Reinforced composite arrangement and method for manufacturing the same

Abstract

A reinforced composite arrangement (20), comprising: comprising a first arc (22) made of carbon fibers and having a first perimeter (P1); a second sheet (24) made of a carbon-free fiber material and having a second perimeter (P2), wherein the second sheet (24) is arranged on the first sheet (22) within the first perimeter (P1); a metal plate (26) with a third circumference (P3), wherein the metal plate (26) is arranged on top of the second arc (24) within the second circumference (P2), wherein the metal plate (26) has: a plurality of holes (28) formed along the third perimeter (P3) of the metal plate (26) and defining a plurality of respective bridge sections (29) between each of the holes (28) and an adjacent outer edge (30) of the metal plate (26); and / or a multitude of extensions (34) extending outwards from a main section (36) of the metal plate (26); and a first arrangement of thread stitches (38) securing each of the bridge sections (29) and extensions (34) to the second arch (24) or to the first arch (22) and the second arch (24).

Description

Technical field

[0001] This disclosure relates generally to reinforced composite assemblies and to methods for manufacturing reinforced composite assemblies. introduction

[0002] Composite materials are frequently used in applications where high strength and low weight are desired, such as in structural components for automotive engineering. While various composite materials can be used, one of the most common is carbon fiber, which is often woven into a single- or multi-layered mesh or mat and then impregnated or infused with resin to create a preform. Such preforms are typically quite flexible and can therefore be draped or arranged in a mold cavity, using a mold plug to press against the preform and the mold cavity to compress the preform into the desired shape. The mold can then be heated for a period of time to cure the resin and fix the preform in the desired shape.

[0003] Sometimes, metallic clamps, plates, and other inserts are inserted into one or more areas of a preform before resin injection to provide additional reinforcement. Such additional hardware can be made of steel, aluminum, or other metals, for example. However, due to the high electrical conductivity of carbon fibers, galvanic corrosion can occur at the interfaces between the carbon fibers and the metal parts.

[0004] DE 10 2012 223 220 A1 describes a turbine blade, in particular a final stage blade for a steam turbine. The turbine blade consists at least partially of fiber-reinforced composite material and includes at least one erosion protection component. The erosion protection component is attached to the turbine blade by means of a positive-locking and a material-locking connection. This ensures a very secure hold of the erosion protection component on the turbine blade, even at high circumferential speeds of the turbine blade. Furthermore, methods for manufacturing such turbine blades are described.

[0005] DE 10 2005 013 154 A1 describes a fastening element for fixing in a malleable material, in particular in a fiber-reinforced composite material. The fastening element comprises a base plate and a fastening element arranged thereon. The base plate has at least one pin on the side opposite the fastening element.

[0006] EP 2 832 526 A1 describes a method for producing a fastener obtained by joining a carbon fiber composite material containing a thermoplastic resin as a matrix and a metal. The method comprises forming an uneven shape with a depth of 0.02 to 0.6 mm on a surface of the metal at a joint section, applying a thermoplastic resin layer with a thickness in the range of 5 µm or more and 5 mm or less at a joint section between the surface of the metal and a surface of the composite material, and melting the thermoplastic resin layer by heating the joint section to fuse the metal and the composite material together.

[0007] DE 10 2013 220 337 A1 describes a method for manufacturing a reinforced fiber composite component comprising the following steps: providing a support element, arranging at least one reinforcement layer on an outer surface of the support element, creating a common sheathing of the support element and the reinforcement layer by braiding with continuous fibers, and impregnating the braided support element with a matrix. Furthermore, a reinforced fiber composite component is proposed, comprising a support element braided with a sheathing comprising a fiber structure, wherein at least a local reinforcement layer is arranged between the support element and the sheathing on at least one outer surface of the support element. Description of the invention

[0008] The invention is defined by the claims.

[0009] According to a first aspect of the invention, a reinforced composite arrangement comprises a first arc made of carbon fibers and having a first perimeter, a second arc made of a carbon-free fiber material and having a second perimeter, the second arc being arranged on the first arc within the first perimeter, and a metal plate having a third perimeter, the metal plate being arranged on the second arc within the second perimeter. The metal plate has a plurality of holes formed therein around a perimeter of the metal plate, defining a plurality of respective bridge sections between each of the holes and an adjacent outer edge of the metal plate, and / or a plurality of extensions extending outwards from a main section of the metal plate.The reinforced composite arrangement also includes a first arrangement of thread stitches that secures each of the bridge sections and extensions to the second arch, or to the first arch and the second arch.

[0010] Each of the many extensions can be formed as a T-shape, an L-shape, a U-shape with a first and a second end, the first and second ends each being adjacent to the main section, a key head shape with a straight section extending outwards from the main section and ending in a closed loop section, and a tab with one or more through holes in it.

[0011] Each of the holes can be shaped as a circular hole, an ellipsoidal hole, a square hole, a rounded straight slot, or a rectangular slot. The metal plate can have at least one opening through it that lies within the plurality of holes.

[0012] The reinforced composite arrangement can further include a metallic element that is attached to the metal plate by a first section and extends away from the metal plate by a second section, and a second arrangement of thread stitches can secure the second arc to the first arc. In the reinforced composite arrangement, the first arc can have a first region, the second arc can have a second region that is smaller than the first region, and the metal plate can have a third region that is smaller than the second region.

[0013] According to a second aspect of the invention, a method for producing a reinforced composite assembly comprises: (i) arranging a metal plate having a third perimeter on a second sheet made of a carbon-free fiber material and having a second perimeter, wherein the metal plate is arranged within the second perimeter and has a plurality of holes formed along the third perimeter, defining a plurality of respective bridge sections between each of the holes and an adjacent outer edge of the metal plate and / or a plurality of extensions extending outwards from a main section of the metal plate; (ii) securing each of the bridge sections and extensions to the second sheet using a first arrangement of thread stitches, thereby producing a sub-assembly of metal plate and second sheet;(iii) Placing the sub-assembly of metal plate and second sheet on a first sheet made of carbon fiber and having a first perimeter, wherein the sub-assembly of metal plate and second sheet is arranged within the first perimeter and the second sheet separates the metal plate from the first sheet; and (iv) attaching the second sheet to the first sheet using a second arrangement of thread stitches, thereby producing a reinforced preform assembly.

[0014] The process may further include: (v) inserting the reinforced preform assembly into a mold cavity; (vi) closing a mold plug against the mold cavity to form a closed mold; (vii) injecting resin into the closed mold to saturate at least one selected section of the reinforced preform assembly with the resin, thereby creating a saturated reinforced preform assembly; (viii) opening the closed mold by separating the mold plug from the mold cavity to expose the saturated reinforced preform assembly; and (ix) removing the saturated reinforced preform assembly from the mold cavity. Additionally, the process may also include: (x) applying heat to the saturated reinforced preform assembly while it is in the closed mold until a predetermined degree of resin curing is achieved.

