Complex superstructure with fiber-reinforced sub-components and method of making

Abstract

Described are complex superstructures having at least two sub-components, where each sub-component has a longitudinal axis and a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, where the difference between a largest circumferential length and a smallest circumferential length of each sub-component is no greater than a factor of 2. A reinforcing outer layer of fiber having an approximately uniform fiber density is bonded to at least a portion of a molded substrate that forms a base for each sub-component. An overlapping mating surface joint is positioned between the sub-components.

Description

COMPLEX SUPERSTRUCTURE WITH FIBER-REINFORCED SUBCOMPONENTS AND METHOD OF MAKINGCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is related to and claims priority benefits from U.S. Provisional Application Serial No. 63 / 591,444, filed October 18, 2023, entitled “Complex Superstructure with Fiber-Reinforced Sub-Components and Method of Making,” the entire contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] This document generally describes reinforced fiber structures, such as consumer products (e.g., sporting equipment) and other components (e.g., airplane components, automotive components), and manufacturing processes to form such reinforced carbon fiber structures.BACKGROUND

[0003] Carbon fiber or similar materials have been used to produce consumer products and other components because of their advantageous properties, including high stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion. For example, due to these properties, carbon fiber has frequently been used in aerospace, civil engineering, military, and motorsports, along with other competition sports.

[0004] Carbon fiber materials often include a combination of carbon fibers (i.e., fiber strands of carbon atoms) with other materials to form a composite that, when permeated with a resin or fluid matrix and cured, can form a carbon-fiber-reinforced polymer (referred to as “carbon fiber”) that has a high strength-to-weight ratio. However, such carbon fiber, while being strong and rigid, can be somewhat brittle and can be susceptible to breaking, cracking, or other structural failures in the event that a sufficient force is applied to the carbon fiberstructure. For example, carbon fiber structures can handle significant stress in certain directions, but impact from a direction in which fibers of the structure are not optimized can cause the carbon fiber to crack, fracture, or break. Once carbon fiber fractures, the carbon fiber loses its structural integrity and may be prone to further fracture.

[0005] Carbon fibers or similar materials have also been used in braiding machines to produce hollow circular tubes. This type of braiding can be used to braid a sheath over a cable as the cable is drawn through the core of the hollow circular tube as it is being formed around the cable. Traditionally, this process has worked well for forming a tubular reinforcement around elongated objects with a regular or slightly irregular circular shape or a tapered shape.

[0006] However, carbon fiber hoses formed using conventional braiding processes experience significant drawbacks when the object to be covered has a very large cross-sectional dimension (typically greater than 8 inches). The reason is because of the step-down ratio from the diameter of the braiding mechanism to the diameter of the finished carbon- fiber hose, which is on the order of 10: 1. While the finished carbon-fiber hose has some ability to stretch, the amount of stretching available that does not significantly impact the physical properties of the carbon fiber is on the order of approximately two times the unstretched diameter. As a result, to create a finished carbon fiber hose that is able to cover a component with a 36-inch diameter, the diameter of the braiding mechanism would need to be on the order of 360 inches. As a result, using a conventional process for creating carbon fiber hoses to encapsulate parts of this size (or larger) requires a braiding machine of a size that is not economically feasible.

[0007] Similarly, carbon fiber hoses formed using conventional braiding processes experience significant drawbacks when the object to be covered has a cross-sectional shape that varies extensively in the elongated direction. As mentioned above, while the finished carbon-fiber hose has some ability to stretch, the amount of stretching available that does not significantly impact the physical properties of the carbon fiber is on the order of approximatelytwo times the unstretched diameter. In other words, variations in size that are greater than 2X (where X is the smallest cross-sectional shape) typically cause inconsistencies in the physical properties of the carbon fiber hose along its length.

[0008] As a result, it is desirable to find a new method of creating a carbon fiber external layer using a conventional braiding machine that can be used with a broad range of sizes and shapes of components.SUMMARY

[0009] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.

[0010] A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions. Implementations of the described techniques may include hardware, a method or process, or a computer tangible medium. Other embodiments includecorresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.

[0011] According to certain embodiments, the method may include determining a shape and dimensions of the complex superstructure; subdividing the complex superstructure into at least two sub-components, where each of the at least two sub-components may include: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, where a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; and an overlapping mating surface joint between the at least two sub-components.

[0012] In some embodiments, the step of determining a shape and dimensions of the complex superstructure may include determining an approximate location of a longitudinal axis of the complex superstructure, where the complex superstructure may include a range of circumferential lengths measured along the longitudinal axis, where a difference between a largest circumferential length and a smallest circumferential length is greater than a factor of 2.

[0013] In some embodiments, the overlapping mating surface arrangement between the at least two sub-components may include having at least a portion of each of the at least two subcomponents extend through a plane formed between the mating surfaces of the at least two subcomponents and into a reciprocally shaped region of an adjacent one of the at least two subcomponents.

[0014] In some embodiments, the step of subdividing the complex superstructure into at least two sub-components may include (1) positioning the at least two sub-components in a side-to-side arrangement, (2) positioning the at least two sub-components in an end-to-end arrangement, (3) creating at least one open region between the at least two sub-components,(4) choosing a shape for each sub-component that will allow a reinforcing outer layer of fiberthat is applied over at least a portion of a molded substrate that forms a base for each the at least two sub-components to have an approximately uniform fiber density after application, and / or (5) choosing a material for a molded substrate base or each of the at least two subcomponents that will provide required physical properties for the complex superstructure in a location of each of the at least two sub-components. In some embodiments, the method may include adding a permanent spacer into the at least one open region. In further embodiments, the material used for the molded substrate base of one of the at least two sub-components is different from the material used for the molded substrate base of another of the at least two sub-components.

[0015] According to certain embodiments, the method may include molding substrate material using a pre-formed mold to form a base for each of the at least two sub-components; applying a reinforcing outer layer of fiber over at least a portion of each base, where the applied reinforcing outer layer has an approximately uniform fiber density after application; bonding the reinforcing outer layer to each base to form each of the at least two sub-components; placing a mating surface of one of the at least two sub-components adjacent to a mating surface of another of the at least two sub-components in an overlapping mating surface arrangement; and bonding the mating surfaces to each other.

[0016] In some embodiments, the step of placing a mating surface of one of the at least two sub-components adjacent to a mating surface of another of the at least two sub-components in an overlapping mating surface arrangement may include having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of the adjacent one of the at least two sub-components.

