curb load cambers of the hybrid leaf spring. The primary leaf and the layer of composite material are positioned in the mold adjacent to one another and with a layer of adhesive therebetween. The layer of adhesive is cured for bonding together the primary leaf and the layer of composite material at the depressed camber so as to generally eliminate bond line shear stress when the camber of the hybrid leaf spring is at the curb height.

Abstract: In a hybrid leaf spring, an elongated primary leaf element is provided having a first modulus of elasticity, a tension surface, and a compression surface. At least one layer of composite material is substantially parallel to and bonded to the tension surface of the primary leaf element with at least a second layer of composite material bonded to the compression surface of the primary leaf. The primary leaf element can also include mounting eyes coupled to the ends of the primary leaf element for mounting the hybrid leaf spring to the frame of a vehicle. The hybrid leaf spring can also include multiple layers of composite material bonded to both the tension and compression surfaces of the primary leaf spring.