[0015] The mold cavity may include a guide pin extending upward from a mold surface, and the metal plate may have a through-hole designed to mate with the guide pin. A corresponding plug seal may be arranged in the mold cavity and / or the mold plug, each plug seal being configured to be preloaded against a threaded hole in a tubular element attached to the metal plate when the mold is closed. A resin seal may be arranged between the mold cavity and the reinforced preform assembly, and around an opening formed in the metal plate when the reinforced preform assembly is inserted into the mold cavity.In this process, the first arc can have a first area, the second arc a second area that is smaller than the first area, and the metal plate a third area that is smaller than the second area.

[0016] According to yet another embodiment, not according to the invention, a reinforced composite arrangement comprises: a first sheet made of carbon fibers and having a first circumference; a first layer of carbon-free fiber material having a second circumference, wherein the first layer is arranged on the first sheet within the first circumference; a metal plate having a third circumference, wherein the metal plate is arranged on the first layer within the second circumference; a second layer of carbon-free fiber material having a fourth circumference, wherein the second layer is arranged on the metal plate such that the metal plate is arranged within the fourth circumference; and a first set of thread stitches securing the first and second layers to each other around the third circumference.

[0017] The first set of thread stitches can further secure the first sheet to the first and second layers, and the first and second layers can be made from a single sheet of carbon-free fiber material folded so that the first and second layers face each other. The first sheet can have a first region, the first layer can have a second region smaller than the first region, and the metal sheet can have a third region smaller than the second region. The metal sheet and the second layer can have corresponding first and second openings through them, the first and second openings overlapping each other so that the entire first opening projects through the second opening.The reinforced composite arrangement may further include a second set of thread stitches securing at least one of the first layer and the second layer to the first arc around the perimeter of the metal plate.

[0018] The above features and advantages, as well as other features and advantages of the present teaching, are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teaching as defined in the attached claims, in conjunction with the attached drawings. Brief description of the drawings Fig. Figure 1 is a schematic elevated exploded view of a set of selected components of a reinforced composite arrangement according to a first configuration. Fig.Figure 2 is a schematic top view of an embodiment of a reinforced composite arrangement according to the first configuration. Fig. Figure 3 is a schematic elevated exploded view of another set of selected components of a reinforced composite arrangement according to a second configuration. Fig. Figure 4 is a schematic top view of another embodiment of a reinforced composite arrangement according to the first configuration. Fig. Figures 5-8 are schematic top views of a sequence of steps for manufacturing a sub-arrangement of metal plates with pockets according to the second configuration. Fig. Figure 9 is a schematic top view in close-up of a portion of a metal plate, showing various hole configurations according to the first configuration. Fig.Figure 10 is a schematic perspective view of a metal plate with T-shaped extensions according to the first configuration. Fig. Figures 11-16 are schematic isolated top views of various extension forms according to the first configuration. Fig. Figure 17 is a schematic perspective exploded view of a further set of selected components of a reinforced composite arrangement according to the first configuration. Fig. Figures 18-19 are schematic perspective views of an optional metallic element with an L-shaped or tubular shape according to the first configuration. Fig. Figure 20 is a schematic perspective exploded view of a reinforced preform arrangement being inserted into an open mold. Fig. Figure 21 is a schematic cross-sectional view of a closed form and a reinforced preform arrangement. Fig. Figures 22A-D are schematic cross-sectional views that represent a first sequence of steps for producing a reinforced composite arrangement according to the first configuration. Fig. Figures 23A-D are schematic elevated cross-sectional views showing a second sequence of steps for producing a reinforced composite arrangement according to the first configuration. Fig. Figures 24A-B are schematic elevated cross-sectional views showing a third sequence of steps for producing a reinforced composite arrangement according to the first configuration. Fig. Figures 25A-B are schematic elevated cross-sectional views showing a fourth sequence of steps for producing an unstressed reinforced composite arrangement according to the second configuration. Fig.Figures 26A-D are schematic elevated cross-sectional views showing a fifth sequence of steps for producing an unstressed reinforced composite arrangement according to the second configuration. Fig. Figures 27 to 31 are flowcharts corresponding to the first to fifth steps in the process of manufacturing a reinforced composite assembly.

[0019] It should be noted that some of the drawings herein are presented in several related views, the related views sharing a common Arabic numerical part of the figure number, and each individual view having its own unique 'alphabetical' part of the figure number. For example, the Fig.Schematic elevated views depicting an initial sequence of steps for fabricating a reinforced composite assembly according to the first configuration; these views share the same Arabic numeral (i.e., 22), but each individual view has its own unique "alphabetical" designation (i.e., A, B, C, or D). When the drawings are numbered in this way, the Arabic numeral alone can be used to refer to all the associated "alphabets" collectively; thus, " Fig. 22" on the Fig. 22A-D in total. Likewise, “ Fig. 23" on the Fig. 23A-D and so on. Detailed description

[0020] With reference to the drawings, in which the same reference numerals denote the same parts in the different views, various configurations and embodiments of a reinforced composite assembly 20 and various methods 100, 200, 300, 400, 500 for manufacturing the reinforced composite assembly 20 are shown and described. It should be noted that certain reference numerals have indices, such as the extensions 34. T , 34 L , 34 U , 34 K and 34 B in the Fig.11-16, which represent various extension forms. In the drawings and in this description, indices are used to refer to individual elements (e.g., the extensions / extension forms mentioned above), while the use of reference numerals without indices can refer to the collective group of such elements and / or to a single, but general, element of these elements. Thus, reference numeral 34 refers to T to a specific (T-shaped) extension / extension form, whereas reference 34 (without the subscript index) can refer to all extensions / extension forms, the group of extensions / extension forms, or a single but generic extension / extension form (i.e., any extension / extension form).

[0021] Fig.Figure 1 shows a schematic elevated exploded view of a set of selected components used to manufacture a reinforced composite assembly 20 according to a first configuration, and Fig.Figure 2 shows a schematic top view of an embodiment of a finished reinforced composite assembly 20 according to the first configuration. In this first configuration, the reinforced composite assembly 20 comprises: a first sheet 22 made of carbon fibers having a first region A1 and a first perimeter P1; a second sheet 24 made of a non-carbon fiber material having a second region A2 and a second perimeter P2, the second sheet 24 being arranged on top of the first sheet 22 (i.e., on the top surface of the first sheet 22) and within the first perimeter P1; and a metal plate 26 having a third region A3 and a third perimeter P3, the metal plate 26 being arranged on top of the second sheet 24 and within the second perimeter P2.In this arrangement, the second arc 24 separates the metal plate 26 from the first arc 22, thus preventing contact between the metal of the metal plate 26 and the carbon fiber material of the first arc 22. This separation between the metal and the carbon fiber material serves to prevent the aforementioned problems of galvanic corrosion.