[0017] In some embodiments, the step of applying a reinforcing outer layer of fiber over at least a portion of each base may include placing the base through an industrial braidingmachine. In further embodiments, the industrial braiding machine has a maximum diameter of 7 feet.

[0018] In some embodiments, the method may include inserting a temporary spacer into a receptacle formed in at least one of the bases prior to applying a reinforcing outer layer of fiber over at least a portion of each base. In further embodiments, the temporary spacer is shaped to protrude above a surrounding outer surface of the base. In some embodiments, the method may include removing the temporary spacer from the receptacle and tucking the reinforcing outer layer material that previously covered the protruding spacer into the receptacle prior to bonding the reinforcing outer layer to each base to form each of the at least two sub-components.

[0019] In some embodiments, the method may include positioning at least one reinforcing intermediate layer on a mold surface in a location where the sub-component requires additional support prior to molding substrate material using a pre-formed mold to form a base for each of the at least two sub-components.

[0020] In some embodiments, the method may include inserting a permanent spacer into an open region between the at least two sub-components prior to bonding the mating surfaces to each other.

[0021] According to certain embodiments, a complex superstructure may include at least two sub-components, where each of the at least two sub-components may include: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, where a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; a reinforcing outer layer of fiber bonded to at least a portion of a molded substrate that forms a base for each of the at least two sub-components, where the reinforcing outer layer of fiber has an approximately uniform fiber density; and an overlapping mating surface joint between the at least two sub-components. In certain embodiments, the complex superstructure may be a rifle stock.

[0022] In some embodiments, a material for the molded substrate base for each of the at least two sub-components may be chosen to provide required physical properties for the complex superstructure in a location of each of the at least two sub-components. In further embodiments, the material for the molded substrate base for each of the at least two subcomponents may be different from the material used for the molded substrate base of another of the at least two sub-components.

[0023] In some embodiments, the overlapping mating surface joint between the at least two sub-components (1) may include having at least a portion of each of the at least two subcomponents extend through a plane formed between the mating surfaces of the at least two subcomponents and into a reciprocally shaped region of an adjacent one of the at least two subcomponents, (2) may be formed when the at least two sub-components are arranged side-to- side, and / or (3) may be formed when the at least two sub-components are arranged end-to-end.

[0024] In some embodiments, the at least one open region may be located between the at least two sub-components. In further embodiments, a permanent spacer may be positioned within the at least one open region.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure is described in conjunction with the appended figures.

[0026] FIG. 1A-1B illustrates a flowchart of a method for manufacturing a complex superstructure, according to certain embodiments of the present disclosure.

[0027] FIG. 2A illustrates a side view of an assembled complex superstructure, according to certain embodiments of the present disclosure.

[0028] FIG. 2B illustrates an exploded side view of the complex superstructure of FIG. 2A.

[0029] FIG. 3 illustrates an exploded top view of the complex superstructure of FIG. 2A.

[0030] FIG. 4 illustrates a top view of the assembled complex superstructure of FIG. 2A.

[0031] FIG. 5A illustrates an exploded simplified side view of a complex superstructure, according to certain embodiments of the present disclosure.

[0032] FIG. 5B illustrates a sectional view taken along plane A-A of the complex superstructure of FIG. 5A.

[0033] FIG. 6A illustrates an exploded perspective view of a portion of a complex superstructure, according to certain embodiments of the present disclosure.

[0034] FIG. 6B illustrates a sectional view taken along plane B-B of the complex superstructure of FIG. 6A.

[0035] FIG. 6C illustrates a perspective view of a portion of the complex superstructure of FIG. 6A, with a temporary spacer in place.

[0036] FIG. 7 illustrates a mold created for molding a complex superstructure, according to certain embodiments of the present disclosure.

[0037] FIG. 8A illustrates a top view of a portion of a complex superstructure, according to certain embodiments of the present disclosure.

[0038] FIG. 8B illustrates a sectional view taken along plane C-C of the complex superstructure of FIG. 8 A.

[0039] FIG. 9A illustrates a front view of a complex superstructure, according to certain embodiments of the present disclosure.

[0040] FIG. 9B illustrates a sectional view taken along plane D-D of the complex superstructure of FIG. 9A.

[0041] FIG. 10 A illustrates a perspective view of a complex superstructure, according to certain embodiments of the present disclosure.

[0042] FIG. 10B illustrates a sectional view taken along plane E-E of the complex superstructure of FIG. 9A.

[0043] FIG. 11 illustrates various cross-sectional views of the complex superstructure of FIG. 2A.

[0044] FIG. 12 is a closer view of the various cross-sectional views of FIG. 11.

[0045] FIG. 13 illustrates a generic cross-sectional view of a complex superstructure broken into multiple smaller regular structures along a longitudinal axis.

[0046] FIG. 14 illustrates how a braided surface covering is applied to a complex superstructure using conventional techniques.

[0047] FIG. 15 is a computer image of various complex superstructures that can be created using the methods described in FIG. 1A-1B.

[0048] FIG. 16 is a computer image of additional complex superstructures that can be created using the methods described in FIG. 1 A-1B.

[0049] FIG. 17 is a computer image of additional complex superstructures that can be created using the methods described in FIG. 1A-1B.

[0050] FIG. 18 is a computer image of additional complex superstructures that can be created using the methods described in FIG. 1 A-1B.

[0051] FIG. 19 illustrates a generic cross-sectional view of how a complex superstructure can be broken into multiple smaller regular structures along a longitudinal axis.

[0052] FIG. 20 is an image of a complex superstructure created using the methods described in FIG. 1A-1B.

[0053] FIG. 21 is another view of the complex superstructure shown in FIG. 20.

[0054] FIG. 22 is another view of the complex superstructure illustrated in FIG. 20.

[0055] FIG. 23 is an image of a complex superstructure described in step 102 of FIG. 1A.

[0056] FIG. 24 is another view of the complex superstructure shown in FIG. 23.

[0057] FIG. 25 is an image of a complex superstructure described in step 102 of FIG. 1A with markings to indicate where it will be sub-divided according to step 104 of FIG. 1 A.

[0058] FIG. 26 is another view of the complex superstructure shown in FIG. 25.

[0059] FIG. 27 is another view of the complex superstructure shown in FIG. 25.

[0060] FIG. 28 is another view of the complex superstructure shown in FIG. 25.

[0061] FIG. 29 is an image of sub-components of a complex superstructure created according to step 104 of FIG. 1A.

[0062] FIG. 30 is another view of the sub-components of FIG. 29.

[0063] FIG. 31 is an image of a sub-component of a complex superstructure created according to step 104 of FIG. 1A.

[0064] FIG. 32 is another view of the sub-component of FIG. 31 positioned adjacent to a mating sub-component created according to step 104 of FIG. 1A.

[0065] FIG. 33 is another view of the sub-components of FIG. 29, along with additional sub-components created according to step 104 of FIG. 1A.

[0066] FIG. 34 is another view of the sub-components of FIG. 33.

[0067] FIG. 35 is another view of the sub-components of FIG. 33.

[0068] FIG. 36 is another view of the sub-components of FIG. 33.

[0069] FIG. 37 is another view of the sub-components of FIG. 33.

[0070] FIG. 38 is another view of the sub-components of FIG. 33.

[0071] FIG. 39 is another view of the sub-components of FIG. 33.

[0072] FIG. 40 is another view of the sub-components of FIG. 33.

[0073] FIG. 41 is another view of the sub-components of FIG. 33.

[0074] FIG. 42 is an image of sub-components of a complex superstructure created according to step 104 of FIG. 1 A.

[0075] FIG. 43 is another view of the sub-components of FIG. 42.

[0076] FIG. 44 is another view of the sub-components of FIG. 42.

[0077] FIG. 45 is another view of the sub-components of FIG. 42.

[0078] FIG. 46 is an image of sub-components of a complex superstructure created according to step 104 of FIG. 1 A.

[0079] FIG. 47 is another view of the sub-components of FIG. 46.

[0080] FIG. 48 is another view of the sub-components of FIG. 46.

[0081] FIG. 49 is another view of the sub-components of FIG. 46.

[0082] FIG. 50 is another view of the sub-components of FIG. 46.

[0083] FIG. 51 is an image of a sub-component of a complex superstructure created according to step 104 of FIG. 1A.

[0084] FIG. 52 is another view of the sub-component of FIG. 51.

[0085] FIG. 53 is another view of the sub-component of FIG. 51, along with additional sub-components created according to step 104 of FIG. 1A.

[0086] FIG. 54 is another view of the sub-components of FIG. 53.

[0087] FIG. 55 is another view of the sub-components of FIG. 53.

[0088] FIG. 56 is an image of a mold for a sub-component of a complex superstructure created according to step 106 of FIG. 1A.

[0089] FIG. 57 is an image of sub-components created in a mold for sub-components of a complex superstructure according to steps 107-110 of FIG. 1A.

[0090] FIG. 58 is an image of sub-components of a complex superstructure created according to step 104 of FIG. 1 A.

[0091] FIG. 59 is another view of the sub-components of FIG. 58.

[0092] FIG. 60 is an image of types of reinforcing outer layers with varying unstretched diameters.

[0093] FIG. 61 is an image of types of reinforcing outer layers with varying unstretched diameters.

[0094] FIG. 62 is an image of an exemplary type of reinforcing outer layer showing unstretched and stretched diameters.

[0095] FIG. 63 is an image of an exemplary type of reinforcing outer layer showing unstretched and stretched diameters.

[0096] FIG. 64 is an image of sub-components following application of a reinforcing outer layer to each sub-component according to steps 112-113b of FIGs. 1A-1B.

[0097] FIG. 65 is another view of the sub-components of FIG. 64.

[0098] FIG. 66 is another view of the sub-components of FIG. 64.

[0099] FIG. 67 is another view of the sub-components of FIG. 64.

[0100] FIG. 68 is another view of the sub-components of FIG. 64.

[0101] FIG. 69 is another view of the sub-components of FIG. 64.

[0102] FIG. 70 is another view of the sub-components of FIG. 64.

[0103] FIG. 71 is another view of the sub-components of FIG. 64.

[0104] FIG. 72 is another view of the sub-components of FIG. 64.

[0105] FIG. 73 is an image of a sub-component following application of a reinforcing outer layer to the sub-component according to steps 112-113b of FIGs. 1A-1B.

[0106] FIG. 74 is another view of the sub-component of FIG. 73.

[0107] FIG. 75 is another view of the sub-component of FIG. 73.

[0108] FIG. 76 is another view of the sub-component of FIG. 73.

[0109] FIG. 77 is another view of the sub-component of FIG. 73.

[0110] FIG. 78 is another view of the sub-component of FIG. 73.

[0111] FIG. 79 is another view of the sub-component of FIG. 73.

[0112] FIG. 80 is another view of the sub-component of FIG. 73 positioned alongside an opposite end of the same sub-component of FIG. 73.

[0113] FIG. 81 is another view of the sub-component of FIG. 73, positioned alongside another component with the reinforcing outer layer applied using conventional methods.

[0114] FIG. 82 is another view of the sub-components of FIG. 81.

[0115] FIG. 83 is an image of sub-components following application of a reinforcing outer layer to each sub-component according to steps 112-1 13b of FIGs. 1A-1B.

[0116] FIG. 84 is another view of the sub-components of FIG. 81.

[0117] FIG. 85 is an image of a sub-component following application of a reinforcing outer layer to the sub-component according to steps 112- 113b of FIGs. 1A-1B.

[0118] FIG. 86 is another view of the sub-component of FIG. 85.

[0119] FIG. 87 is another view of the sub-component of FIG. 85.

[0120] FIG. 88 is another view of the sub-component of FIG. 85.

[0121] FIG. 89 is another view of the sub-components of FIG. 81 with a permanent spacer positioned therebetween according to steps 117-117a of FIG. IB.

[0122] FIG. 90 is another view of the sub-components of FIG. 89 positioned alongside the mold of FIG. 56 used to form the sub-components of FIG. 89.

[0123] FIG. 91 is another view of the sub-components of FIG. 89.

[0124] FIG. 92 is another view of the sub-components of FIG. 89.

[0125] FIG. 93 is an image of assembled sub-components following application of heat to join reinforcing layer mating surfaces according to steps 118-119 of FIG. IB.

[0126] FIG. 94 is another view of the assembled sub-components of FIG. 93.

[0127] FIG. 95 is an image of a sub-component following application of energy to bond a reinforcing outer layer to the sub-component according to step 114 of FIG. IB.

[0128] FIG. 96 is an image of a sub-component following application of energy to bond a reinforcing outer layer to the sub-component according to step 114 of FIG. IB.

[0129] FIG. 97 is an image of a fully assembled superstructure prior to application of coating to the outer surface according to step 120 of FIG. IB.