[0022] In the present disclosure, the metal plate 26 can have one of two configurations, resulting in two corresponding configurations of the reinforced composite arrangement 20. In the first configuration, the metal plate 26 has a plurality of holes 28 formed therein around a perimeter or circumference P3 of the metal plate 26 (as shown in the Fig. 2, Fig. 4, Fig. 9 and Fig. 17), and / or a plurality of extensions 34 extending outwards from a main section 36 of the metal plate 26 (as shown in the Fig. (shown in Figures 10-16). In the second, non-inventive configuration (which will be discussed in more detail below), however, the metal plate 26 neither has a plurality of holes 28 formed in it around its circumference P3, nor does it have a plurality of extensions 34 extending outwards from its main section 36. (It should be noted that the use of the word "around" in connection with a given circumference means one or more of the following: along the circumference, around the circumference, close to the circumference, close to the circumference and just outside the circumference, along the length of the circumference, connected with the circumference, and along / around the entire area of ​​the circumference, depending on the context and as may be illustrated by one or more of the drawings).

[0023] If the metal plate 26 has the first configuration and a plurality of peripheral holes 28, the holes 28 define a plurality of respective bridge sections 29 between each of the holes 28 and an adjacent outer edge 30 of the metal plate, as shown in Fig. Figure 9 shows a schematic close-up of part of a metal plate 26, which has various hole configurations, such as a circular hole 28. C , a square hole 28s and a rounded straight slot 28 RSS . In the in Fig.In the nine hole configurations shown, each bridge section 29 is bounded by dashed lines 31 on the left and right sides of the associated bridge section 29, by the outer edge 30 of the metal plate 26 at the top of the bridge section 29, and by the edge of the adjacent hole 28 at the bottom of the bridge section 29. The dashed lines 31 associated with each bridge section 29 are shown extending from the left and right sides of the associated hole 28 and perpendicular to the outer edge 30. Each bridge section 29 may also include its respective adjacent sections 32, which are located on both sides of each associated hole 28. As shown in Fig.As shown in Figure 9, each adjacent section 32 lies between a corresponding dashed line 31, an adjacent dotted line 33 extending from the side of the hole 28 and angled outwards from the hole 28, and the outer edge 30 of the metal plate 26. (For some hole shapes, such as the square hole 28s and the rounded straight slot 28 RSS a side of each associated adjacent section 32 may be bounded by a combination of the dashed line 31 and the side of the hole 28 from which the dashed line 31 extends).

[0024] If the metal plate 26 has the first configuration and a multitude of extensions 34 extending outwards from the main section 36 of the metal plate 26, as shown in the Fig. As shown in Figures 10-16, the extensions 34 can be provided in a variety of different shapes. For example, each extension 34 can be a T-shape 34.T , an L-shape 34 L , a U-shape 34 U with a first and a second end 35, 37, wherein the first and the second end 35, 37 each adjoin the main section 36 and extend outwards from it, a key head shape 34 K with a straight section 39 S , which extends outwards from the main section 36 and in a closed loop section 39 CL ends, or a tab shape 34 B , extending outwards from the main section 36 and having one or more through holes TH. A version of a U-shaped extension 34 U is in Fig. 14 shown, in which both the first and second ends 35, 37 are formed adjacent to the main section 36 (e.g. by a stamping process), and another version of a U-shaped extension 34 U is in Fig.Figure 15 shows that the first and second ends 35, 37 are welded to the main section 36 via welds W. In the case of Fig. 15 can the U-shaped extension 34 U be made of the same metal as the main section 36 of the metal plate 26 or of a different metal that can be welded to the main section 36. Optionally, the U-shaped extension 34 can U from Fig. 15 have the form of a wire mesh or a flat U-shaped stamped part.

[0025] In the first configuration of the metal plate 26, the holes 28 and / or extensions 34 serve as features that can be used to secure or anchor the metal plate 26 to the surface(s) on which the metal plate 26 is mounted. This securing or anchoring can be accomplished using "thread stitches," that is, a collection, arrangement, or set of stitches sewn with threads or filaments. These stitches can be sewn with a needle, for example, using an industrial sewing machine, which can be operated manually or by computer numerical control (CNC) or other automated methods.

[0026] For example, the Fig. 2 and Fig. 4 schematic top views of two different embodiments of a reinforced composite arrangement 20, which uses the first configuration of the metal plate 26. In particular Fig.Figure 2 shows a metal plate 26 with a multitude of circular holes 28 C and ellipsoidal holes 28 E around the circumference P3 of plate 26, and Fig. Figure 4 shows a variety of rectangular slots. 28 RS around the circumference P3. In such embodiments, the holes 28 are fastened to the underlying second plate 24 made of carbon-free fiber material by a first arrangement of thread stitches 38. It should be noted that the drawings show one or two individual stitches or strands of thread 38' for fastening each circular hole 28. C , two single stitches 38' to secure each elliptical hole 28 E and two, three or four single stitches 38' to fasten each rectangular slit 28 RS to show, however this is only for illustration purposes, since any number of such individual stitches 38' can be assigned to each hole 28.

[0027] Similarly, it shows Fig. 10 a schematic perspective view of a metal plate 26 with T-shaped extensions 34 T , which are attached to a second sheet 24 of carbon-free fiber material by a first arrangement of thread stitches 38. It should be noted that, although the drawing shows four individual stitches 38' with which each T-shaped extension 34 T The fact that this is attached is only for illustrative purposes, since each extension 34 can have any number of such individual stitches 38'. As a further example, it shows Fig. 11 a T-shaped extension 34 T with four individual stitches 38' across the main leg of the extension 34 T, extending outwards from the main section 36 of the metal plate 26, and three individual stitches 38' across each of the two legs extending transversely to the main leg, but any number of stitches 38' may be arranged transversely to the main leg and each transverse leg.

[0028] Each individual stitch 38' appears schematically in the drawings as a single line (in some views also with a circular endpoint at each of the two ends of the line), but in practice, each individual stitch 38' can consist of a collection of repeated stitches, which is common sewing practice. Each stitch 38' extends over a corresponding bridge section 29 or extension 34 and passes through the underlying layer(s) on each side of the bridge section 29 or extension 34. Each of these stitches 38' can stand separately from the adjacent stitches 38', or (as is the more common sewing practice) each stitch 38' can be joined to one or more adjacent stitches 38', thus forming a continuous arrangement or chain of stitches 38' made from a single continuous thread or filament.Using standard sewing techniques, the stitches 38' fasten the bridge sections 29 and / or extensions 34 to the underlying arch(s) or layer(s). Thus, in the first configuration of the metal plate 26, in which holes 28 and / or extensions 34 are used, a first arrangement of thread stitches 38 secures each of the bridge sections 29 and extensions 34 to the second arch 24 or to the first arch and the second arch 22, 24. (That is, the stitches 38' can extend only through the second arch 24 or through both the first arch and the second arch 22, 24).

[0029] As in the Fig. As shown in Figures 18-19, the first configuration of the reinforced composite arrangement 20 can further comprise a metallic element 40 which is attached to the metal plate 26 by a first section 41 and whose second section 42 extends away from the metal plate 26. Fig.18 is the metallic element 40 an L-shaped plate 40 L , the first section 41 of which is welded to the exposed surface of the metal plate 26 via a weld seam W, the second section 42 extending perpendicular to the metal plate 26. And in Fig. 19 is the metallic element 40 a pipe or a tubular element 40 T with a threaded bore 84 (i.e. with an internal thread), wherein the first section 41 is attached to the metal plate 26 and the second section 42 extends perpendicular to the metal plate 26.

[0030] The first configuration of the reinforced composite assembly 20 can also include at least one opening 45 through the metal plate 26, wherein the opening(s) 45 are arranged within the plurality of peripheral holes 28 (e.g., closer to the center of the metal plate 26 than to the edge 30). These one or more openings 45 can serve to position and orient the reinforced composite assembly 20 in a mold, as described below. Furthermore, the second arc 24 can be arranged within the first circumference P1 of the first arc 22, and the metal plate 26 can be arranged within the second circumference P2 of the second arc 24.It should be noted that when an object is described herein as being "within" a given perimeter, each of the edges of that object (including a portion of each edge) may lie "within" the given perimeter or directly "on" the given perimeter, but may not extend beyond or "outside" the given perimeter. For example, the metal plate 26 may have a third perimeter P3 that has exactly the same shape and size as the second perimeter P2 of the second arc 24; in this case, the metal plate 26 may be arranged on the second arc 24 such that its third and second perimeters P3, P2 extend equidistantly. Furthermore, in some embodiments, the second perimeter A2 may be smaller than the first perimeter A1, and the third perimeter A3 may be smaller than the second perimeter A2.

[0031] As in the Fig. 2 and Fig.As shown in Figure 4, a second arrangement of thread stitches 43 can be used to secure the second arch 24 to the first arch 22. Like the first arrangement of thread stitches 38 described above, the second arrangement of thread stitches 43 is a collection, row, or arrangement of individual stitches 43' sewn with thread or filaments. Each individual stitch 43' appears schematically in the drawings as a single line (in some views also with a circular endpoint at each of the two ends of the line), but in practice, each individual stitch 43' may consist of a collection of repeated stitches. Each stitch 43' extends through the first arch 22 and the second arch 24, thereby attaching and securing the two arches 22, 24 to one another.Each of these stitches 43' can stand separately from its neighboring stitches 43', or each stitch 43' can be connected to one or more neighboring stitches 43', thus forming a continuous arrangement or chain of stitches 43' made from a single continuous thread or filament.

[0032] The thread or filament used in the first and second arrangements of thread stitches 38, 43 can be made of a variety of materials, including at least one of glass fiber, carbon filaments, nylon, and polyester. The first and second arrangements of thread stitches 38, 43 can be made of two different materials or of the same material. Regarding other materials that can be used in the reinforced composite arrangement 20, the carbon-free fiber material used in the second sheet 24 can be selected from at least one of the materials glass fiber, aramid, nylon, polyester, and polytetrafluoroethylene, and the metal plate 26 can be made of at least one of the materials iron, steel, aluminum, titanium, and molybdenum.

[0033] In the Fig.Figures 3 and 5-8 show the second, non-inventive configuration of the reinforced composite arrangement. Note that, unlike the first configuration, the second configuration does not have a plurality of holes 28 or extensions 34 for securing the metal plate 26 to the underlying layer(s). Instead, in the second configuration, the metal plate 26 is enclosed (i.e., encased, clamped, and / or held) in a “closed pocket” 88 formed around the metal plate 26 by a first and a second layer 44, 46 of carbon-free fiber material, which are sewn together (around most or all of the circumference P3 of the metal plate 26) by a first set of thread stitches 48.

[0034] Fig.Figure 3 shows a schematic elevated exploded view of a set of selected components used to manufacture the second configuration of the reinforced composite assembly 20.In this second configuration, the reinforced composite arrangement 20 comprises: a first arc 22 made of carbon fibers having a first region A1 and a first perimeter P1; a first layer 44 of non-carbon fiber material having a second region A2 and a second perimeter P2, the first layer 44 being arranged on the first arc 22 and within the first perimeter P1; a metal plate 26 having a third region A3 and a third perimeter P3, the metal plate 26 being arranged on the first layer 44 and within the second perimeter P2; and a second layer 46 of non-carbon fiber material having a fourth region A4 and a fourth perimeter P4, the second layer 46 being arranged on the metal plate 26 such that the metal plate 26 is arranged within the fourth perimeter P4.In this configuration, the first layer 44 can be arranged within the first perimeter P1, and the metal plate 26 can be arranged within the second perimeter P2 (and optionally also within the fourth perimeter P4). Additionally, in this configuration, the second perimeter A2 can be smaller than the first perimeter A1, the third perimeter A3 can be smaller than the second perimeter A2, and optionally the fourth perimeter A4 can be approximately the same size as the second perimeter A2.

[0035] As in Fig. As shown in Figure 8, the reinforced composite arrangement 20 according to the second configuration further comprises a first set of thread stitches 48 that hold the first layer 44 and the second layer 46 together around the perimeter P3 of the metal plate 26, thus forming a closed pocket 88 that surrounds and contains the metal plate 26. (It should be noted that the perimeter P3 of the metal plate 26 in Fig.8 (shown by dashed lines). If the closed pocket 88 is arranged on the first sheet 22, a second set of thread stitches 53 can be used to fasten at least one of the first layer 44 and the second layer 46 to the first sheet 22 around the circumference P3 of the metal plate 26. Alternatively, the first sheet 22, the first layer 44, the metal plate 26 and the second layer 46 can be in the Fig.3 proposed arrangement be sandwiched together, and the first set of thread stitches 48 can be sewn through the first arch 22, the first layer 44 and the second layer 46 - around, along and over the perimeter P3 of the metal plate 26 (i.e., just outside the perimeter P3) - thereby capturing the metal plate 26 in the closed pocket 88 formed by the first layer 44 and the second layer 46 and the first set of thread stitches 48, and securing or joining the first arch 22, the first layer 44 and the second layer 46 to one another.

[0036] The Fig. Figures 5 to 7 illustrate a process used to manufacture the reinforced composite arrangement 20 according to the second configuration of Fig. 8 can be used. In Fig.In the arrangement shown, a single sheet 49 of carbon-free fiber material is folded along a line 50, forming a crease or fold 51 in the single sheet 49. In the arrangement shown, the fold 51 divides the single sheet 49 into two identical halves, one half serving as the first layer 44 (with a second perimeter P2 and a second region A2) and the other half as the second layer 46 (with a fourth perimeter P4 and a fourth region A4). An optional second opening 52 can be formed in the half serving as the second layer 46.

[0037] Fig. Figure 6 shows the two halves folded on top of each other along the fold 51, with the second layer 46 lying on top of the first layer 44, so that the first layer 44 and the second layer 46 are facing each other. Fig.Figure 7 shows a first row of thread stitches 48 extending through both the first layer 44 and the second layer 46, connecting the two layers 44, 46. (Note that the features of the first and second arrangements of thread stitches 38, 43 and their associated individual stitches 38', 43', discussed above, also apply to the first and second sets of thread stitches 48, 53 and their individual stitches 48', 53' discussed here.) Fig. 7 The first set of thread stitches 48 extends only around three of the four edges of the perimeter P2, P4. This set of stitches can be considered an initial section 481 of the first set of thread stitches 48, with the first layer 44 and the second layer 46 and the initial section 481 of the thread stitches 48 forming an "open pocket" 87. As indicated by the arrow in Fig. As indicated in 7, a metal plate 26 can be inserted into the open pocket 87. Then, as shown in Fig.As shown in Figure 8, the remaining edge of the circumference P2, P4 is sewn with a subsequent section 482 of thread stitches 48, whereby the first set of thread stitches 48 extends around or along the entire circumference P3 of the metal plate 26 and the metal plate 26 is held in a closed pocket 88 formed by the first layer 44 and the second layer 46 and the first set of thread stitches 48. It should be noted that in the Fig. In the embodiment shown in Figure 8, a first opening 45 in the metal plate 26 can be visible through the second opening 52, which is formed in the second layer 46.