[0130] FIG. 98 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0131] FIG. 99 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0132] FIG. 100 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0133] FIG. 101 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0134] FIG. 102 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0135] FIG. 103 is an image of a cross-section of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0136] FIG. 104 is an image of a mold for a sub-component of a complex superstructure with a reinforcing layer applied to a portion of the mold surface according to steps 107- 107b of FIG. 1A.

[0137] FIG. 105 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0138] FIG. 106 is another view of the fully assembled superstructure of FIG. 105.

[0139] FIG. 107 is another view of the fully assembled superstructure of FIG. 105.

[0140] FIG. 108 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0141] FIG. 109 is another view of the fully assembled superstructure of FIG. 108.

[0142] FIG. 110 is another view of the fully assembled superstructure of FIG. 108.

[0143] FIG. 11 1 is another view of the fully assembled superstructure of FIG. 108.

[0144] FIG. 112 is another view of the fully assembled superstructure of FIG. 108.

[0145] FIG. 113 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0146] FIG. 114 is an image of a complex superstructure that can be created using the methods described in FIG. 1A-1B.

[0147] FIG. 115 is an image of a fully assembled superstructure following application of coating to the outer surface according to step 120 of FIG. IB.

[0148] FIG. 116 is an image of a partially assembled superstructure according to certain steps of FIGs. 1A-1B.

[0149] FIG. 117 is another view of the partially assembled superstructure of FIG. 116.

[0150] FIG. 118 is another view of the partially assembled superstructure of FIG. 116.

[0151] FIG. 119 is another view of the partially assembled superstructure of FIG. 116.

[0152] FIG. 120 is another view of the partially assembled superstructure of FIG. 116.DETAILED DESCRIPTION

[0153] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

[0154] Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the sub-components of the systems and apparatuses may be integrated or separated. Moreover,the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other sub-components and the methods described may include more, fewer, or other steps. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. The claimed subject matter may be used in conjunction with other existing or future technologies.

[0155] Other technical advantages may become readily apparent to one of ordinary skill in the relevant art after review of the following figures and description. Moreover, those of ordinary skill in the relevant art will recognize and appreciate that many changes can be made to the various examples of the disclosure described herein, while still obtaining the beneficial results of the invention.

[0156] As used throughout this document, “each” refers to each member of a set or each member of a subset of a set. Moreover, the singular forms "a," "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a fastener" can include two or more such fasteners unless the context indicates otherwise. Ranges can be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another example includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," the particular value forms another example. Moreover, the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0157] As used herein, the terms "optional" or "optionally" mean that the subsequently described feature may or may not be present, and that the description includes instances where said feature is present and instances where it is not. The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list.

[0158] Further, conditional language, such as among others, “may,” "can," "could," or "might," unless specifically stated otherwise or otherwise understood within the context as used, is generally intended to convey that certain examples include, while other examples do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more particular examples.

[0159] Directional references such as "up," "down," "top," "bottom," "left," "right," "front," "back," "rear," and "comers," among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. Unless otherwise specifically noted, articles depicted in the drawings are not necessarily drawn to scale.

[0160] To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim element to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

[0161] Embodiments described herein are generally related to a method and a system for manufacturing fiber-reinforced complex superstructure 130. In particular, some embodiments of the disclosure describe a method of manufacturing a fiber-reinforced complex superstructure 130 using molded sub-components.

[0162] Referring to FIG. 1A-1B, a flowchart of method 100 for manufacturing a fiber- reinforced complex superstructure 130 by performing steps is described. Block 102 describes a step for determining shape and dimensions of a finished complex superstructure 130, block 104 describes a step for subdividing the shape of the complex superstructure 130 into two or more sub-components 132, block 106 describes a step for creating a separate mold 139 for each of the sub-components 132, blocks 107, 107a, and 107b describe steps for optionally includingreinforcing intermediate layers 144 on at least one of the mold 139 surfaces, block 108 describes a step for adding substrate material 134 to the mold 139, block 110 describes a step of applying energy to the mold 139 and removing the molded sub-component 132, blocks 111, Illa, 111b describe steps for optionally inserting temporary spacers 141 within any receptacles 140 in the molded sub-component 132, block 112 describes a step for applying a reinforcing outer layer 136 to the molded sub-component 132, block 113a describes a step for removing any temporary spacer(s) 141 from receptacle(s) 140 added to the molded sub-component 132 in the step of block Illa, block 113b describes a step for tucking extra fiber of the reinforcing outer layer 136 into the receptacle(s) 140, block 114 describes a step of applying energy to bond the reinforcing outer layer 136 to the molded sub-component 132, block 116 describes a step of placing longitudinal mating surface(s) 146 or lateral mating surface(s) 148 of the subcomponents) 132 adjacent to the corresponding longitudinal mating surface(s) 146 or lateral mating surface(s) 148 of other sub-component(s) 132, blocks 117, 117a, 117b describe steps for optionally inserting permanent spacers 143 within any receptacles 140 formed between the adjacent mating surfaces, block 118 describes a step of applying energy to bond the adjacent mating surfaces to each other, block 119 describes repeating steps in blocks 106-118 until all sub-components 132 have been assembled and the superstructure 130 three-dimensional shape defined in the step of block 102 has been achieved, and block 120 describes a step for applying additional coating or other finishings to the outer surface of the three-dimensional superstructure 130.

[0163] At block 102 of FIG. 1A, steps for determining shape and dimensions of the finished complex superstructure 130 are performed. As an example, FIGs. 2A, 9A, and 10A illustrate views of a complex superstructure 130 having a three-dimensional shape defined by an outer surface with varying cross sections along its length. The finished complex superstructure 130 has a three-dimensional shape and dimensions that may be determined by using varioustechniques. In certain embodiments, the shape may be created and dimensions may be determined using Computer Aided Designing (“CAD”) software. The CAD software enables the creation and processing of a CAD file containing a three-dimensional design of the finished complex superstructure 130. The CAD file for the design may be created in the CAD software itself or it may be generated using various 3D-scanning techniques. Once the CAD file is created / generated, the finished complex superstructure 130 design may be manipulated or modified in a three-dimensional orthogonal Cartesian coordinate system of the CAD software. Other coordinate systems e.g., cylindrical coordinate system, spherical coordinate system may be used to manipulate or modify the finished complex superstructure 130. Once the design contained in the CAD file is manipulated or modified, various dimensions e.g., length, width, thickness, radius, and surface area may be calculated using the CAD software. The CAD software may enable different views for the complex superstructure 130 e.g., perspective view, top view, sectional view, exploded view, or any other suitable view angle enabling easy manipulation of the shape of the complex superstructure 130.

[0164] At block 104 of FIG. 1 A, steps for sub-dividing the finished complex superstructure 130 shape into two or more sub-components 132 are performed. As an example, FIG. 2B illustrates an exploded view of the complex superstructure 130 illustrated in FIG. 2A along with its sub-components 132. In certain embodiments, the finished complex superstructure 130 shape is subdivided into at least two sub-components 132. In further embodiments, the complex superstructure 130 can have as many sub-components 132 as needed to build out to the three- dimensional shape of the complex superstructure 130. In additional embodiments, some subcomponents 132 may be completely internal, which means those sub-components 132 may not have a portion exposed on the outer surface of the complex superstructure 130. In some embodiments, certain sub-components 132 are shaped in a way that leaves at least one portion of the three-dimensional shape of the complex superstructure 130 hollow, thereby creating atleast one receptacle 140. The internal sub-components 132, such as webs and flanges of any shape, may be formed in the desired manner. In some embodiments, the internal and external surfaces of the sub-components 132 are completely covered, if desired, to provide continuous foam coverage.

[0165] According to certain embodiments, as best illustrated in FIG. 3, a top view of the complex superstructure 130 is subdivided into sub-components 132. In these illustrative embodiments, the sub-components 132 are subdivided along a longitudinal axis of the complex superstructure 130 such that the top view exposes the mating surfaces 146 of the subcomponents 132. FIG. 3 also illustrates receptacles 140 in the sub-components 132.

[0166] According to certain embodiments, as best illustrated in FIG. 4, a bottom view of the sub-components 132 of FIG. 3 assembled into a complex superstructure 130 is shown.

[0167] According to certain embodiments, the finished complex superstructure 130 shape may be manipulated to define multiple sub-components 132. The purpose of subdividing the complex superstructure 130 into sub-components 132 is to achieve a more uniform reinforcing outer layer 136 (applied at block 112, described in more detail below) with a density and / or application shape across the complex shape of the superstructure 130 that could not be achieved by applying e.g., a reinforcing outer layer 136 over the complex superstructure 130 as a whole. With a more uniform application of the reinforcing outer layer 136 over the entire complex superstructure 130, the physical properties of the superstructure 130 are likewise more uniform. Examples of such configured physical properties include but are not limited to stiffness, damping, strength, hardness, magnetic permeability, weight and balance, conductivity, isotropic or directional, configured for the whole superstructure 130 or just as a function of a sub-component 132 position, e.g., stronger in the back, more damping in the front, etc., resistance to crack formation, intentional crack propagation for configured failure and mitigation. The use of sub-components 132 also provides a mechanism to optimize the totalamount of material needed for manufacturing the complex superstructure 130. The material type, density, and / or strength may be locally selected for certain sub-components 132 to achieve extra strength, increased internal bond dimensions, etc. For example, the subcomponents 132 may be shaped to create internal receptacles 140 for compensating crosssection variation along the length and insertion of interlocking elements 143, e.g., biscuits, across multiple constituent cross-sections.

[0168] Furthermore, the disparity of shapes among individual sub-components 132 may be handled by adding longitudinal mating surfaces 146 and / or lateral mating surfaces 148 to each sub-component 132, which are in turn to be joined with the longitudinal mating surfaces 146 and / or lateral mating surfaces 148 of other sub-components 132. A person of ordinary skill in the relevant art will understand that the terms “longitudinal” and “lateral” should not be limited to mean “parallel” and “perpendicular” to a longitudinal axis of the superstructure 130. For example, the term longitudinal mating surface 146 refers to a surface on the sub-component 132 having a “best fit” line that is more aligned with a longitudinal axis X of the superstructure 130 than with a lateral axis Y of the superstructure 130. Conversely, the term lateral mating surface 148 refers to a surface on the sub-component 132 having a “best fit” line that is more aligned with a lateral axis Y of the superstructure 130 than with a longitudinal axis X of the superstructure 130.

[0169] Furthermore, the longitudinal mating surfaces 146 and / or the lateral mating surfaces 148 may be joined using an overlapping structure. This overlapping arrangement provides a manner to add appropriate and / or necessary length and / or girth such that a series of disparate sub-component 132 shapes may be unified into a complex superstructure 130 without loss of desired shape or strength as compared to a monolithic design of the same superstructure 130.

[0170] According to certain embodiments, as best illustrated in FIGs. 5A-5B, a simplified view of a complex superstructure 130 having sub-components 132 is shown. The substratematerial 134 of the sub-components 132 is covered with the reinforcing outer layer 136. The sub-components 132 are shown in a non-attached configuration relative to each other. A section plane A-A cutting one of the sub-components 132 is shown in FIG. 5A. FIG. 5B illustrates the sectional view of the cross-section generated by section plane A-A. In the sectional view, the molded sub-component 132 includes the substrate material 134 to which a reinforcing outer layer 136 has been applied by the steps of blocks 112 and 114 of FIGs. 1A-1B.

[0171] According to certain embodiments, the sub-components 132 have at least a first cross-sectional shape and a second cross-sectional shape along its length. The cross-sectional shapes may be irregular- shaped or regular-shaped, e.g., square pyramid, triangular pyramid, other pyramids with a regular or irregular base having five or more sides, conical, bottle, organic, blended shapes, or any three-dimensional shape that changes its cross-sectional shape along a longitudinal axis X. Moreover, the first cross-sectional shape may be the same as or different from the second cross-sectional shape. Each of the first and second cross-sectional shapes has a circumference. A person of ordinary skill in the relevant art will understand that the term circumference means the distance around the perimeter of the cross-sectional shape in this context and does not mean that the cross-sectional shape limited to a circular or rounded shape.

[0172] Each circumference ranges from .5 inches - 8 inches. In some embodiments, the largest circumference is no more than twice the length of the smallest circumference. Limiting the maximum circumference of each sub-component 132 allows for the use of relatively small braiding machines [1-6 feet, 8 carrier -144 carrier] for forming the reinforcing outer layer 136 to reduce component size, capital equipment cost, transportation costs of sub-components 132, and the use and size of specific work cells.