[0038] Fig.Figure 3 shows a connecting section 47 of a single sheet 49 of carbon-free fiber material, joining the first layer 44 and the second layer 46. It should be noted, however, that this connecting section 47 of a single sheet 49 is shown in dotted lines, with the associated reference numerals in brackets and the leader line drawn as a dashed line; this is to indicate that the connecting section 47 is optional. In other words, the first layer 44 and the second layer 46 can be two separate layers or sheets of carbon-free fiber material, rather than two folded halves of a single sheet 49 of carbon-free fiber material. In arrangements where the first layer 44 and the second layer 46 are two separate layers or sheets, they can be made of the same carbon-free fiber material or of two different carbon-free fiber materials.In each of the aforementioned arrangements, the metal plate 26 and the second layer 46 can include a corresponding first opening 45 and a corresponding second opening 52, wherein the first and second openings 45, 52 overlap each other in such a way that the entire first opening 45 is projected through the second opening 52 (e.g., is visible through it).

[0039] The description above of the materials that can be used in the first configuration of the reinforced composite arrangement 20 applies similarly to the materials that can be used in the second configuration. For example, the thread or filament used in the first and second sets of thread stitches 48, 53 can be made of a variety of materials, including at least one of glass fiber, carbon filaments, nylon, and polyester. The first and second sets of thread stitches 48, 53 can be made of two different materials or of the same material.With regard to other materials that may be used in the second configuration of the reinforced composite arrangement 20, the carbon-free fiber material used in the first and second layers 44, 46 may be at least one of glass fiber, aramid, nylon, polyester and polytetrafluoroethylene, and the metal plate 26 may be made of at least one of iron, steel, aluminum, titanium and molybdenum.

[0040] In each of the two configurations, the first arc 22 made of carbon fibers can be a continuous layer, or it can have a window or a cutout 23, as in the Fig. Figures 17, 20-21 and 26A-D are shown. Additionally, in the first configuration, the second arc 24 can have a window or a cutout 25 (as shown in the Fig.17 and 20-21 shown); and in the second configuration, the first layer 44 can have a window or cutout 57, with an optional second opening 52 formed in the second layer 46 (as shown in the Fig. (26A-D shown). In the first configuration, the windows or cutouts 23, 25 and the opening 45 in the metal plate 26 can all be concentric or otherwise aligned with each other, and in the second configuration, the first opening 45, the optional second opening 52 and the window or cutout 57 can also all be concentric or otherwise aligned with each other. These alignments can be useful for correctly positioning the reinforced composite assembly 20 when it is placed in a mold cavity 60 on a guide pin 76 that aligns with the opening 45 in the metal plate 26, as explained below.

[0041] The following section discusses various methods for fabricating the two configurations of the reinforced composite assemblies 20. To facilitate this discussion, the following table is presented, which shows the figures (and selected reference symbols in parentheses) representing the structure and the methods for fabricating the two configurations: TABLE 1 Illustrations (and reference symbols) assigned to the first and second configurations First configuration: Metallic plate 26 WITH holes 28 and / or extensions 34 Second configuration: Metallic plate 26 WITHOUT holes 28 and / or extensions 34 Reinforced composite arrangement Fig. 1-2, 4, 9-19(24; 38, 43) Fig. 3, 5-8(44, 46; 48, 53) Method for manufacturing a reinforced composite assembly Fig. 20-24, 27-29(100, 200, 300) Fig. 25-26, 30-31(400, 500)

[0042] It should be noted that, although both configurations of the reinforced composite assembly 20 include a first sheet 22 and a metal plate 26, they differ in certain other aspects. For example, the first configuration uses a second sheet 24 made of carbon-free fiber material, while the second configuration uses first and second layers 44, 46 made of carbon-free fiber material. Furthermore, the first configuration may use a first arrangement of thread stitches 38 or first and second arrangements of thread stitches 38, 43, while the second configuration uses a first set of thread stitches 48 or first and second sets of thread stitches 48, 53. Three methods (100, 200, 300) for fabricating the first configuration are presented below, followed by two methods (400, 500) for fabricating the second configuration.For the sake of simplicity, these manufacturing processes are designated as the first process 100, the second process 200, the third process 300, the fourth process 400 and the fifth process 500.

[0043] Fig. Figures 22A-D show a sequence of manufacturing steps for the first process 100, in which the reinforced composite arrangement 20 has the first configuration, and Fig. Figure 27 is a flowchart of the first procedure 100. (It should be noted that some of the features in the following description also appear in drawings other than the one in Figure 27.) Fig. 22 and Fig. 27 can be found). In block 110 ( Fig. 22A) a metal plate 26 with a third area A3 and a third perimeter P3 is arranged on a second sheet 24 made of a carbon-free fiber material which has a second area A2 and a second perimeter P2.

[0044] Here, the metal plate 26 is arranged within the second circumference P2 and has (i) a plurality of holes 28 formed along the third circumference P3, defining a plurality of respective bridge sections 29 between each of the holes 28 and an adjacent outer edge 30 of the metal plate 26, and / or (ii) a plurality of extensions 34 extending outwards from a main section 36 of the metal plate 26. In block 120 ( Fig. 22B) Each of the bridge sections 29 and the extensions 34 is attached to the second arch 24 using a first arrangement of thread stitches 38, creating a sub-arrangement of metal plate and second arch 54. In block 130 ( Fig.22C) the sub-arrangement of metal plate and second sheet is placed on a first sheet 22 made of carbon fiber with a first region A1 and a first perimeter P1, wherein the sub-arrangement of metal plate and second sheet is arranged within the first perimeter P1 and the second sheet 24 separates the metal plate 26 from the first sheet 22. And in block 140 ( Fig.In step 22D, the second arch 24 is attached to the first arch 22 using a second arrangement of thread stitches 43, thereby producing a reinforced preform assembly 56, which is also a reinforced composite assembly 20. In the steps above (and as mentioned previously), the first arch 22 has a first perimeter P1, the second arch 24 has a second perimeter P2 and is positioned within the first perimeter P1, and the metal plate 26 has a third perimeter P3 and is positioned within the second perimeter P2. Furthermore, the second perimeter A2 can be smaller than the first perimeter A1, and the third perimeter A3 can be smaller than the second perimeter A2.