[0173] According to certain embodiments, the sub-components 132 may have a more uniform core circumference. By applying the reinforcing outer layer(s) 136 to the more uniform(and typically thinner) sub-components 132 as compared to the original complex superstructure 130, the processing time of covering the sub-components 132 improves by a factor of 2-10.

[0174] According to certain embodiments, some of the sub-components 132 may have highly variable outer dimensions, being irregular and laterally asymmetric, of the superstructure 130. These sub-components 132 having highly variable outer dimensions may be selected to create molded sub-components 132 with uniform axisymmetric segments. The overall shape of each sub-component 132 is selected in such a way as to achieve the most uniform density of the reinforcing outer layer(s) 136 over the outer surface of the molded subcomponents 132 and, ultimately, over the outer surface of the complex superstructure 130. The sub-components 132 may further include additional features that unify the circumference to produce a circumferential shell with internal features that unify the circumference of the subcomponents 132 along its length.

[0175] At block 106 of FIG. 1 A, steps of creating separate molds 139 for each of the subcomponents 132 are performed, as best illustrated in FIG. 7. In some embodiments, a separate mold 139 for each sub-component 132 is created such that the shape and outer dimensions of the mold 139 interior substantially correspond to the outer dimensions and the final shape for the sub-component 132.

[0176] At block 107 of FIG. 1 A, steps of introducing additional strength or support in the form of additional reinforcing outer layer(s) 136 to the molds of the sub-components 132 may be optionally performed. First, it is determined if additional strength is entailed in a particular area of the sub-component 132 or not. If additional strength is desired, the step of block 107a of placing one or more reinforcing intermediate layers 144 inside the mold 139 before the block 108 of adding the substrate material 134 is performed. In other words, the amount of substrate material 134 added to the mold is reduced by the amount of reinforcing intermediate layers 144 that have been placed inside the mold 139 prior to the addition of the substrate material 134. Ifadditional strength or support is not needed, the step of block 107b is performed (i.e., a reinforcing intermediate layer 144 is not added to the mold 139).

[0177] In some embodiments, as best illustrated in FIG. 7, a reinforcing intermediate layer 144 may be applied strategically in particular load-bearing areas of the sub-components 132 where stress loads require it. In some embodiments, it may be applied to all sub-components 132. The reinforcing intermediate layer 144 may have the same or different fiber density, orientation, and formation as the reinforcing outer layer 136. In some embodiments, the reinforcing intermediate layer 144 may have suitable fiber material & diameters as follows:In additional embodiments, the material for the reinforcing intermediate layer 144 may selectee from natural, textile grade, and high-strength synthetics such as hemp, aramid, high-density polymers, liquid crystal polymers, glass, metallic, and ceramics. In certain embodiments, the reinforcing intermediate layer 144 material may be carbon fiber.

[0178] At block 108 of FIG. 1A, steps for creating sub-components 132, by adding substrate material 134 to the molds 139 of the sub-components 132, are performed. In some embodiments, desired inserts such as metallic threads and bearing surfaces may be integrated into the mold 139 as reinforced section joints, eliminating post-processing of sub-components 132, such as drilling, cutting, and bonding.

[0179] According to certain embodiments, the substrate material 134 used for molding the sub-components 132 may be any type of foam or other material (e.g., reinforced particles, fibrous forms, and the like). In some embodiments, the substrate material 134 may be plastic, cast wax, polymer blends, and / or any other removable or sacrificial materials that provide a suitable three-dimensional object that supports application of the reinforcing layer(s) 136 and / or layer(s) 144. Further, the substrate material 134 bonds to the reinforcing layer(s) 136and / or layer(s) 144, giving a desired final shape and dimensions of the sub-component 132. In some embodiments, a substrate material 134 that is strong, durable, lightweight, flameretardant, cost-effective, and resistant to chemicals compared to metals may be used.

[0180] According to certain embodiments, the substrate material 134 may only be needed as a base structure for shaping the reinforcing outer layers 136 into the desired sub-component 132 shape because the reinforcing outer layer 136 is able to provide all of the required strength. In other embodiments, the substrate 134 may also provide strength to the sub-component 132.

[0181] According to certain embodiments, the substrate 134 material may have physical properties e.g., densities, compressive strength, and hardness, with their values ranging, based on the complex superstructure 130. For example, according to certain embodiments, as best illustrated in FIGs. 2A-7, the complex superstructure 130 may be a firearm stock made from a substrate material 134 having a Density in the range of 1-40 PCF (pounds per cubic foot) and compressive strength and hardness in the 15-4000 psi range. In additional embodiments, as best illustrated in FIGs. 9A-9B, the complex superstructure 130 may be a bicycle frame made from a substrate material 134 having Density in the range of 1-4 PCF (pounds per cubic foot) and compressive strength and hardness in the 1-50 psi range. In further embodiments, the complex superstructure 130 may be an offshore reel made from a substrate material 134 having a Density in the range of 4-20 PCF (pounds per cubic foot) and compressive strength and hardness in the 50-1500 psi range.

[0182] In certain embodiments, the substrate material 134 may be Ethylene-Vinyl Acetate (EVA), polyethylene (PE), polyurethane (PU), expanded polypropylene (EPP), polystyrene, rubber (NBR, EPDM, Normal caoutchouc), thermoplastic elastomer (TPE), polyvinyl (PVC), polyvinylidene chloride (PVDC) microspheres, latex, polyester, polyether, ethafoam, volara, closed-cell sponge rubber, open-cell sponge rubber, cellulose, viscoelastic, lux, rebond, latex,ceramic, syntactic glass bead filled foams, epoxy, polyisocyanurate, carbon, polystyrene, rarified polymer resin, microspheres.

[0183] At block 110 of FIG. 1A, steps for creating a molded sub-component 132 by applying energy to the mold 139 containing the added substrate material 134 and removing the molded sub-component 132 from the mold 139 are performed. Techniques that may be used to apply energy to the mold 139 to form the molded sub-component 132 include but are not limited to Compression Molding, Melt Molding, Injection Molding, Transfer Molding, or any other molding techniques suitable for embodiments of the present disclosure.

[0184] At block 111 of FIG. 1A, steps for inserting temporary spacers 141, if entailed, are performed. At block 111, it is determined whether any receptacles 140 are present in the subcomponent 132. If so, then the step of block Illa is performed by insertion of temporary spacers 141. If not, then the step of block 111b is performed by proceeding to the next step of manufacturing without inserting the temporary spacer 141.

[0185] At block Illa of FIG. 1A, when forming a sub-component 132 with a receptacle 140, the temporary spacer 141 may be positioned in the area where the receptacle 140 is to be located within the sub-component 132 before the application of the reinforcing outer layer 136. The temporary spacer 141 may be shaped to fill the receptacle 140 until it reaches the same height as the surrounding outer surface of the sub-component 132 and may also protrude above the surrounding outer surface of the sub-component 132 to create additional surface area that must be covered by the reinforcing outer layer 136. When the temporary spacer 141 is subsequently removed, excess reinforcing outer layer 136 material is located above the now- empty receptacle 140. This excess reinforcing outer layer 136 material may be tucked inside the receptacle 140 without stretching the reinforcing outer layer 136 - thereby avoiding unnecessarily stretching the reinforcing outer layer 136 at least in the vicinity of the receptacle140 (and therefore also avoiding changing the material properties of the reinforcing outer layer 136).

[0186] At block 112 of FIG. 1A, steps for applying a reinforcing outer layer 136 to the molded substrate 134 are performed. In this step, the molded substrate 134 for each of the subcomponents 132 may be covered with a reinforcing outer layer 136. The reinforcing outer layer 136 may cover the molded substrate 134 for each of the sub-components 132 in such a manner that it covers a portion of the outer surface of the complex superstructure 130. The reinforcing outer layer 136 may be applied to also cover some or all of the internal surfaces of the molded substrate 134 of the sub-components 132. In many embodiments, the reinforcing outer layer 136 may not cover the entire circumference of each cross-sectional shape, e.g., a flat reinforcing outer layer 136 may be adhered to only a portion of the circumference of the sub-components 132, e.g., a longitudinal mating surface 146 or a lateral mating surface 148 of the subcomponent 132 and / or the portion of the sub-component 132 that forms the portion of the outer surface of the complex superstructure 130. In other words, the reinforcing outer layer 136 may or may not cover the entire surface of the molded substrate 134. The reinforcing outer layer 136 material may be any suitable fiber material, capable of being spread over the molded surfaces uniformly to provide strength to the molded sub-components 132 and the complex superstructure 130. The reinforcing outer layer 136 may be a circular sleeve with no longitudinal seam. In some embodiments, the longitudinal seam may be biaxial, triaxial, unidirectional elastic, or it may be a flat reinforcing outer layer 136 that may be directly applied to the selected surfaces of the molded sub-components 132 such that it uniformly spreads across the entire selected surface(s) of the sub-components 132. In embodiments of the present disclosure, the reinforcing outer layer 136 may be a carbon fiber layer, aramid layer, glass fiber layer, or ceramic fiber layer. In certain embodiments, all types of natural, textile grade, andhigh-strength synthetics such as hemp, aramid, high-density polymers, liquid crystal polymers, metallic, and glass may be used to cover the molded substrate 134 of the sub-components 132.

[0187] At block 113 of FIG. IB, the step of removing the temporary spacer(s) 141, if added previously at block Illa, is performed. In the step after removing the temporary spacer 141, if previously added, the extra reinforcing outer layer 136 material that previously covered the temporary spacers 141 may be tucked into a receptacle 140 located inside the molded substrate 134 of the sub-components 132 in a manner that does not stretch the fabric. As a result, the substrate 134 has an evenly-applied reinforcing outer layer 136.

[0188] At block 114 of FIG. IB, steps for applying energy to bond reinforcing outer layer 136 and molded substrate 134 are performed. Any suitable form of energy including but not limited to chemical, thermal, mechanical, electrical, nuclear, ultrasonic, radiant, electromagnetic radiation, microwave, infrared, light, ultraviolet, X-ray, gamma ray may be used for bonding the reinforcing outer layer 136 and the molded substrate 134. In exemplary embodiments, a bonding chemical may be applied to the molded substrate 134 and the fiber to bond the reinforcing intermediate layer 144 to the substrate 134.

[0189] At block 116 of FIG. IB, steps are performed for placing longitudinal mating surface(s) 146 or lateral mating surface(s) 148 of the sub-component 132 adjacent to longitudinal mating surface(s) 146 or lateral mating surface(s) 148 of other at least one other sub-component 132. This step may be achieved by arranging the sub-components 132 such that their joint mating surfaces are in a longitudinal mating configuration (see FIG. 5A, 6B) or a lateral mating configuration see FIG. 5A) depending on how the complex superstructure 130 was subdivided at block 104. In a longitudinal mating configuration, the joint mating surfaces 146 are formed along longitudinal cuts that are applied to the complex superstructure 130. In a lateral mating configuration, the joint mating surfaces 148 are formed along lateral section cutsthat are applied to the complex superstructure 130. In some embodiments, the joint mating surfaces are joined in an interlocking manner, as described in more detail below.

[0190] At block 117 of FIG. IB, steps are performed for placing permanent spacer(s) 143 between the joint mating surfaces 146 (or 148) of the sub-components 132. First, it is determined if a receptacle 140 is present between joint mating surfaces 146 (or 148) of the adjacent sub-components 132 or not. If the receptacle 140 is present, then the step of block 117a is performed to place permanent spacer(s) 143 in the receptacle 140. If the receptacle 140 is not present, the manufacturing process continues to the next step without placing a permanent spacer 143 between the joint mating surfaces 146. In some embodiments, a permanent spacer 143 may be placed in the receptacle 140 to provide some support to a joint made by placing the joint mating surfaces 146 (or 148) of the adjacent sub-components 132 in overlapping positions of the joint. For example, a biscuit or other structure may be used to fill the receptacle 140 to provide some additional or predefined targeted strength to the overlapping joint.

[0191] At block 118 of FIG. IB, steps for applying energy to join mating surfaces 146 (or 148) of the sub-components 132, are performed. Any suitable form of energy including but not limited to chemical, thermal, mechanical, electrical, nuclear, ultrasonic, radiant, electromagnetic radiation, microwave, infrared, light, ultraviolet, X-ray, and gamma rays may be used for bonding the reinforcing outer layer 136 and the molded substrate 134. In exemplary embodiments, a joining chemical e.g., adhesive may be applied to the mating surfaces 146 (or 148) of the sub-components 132.

[0192] According to certain embodiments, as best illustrated in FIG. 3-6B, two adjacent sub-components 132 are joined along the longitudinal mating surfaces 146. In some embodiments, at least a portion of the reinforcing outer layer 136 is positioned over the longitudinal mating surface 146 of each sub-component 132.