[0045] Following the assembly steps described above, the reinforced preform assembly 56 can be subjected to the following forming steps as part of the first process 100. In block 150, the reinforced preform assembly 56 can be placed into a mold cavity 60 (see Fig.20) can be inserted or placed, and in block 160 a mold plug 62 can be closed against the mold cavity 60 to form a closed mold 64 (see Fig. 21) to form. In block 170, a resin 66 can be placed into the closed form 64 (see Fig.21) are injected to saturate at least one or more selected sections 68 of the reinforced preform assembly 56 with the resin 66, creating a saturated reinforced preform assembly 70. (It should be noted that some other sections 69 of the reinforced preform assembly 56 may not be saturated with resin 66, but the selected / saturated sections 68 and the other / unsaturated sections 69 together form the saturated reinforced preform assembly 70). In block 180, the closed mold 64 is opened by separating the mold plug 62 from the mold cavity 60 to expose the saturated reinforced preform assembly 70, and in block 190, the saturated reinforced preform assembly 70 is removed from the mold cavity 60.It should be noted that in block 175 an optional step can be carried out in which a predetermined amount of heat 72 is applied to the saturated reinforced preform assembly 70 while it is in the closed mold 64 until a predetermined degree of curing 74 of the resin 66 is reached in the saturated reinforced preform assembly 70.

[0046] It should be noted that the Fig. 27-31 have a central vertical column of blocks or steps and that some of these central column blocks have another block on the left, with an arrow pointing from the left block to the central column block, and / or another block on the right, with an arrow pointing from the central column block to the right block. In Fig.For example, in 27, blocks 120 and 140 each have a block on the right (i.e., blocks 54 and 56), while blocks 170 and 175 each have a block on the left (i.e., blocks 66 and 72) and one on the right (i.e., blocks 70 and 74). The blocks on the left represent inputs for the associated central column block, and the blocks on the right represent outputs or results for the associated central column block. Thus, in Fig. 27 block 72 (heat) is an input for block 175 (the step of applying heat 72 to the saturated reinforced preform assembly 70), and block 74 (a predetermined degree of curing) is an output or result for block 175.

[0047] The Fig. Figures 20-21 show elevated cross-sectional views of two shape arrangements whose features can be combined as desired. As in Fig.As shown in Figure 20, the mold cavity 60 can have a guide pin 76 extending upwards from a mold surface 78, and the metal plate 26 can have a through opening 45 designed to fit the guide pin 76 in order to position the metal plate 26 relative to the mold cavity 60. Fig. As shown in Figure 21, a respective plug seal 80 can be arranged in at least one of the mold cavity 60 and the mold plug 62, wherein each respective plug seal 80 is configured to be held against a threaded bore 84 in a metal plate 26 by means of preload elements 82 (e.g. springs, hydraulics, pneumatics, etc.). TThe attached tubular element 40 is pre-tensioned when the mold is closed (i.e., when the closed mold 64 is formed). Each corresponding plug seal 80 can be made of an elastomer or other sealing material and serves to prevent the flow of resin 66 into the threaded hole of the tubular element 40. T to prevent. And as in Fig. As shown in Figure 20, a resin seal 86 can be arranged between the mold cavity 60 and the reinforced preform assembly 56 and around an opening 45 formed in the metal plate 26 when the reinforced preform assembly 56 is inserted into the mold cavity 60. This resin seal 86 can be formed as a ring or in another shape and serves to seal the opening 45 against the flow of the resin 66 when the resin 66 is injected into the closed mold 64.

[0048] Fig.Figures 23A-D show a sequence of manufacturing steps for the second process 200, in which the reinforced composite arrangement 20 has the first configuration, and Fig. Figure 28 is a flowchart of the second procedure 200. (It should be noted that some of the features in the following description also appear in drawings other than the one in Figure 28.) Fig. 23 and Fig. 28 can be found). In block 210 ( Fig. 23A) A second sheet 24, made of a carbon-free fiber material and having a second region A2 and a second perimeter P2, is positioned on a first sheet 22, made of carbon fibers and having a first region A1 and a first perimeter P1, with the second sheet 24 being arranged within the first perimeter P1. In block 220 ( Fig. 23B) the second arch 24 is attached to the first arch 22 with a second arrangement of thread stitches 43. In block 230 ( Fig.23C) a metal plate 26 with a third area A3 and a third perimeter P3 is arranged on the second arc 24 within the second perimeter P2.

[0049] Here, the metal plate 26 has (i) a plurality of holes 28 formed therein around the third circumference P3, defining a plurality of respective bridge sections 29 between each of the holes 28 and an adjacent outer edge 30 of the metal plate 26, and / or (ii) a plurality of extensions 34 extending outwards from a main section 36 of the metal plate 26. And in block 240 ( Fig.23D) Each of the bridge sections 29 and extensions 34 is attached to the second arch 24, or to the first arch 22 and the second arch 24, using a first arrangement of thread stitches 38, thereby producing a reinforced preform assembly 56, which is also a reinforced composite assembly 20. In the above steps (and as mentioned previously), the first arch 22 has a first perimeter P1, the second arch 24 has a second perimeter P2 and is arranged within the first perimeter P1, and the metal plate 26 has a third perimeter P3 and is arranged within the second perimeter P2. Furthermore, the second perimeter A2 can be smaller than the first perimeter A1, and the third perimeter A3 can be smaller than the second perimeter A2.

[0050] Following the assembly steps described above, the reinforced preform assembly 56 can be subjected to the following forming steps as part of the second process 200. In block 250, the reinforced preform assembly 56 can be placed into a mold cavity 60 (see Fig. 20) can be inserted or placed, and in block 260 a mold plug 62 can be closed against the mold cavity 60 to form a closed mold 64 (see Fig. 21) to form. In block 270, a resin 66 can be placed into the closed form 64 (see Fig.21) are injected to saturate at least one or more selected sections 68 of the reinforced preform assembly 56 with the resin 66, creating a saturated reinforced preform assembly 70. (It should be noted that some other sections 69 of the reinforced preform assembly 56 may not be saturated with the resin 66, but the selected / saturated sections 68 and the other / unsaturated sections 69 together form the saturated reinforced preform assembly 70). In block 280, the closed mold 64 is opened by separating the mold plug 62 from the mold cavity 60 to expose the saturated reinforced preform assembly 70, and in block 290, the saturated reinforced preform assembly 70 is removed from the mold cavity 60.It should be noted that in block 275 an optional step can be performed in which a predetermined amount of heat 72 is applied to the saturated reinforced preform assembly 70 while it is in the closed mold 64 until a predetermined degree of curing 74 of the resin 66 is reached in the saturated reinforced preform assembly 70.

[0051] It should be noted that the description of the shape features (as in the Fig. 20-21), which were discussed above in connection with the first procedure 100, also apply to the second procedure 200.

[0052] Fig. Figures 24A-B show a sequence of manufacturing steps for the third process 300, in which the reinforced composite arrangement 20 has the first configuration, and Fig.Figure 29 is a flowchart of the third process 300. (It should be noted that some of the features in the following description also appear in drawings other than the one in Figure 29.) Fig. 24 and Fig. 29 can be found). In Block 310 ( Fig.24A) A second sheet 24 made of a carbon-free fiber material (with a second region A2 and a second perimeter P2) is inserted between a first sheet 22 made of carbon fibers (with a first region A1 and a first perimeter P1) and a metal plate 26 (with a third region A3 and a third perimeter P3). Here, the metal plate 26 has (i) a plurality of holes 28 formed therein around the third perimeter P3, defining a plurality of respective bridge sections 29 between each of the holes 28 and an adjacent outer edge 30 of the metal plate 26, and / or (ii) a plurality of extensions 34 extending outwards from a main section 36 of the metal plate 26. And in block 320 ( Fig.24B) Each of the bridge sections 29 and the extensions 34 is connected to the first arch 22 and the second arch 24 using a first arrangement of thread stitches 38, thereby producing a reinforced preform assembly 56, which is also a reinforced composite assembly 20. In the above steps (and as already mentioned), the first arch 22 has a first perimeter P1, the second arch 24 has a second perimeter P2 and is arranged within the first perimeter P1, and the metal plate 26 has a third perimeter P3 and is arranged within the second perimeter P2.

[0053] Furthermore, the second area A2 can be smaller than the first area A1 and the third area A3 can be smaller than the second area A2.

[0054] Following the assembly steps described above, the reinforced preform assembly 56 can be subjected to the following forming steps as part of the third process 300. In block 330, the reinforced preform assembly 56 can be placed into a mold cavity 60 (see Fig. 20) can be inserted or placed, and in block 340 a mold plug 62 can be closed against the mold cavity 60 to form a closed mold 64 (see Fig. 21) to form. In block 350, a resin 66 can be placed into the closed form 64 (see Fig.21) are injected to saturate at least one or more selected sections 68 of the reinforced preform assembly 56 with the resin 66, creating a saturated reinforced preform assembly 70. (It should be noted that some other sections 69 of the reinforced preform assembly 56 may not be saturated with the resin 66, but the selected / saturated sections 68 and the other / unsaturated sections 69 together form the saturated reinforced preform assembly 70). In block 370, the closed mold 64 is opened by separating the mold plug 62 from the mold cavity 60 to expose the saturated reinforced preform assembly 70, and in block 380, the saturated reinforced preform assembly 70 is removed from the mold cavity 60.It should be noted that in block 360 an optional step can be performed in which a predetermined amount of heat 72 is applied to the saturated reinforced preform assembly 70 in the closed mold 64 until a predetermined degree of curing 74 of the resin 66 in the saturated reinforced preform assembly 70 is reached.

[0055] It should be noted that the description of the shape features (as in the Fig. 20-21), which were discussed above in connection with the first procedure 100, also apply in connection with the third procedure 300.

[0056] Fig. Figures 25A-B show a sequence of manufacturing steps for the exemplary, but unclaimed, fourth method 400, in which the reinforced composite arrangement 20 has the second configuration, and Fig.Figure 30 is a flowchart of the unclaimed, exemplary, fourth method 400. (It should be noted that some of the features in the following description are also shown in drawings other than the one in Figure 30.) Fig. 25 and Fig. 30 can be found). In block 410 ( Fig.25A) A first layer 44, made of carbon-free fiber material and having a second region A2 and a second perimeter P2, is stacked onto a first sheet 22, made of carbon fibers and having a first region A1 and a first perimeter P1 (with the first layer 44 being arranged within the first perimeter P1); a metal plate 26 with a third region A3 and a third perimeter P3 is stacked onto the first layer 44 (with the metal plate 26 being arranged within the second perimeter P3); and a second layer 46, made of carbon-free fiber material and having a fourth region A4 and a fourth perimeter P4, is stacked onto the metal plate 26 (so that the metal plate 26 is arranged within the fourth perimeter P4). And in block 420 ( Fig.25B) The first layer 44, the second layer 46, and the first arc 22 are joined together around the third circumference P3 of the metal plate 26 using a first set of thread stitches 48, thereby producing a reinforced preform assembly 56, which is also a reinforced composite assembly 20. In the above steps, the first arc 22 has a first circumference P1, the first layer 44 has a second circumference P2 and is arranged within the first circumference P1, and the metal plate 26 has a third circumference P3 and is arranged within the second circumference P2 and the fourth circumference P4. Additionally, the second region A2 can be smaller than the first region A1, the third region A3 can be smaller than the second region A2, and optionally, the fourth region A4 can be approximately the same size as the second region A2.

[0057] Following the above assembly steps, the reinforced preform assembly 56 can be subjected to the following forming steps as part of the unclaimed fourth method 400. In block 430, the reinforced preform assembly 56 can be placed into a mold cavity 60 (see Fig. 20) can be inserted or placed, and in block 440 a mold plug 62 can be closed against the mold cavity 60 to form a closed mold 64 (see Fig. 21) to form. In block 450, a resin 66 can be placed into the closed form 64 (see Fig.21) are injected to saturate at least one or more selected sections 68 of the reinforced preform assembly 56 with the resin 66, creating a saturated reinforced preform assembly 70. (It should be noted that some other sections 69 of the reinforced preform assembly 56 may not be saturated with resin 66, but the selected / saturated sections 68 and the other / unsaturated sections 69 together form the saturated reinforced preform assembly 70). In block 470, the closed mold 64 is opened by separating the mold plug 62 from the mold cavity 60 to expose the saturated reinforced preform assembly 70, and in block 480, the saturated reinforced preform assembly 70 is removed from the mold cavity 60.It should be noted that in block 460 an optional step can be carried out in which a predetermined amount of heat 72 is applied to the saturated reinforced preform assembly 70 in the closed mold 64 until a predetermined degree of curing 74 of the resin 66 in the saturated reinforced preform assembly 70 is reached.

[0058] It should be noted that the description of the shape features (as in the Fig. 20-21), which were discussed above in connection with the first procedure 100, also apply in connection with the fourth procedure 400.

[0059] Fig. 26A-D shows a sequence of manufacturing steps for the exemplary, but unclaimed, fifth method 500, in which the reinforced composite arrangement 20 has the second configuration, and Fig.Figure 31 is a flowchart of the unclaimed, exemplary fifth method 500. (It should be noted that some of the features in the following description may also appear in drawings other than those shown in the Fig. 26 and Fig. 31 can be found). In block 510 ( Fig. 26A) A metal plate 26 with a third region A3 and a third perimeter P3 is inserted between a first layer 44 and a second layer 46 of carbon-free fiber material, which accordingly have a second region A2 and a fourth region A4 and correspondingly a second perimeter P2 and a fourth perimeter P4. In this insertion, the metal plate 26 is positioned within the third perimeter P3 and the fourth perimeter P4. In block 520 ( Fig.26B) the first layer 44 and the second layer 46 are joined around the third circumference P3 of the metal plate 26 using a first set of thread stitches 48 to trap the metal plate 26 in a closed pocket 88 formed by the first layer 44 and the second layer 46 and the first set of thread stitches 48 around the metal plate 26, thereby forming a sub-assembly 90 with the metal plate 26 packed. In block 530 ( Fig. 26C) the subassembly 90 with wrapped metal plate 26 is arranged on a first arc 22 made of carbon fiber, which has a first region A1 and a first perimeter P1, wherein the subassembly 90 with wrapped metal plate 26 is arranged within the first perimeter P1. And in block 540 ( Fig.26D) at least one of the first and second layers 44, 46 is attached to the first arc 22 around the third circumference P3 of the metal plate 26 with a second set of thread stitches 53, thereby producing a reinforced preform assembly 56, which is also a reinforced composite assembly 20. In the above steps (and as already mentioned), the first arc 22 has a first circumference P1, the first layer 44 has a second circumference P2 and is arranged within the first circumference P1, and the metal plate 26 has a third circumference P3 and is arranged within the second circumference P2 and the fourth circumference P4. Additionally, the second region A2 can be smaller than the first region A1, the third region A3 can be smaller than the second region A2, and optionally, the fourth region A4 can be approximately the same size as the second region A2.

[0060] Following the above assembly steps, the reinforced preform assembly 56 can be subjected to the following forming steps as part of the unclaimed fifth method 500. In block 550, the reinforced preform assembly 56 can be placed into a mold cavity 60 (see Fig. 20) can be inserted or placed, and in block 560 a mold plug 62 can be closed against the mold cavity 60 to form a closed mold 64 (see Fig. 21) to form. In block 570, a resin 66 can be placed into the closed form 64 (see Fig.21) are injected to saturate at least one or more selected sections 68 of the reinforced preform assembly 56 with the resin 66, creating a saturated reinforced preform assembly 70. (It should be noted that some other sections 69 of the reinforced preform assembly 56 may not be saturated with resin 66, but the selected / saturated sections 68 and the other / unsaturated sections 69 together form the saturated reinforced preform assembly 70). In block 580, the closed mold 64 is opened by separating the mold plug 62 from the mold cavity 60 to expose the saturated reinforced preform assembly 70, and in block 590, the saturated reinforced preform assembly 70 is removed from the mold cavity 60.It should be noted that in block 575 an optional step can be carried out in which a predetermined amount of heat 72 is applied to the saturated reinforced preform assembly 70 in the closed mold 64 until a predetermined degree of curing 74 of the resin 66 in the saturated reinforced preform assembly 70 is reached.

[0061] It should be noted that the description of the shape features (as in the Fig. 20-21), which were discussed above in connection with the first procedure 100, also apply in connection with the fifth procedure 500.

[0062] It should be noted that the terms “securing,” “fastening,” “connecting,” “joining,” “attaching,” and “linking together” (and their related forms) have been used in various ways in the present revelation to describe connections between or beneath two or more sheets 22, 24, and / or layers 44, 46. These terms can be considered interchangeable equivalents, as they represent different ways of describing the aforementioned connections between or beneath two or more sheets 22, 24, and / or layers 44, 46. In all these cases, the connections are made by sewing or stitching with suitable threads or filaments.

Claims

[1] A reinforced composite arrangement (20) comprising: comprising a first arc (22) made of carbon fibers and having a first perimeter (P1); a second sheet (24) made of a carbon-free fiber material and having a second perimeter (P2), wherein the second sheet (24) is arranged on the first sheet (22) within the first perimeter (P1); a metal plate (26) with a third circumference (P3), wherein the metal plate (26) is arranged on top of the second arc (24) within the second circumference (P2), wherein the metal plate (26) has: a plurality of holes (28) formed along the third perimeter (P3) of the metal plate (26) and defining a plurality of respective bridge sections (29) between each of the holes (28) and an adjacent outer edge (30) of the metal plate (26); and / or a multitude of extensions (34) extending outwards from a main section (36) of the metal plate (26); and a first arrangement of thread stitches (38) securing each of the bridge sections (29) and extensions (34) to the second arch (24) or to the first arch (22) and the second arch (24). [2] The reinforced composite arrangement (20) according to claim 1, wherein each of the plurality of extensions (34) is a T-shape (34 T ), an L-shape (34 L ), a U-shape (34 U ) with a first end (35) and a second end (37), wherein both the first end (35) and the second end (37) are adjacent to the main section (36), a key head shape (34 K ) with a straight section (39 S ), which extends outwards from the main section (36) and in a closed loop section (39) CL ) ends, and a tab (34 B) with one or more through holes (TH) in it. [3] The reinforced composite arrangement (20) according to claim 1, wherein each of the holes (28) is a circular hole (28 C ), an ellipsoidal hole (28 E ), a square hole (28s), a rounded straight slot (28 RSS ) or a rectangular slot (28 RS ) is shaped. [4] The reinforced composite arrangement (20) according to claim 1, further comprising: a metallic element (40) which is attached to the metal plate (26) by a first section (41) and extends away from the metal plate (26) by a second section (42). [5] The reinforced composite arrangement (20) according to claim 1, wherein the metal plate (26) has at least one opening (45) passing through it, which is located within the plurality of holes (28). [6] The reinforced composite arrangement (20) according to claim 1, further comprising: a second arrangement of thread stitches (43) that secures the second bow (24) to the first bow (22). [7] A method (100) for producing a reinforced composite arrangement (20), comprising: Arranging (110) a metal plate (26) with a third perimeter (P3) on a second sheet (24) made of a carbon-free fiber material and having a second perimeter (P2), wherein the metal plate (26) is arranged within the second perimeter (P2) and has a plurality of holes (28) formed along the third perimeter (P3) and defining a plurality of respective bridge sections (29) between each of the holes (28) and an adjacent outer edge (30) of the metal plate (26) and / or a plurality of extensions (34) extending outwards from a main section (36) of the metal plate (26); Securing (120) each of the bridge sections (29) and extensions (34) to the second arch (24) using a first arrangement of thread stitches (38), thereby producing a sub-arrangement (54) of metal plate (26) and second arch (24); Arranging (130) the sub-arrangement (54) of metal plate (26) and second arc (24) on a first arc (22) made of carbon fibers and having a first perimeter (P1), wherein the sub-arrangement (54) of metal plate (26) and second arc (24) is arranged within the first perimeter (P1) and the second arc (24) separates the metal plate (26) from the first arc (22); and Attaching (140) the second sheet (24) to the first sheet (22) using a second arrangement of thread stitches (43), thereby producing a reinforced preform arrangement (56). [8] The method (100) according to claim 7, further comprising: Insertion (150) of the reinforced preform arrangement (56) into a mold cavity (60); Closing (160) a mold stopper (62) against the mold cavity (60) to form a closed mold (64); Injecting (170) a resin (66) into the closed mold (64) to saturate at least one selected section of the reinforced preform assembly (56) with the resin (66), thereby creating a saturated reinforced preform assembly (70); Opening (180) the closed mold (64) by separating the mold stopper (62) from the mold cavity (60) to expose the saturated reinforced preform assembly (70); and Removal (190) of the saturated reinforced preform assembly (70) from the mold cavity (60). [9] The method (100) according to claim 8, further comprising: Applying (175) heat to the saturated reinforced preform assembly (70) while it is in the closed mold (64) until a predetermined degree (74) of resin curing (66) is reached.

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