[0193] In some embodiments, the longitudinal mating surface 146 has a three-dimensional overlapping design, meaning that at least a portion of each sub-component 132 extends through a plane formed between the two sub-components 132 and into a reciprocally shaped region of the other sub-component 132. In some embodiments, as best illustrated in FIG. 6B, the two sub-components 132 may confront each other in such a way that a projection 142 of a first subcomponent 132 is positioned along a longitudinal mating surface 146 in a location that allows the projection 142 to fit within a corresponding receptacle 140 in the longitudinal mating surface 146 of the second sub-component 132 when the two sub-components 132 are joined along longitudinal mating surfaces 146 of the two sub-components 132.

[0194] Examples of a three-dimensional overlapping joint design include but are not limited to a sinusoidal wave, sawtooth, miter, coped, tongue-and-groove, mortise, half-lap, dado, rabbet, pocket-hole, dowel, biscuit, dovetail, jigsaw, orthogonal mates, and any other suitable overlapping design that provides for additional surface area beyond a two-dimensional mating surface.

[0195] By using a three-dimensional overlapping joint, the joint’s surface area is substantially increased, thereby making the joint stronger. In addition, the three-dimensional overlapping design causes at least some of the reinforcing outer layers 136 to be arranged at an angle to the longitudinal direction of the sub-component 132. This angular disposition of the reinforcing outer layer(s) 136 places the carbon fibers at an angle to a force that is applied along the longitudinal direction of the sub-component 132. The carbon fibers can better prevent a crack from forming and / or propagating along the longitudinal mating surfaces 146.

[0196] By forming the three-dimensional overlapping joint along longitudinal mating surfaces 146, the use of sub-components 132 to form the complex superstructure 130 has none of the drawbacks previously associated with the use of modular designs. Moreover, the process can produce a complex superstructure 130 that is practically unlimited in scale without the needfor investing in a machine that can produce a reinforcing outer layer 136 on the same scale as the end product. By eliminating the weak points typically associated with joints, there is no longer a need to design around comers in window frames and the like. For example, the windows on water vessels have classically been designed with a circular shape to avoid leakage or failure at the corner joints - a well-known failure point with conventional joints. In addition to providing additional strength and crack resistance, the overlapping joint design allows the joint to absorb and disperse a force applied to the superstructure 130 throughout the interfaces and adjacent sections, maximizing and distributing loads among the laminate members.

[0197] According to certain embodiments, as best illustrated in FIGs. 3 and 8A, the two sub-components 132 may have longitudinal mating surfaces 146 that include areas where a receptacle 140 is left open between the two sub-components 132. Such a design may be useful to reduce the weight, provide additional flexibility in certain areas, or otherwise influence the overall strength of the superstructure 130, configure buoyancy, or allow for subsequent subcomponents 132 to be introduced. In some embodiments, a permanent spacer 143 may be placed in these receptacles 140 to provide some support, but of a different strength than if the gap were filled by the sub-component material. For example, a biscuit or other structure may be used to at least partially fill these receptacles 140 and provide some additional / targeted strength to the overlapping joint. The joining elements may be inserted longitudinally or perpendicularly, wedge-like elements that align and sit as sub-components 132 come together, and helical-shaped elements may be rotated and actuated into the desired position.

[0198] According to certain embodiments, two adjacent sub-components 132 are joined along the lateral mating surfaces 148. In some embodiments, the lateral mating surface 148 may be utilized when the superstructure 130 is so large or irregular that the longitudinal axis X must be segmented into multiple sub-components 132 to be joined end-to-end. In these cases, the lateral mating surfaces 148 may be covered with the reinforcing outer layer 136, or it mayonly have the substrate 134 surface and / or one or more reinforcing intermediate layer(s) 144. As described above with respect to the longitudinal mating surfaces 146, the lateral mating surfaces may likewise have a three-dimensional overlapping design, as best illustrated in FIG. 5A.

[0199] According to certain embodiments, the reinforcing outer layer 136 may be applied to one of the sub-components 132 in a manner where the reinforcing outer layer 136 extends beyond the location of the lateral mating surface. In other words, some extra material of the reinforcing outer layer 136 is applied beyond the end of the substrate 134. In these embodiments, the extra material of the reinforcing outer layer 136 may be pulled back over the substrate 134 to expose the lateral mating surface 148 of one of the sub-components 132. The lateral mating surface 148 of the other sub-component 132 is then joined to the exposed lateral mating surface 148, and the reinforcing outer layer 136is pulled over the lateral joint and over at least a portion of the joined sub-components 132. As a result, the joint between the two subcomponents 132 is reinforced by the application of a continuous reinforcing outer layer 136 extending beyond the location of the lateral joint 148.

[0200] At block 119 of FIG. IB, by repeating steps performed from block 111 to block 118 all the sub-components 132 are joined to each other, thus forming the complex superstructure 130.

[0201] At block 120 of FIG. IB, steps for applying an additional coating or finishing to the outermost surface of the complex superstructure 130 formed at block 119 are performed. In certain embodiments, a glossy finish coating is applied to the outermost surface of the formed complex superstructure 130. In other exemplary embodiments, layers of paint or lacquer may be applied to the outermost surface of the formed complex superstructure 130 to provide an aesthetic appearance to the complex superstructure 130.

[0202] According to certain embodiments, as best illustrated in FIGs. 6A-6C, a perspective view of a portion of the complex superstructure 130 having sub-components 132 is shown. The substrate material 134 of the sub-components 132 is covered with the reinforcing outer layer 136. The sub-components 132 are shown in a non-attached configuration relative to each other. A section plane B-B cutting one of the sub-components 132 is shown in FIG. 6A. FIG. 6B illustrates the sectional view of the cross-section generated by section plane B-B. In the sectional view, the molded sub-component 132 includes the substrate material 134 to which a reinforcing outer layer 136 has been applied by the steps of blocks 112 and 114 of FIGs. 1A- 1B.

[0203] According to certain embodiments, as best illustrated in FIGs. 8A-8B, a top view of a portion of a complex superstructure 130 having sub-components 132 is shown. The substrate material 134 of the sub-components 132 is covered with the reinforcing outer layer 136. A section plane C-C cutting one of the sub-components 132 is shown in FIG. 8A. FIG. 8B illustrates the sectional view of the cross-section generated by section plane C-C. In the sectional view, the molded sub-component 132 includes the substrate material 134 to which a reinforcing outer layer 136 has been applied by the steps of blocks 112 and 114 of FIGs. 1A- 1B.

[0204] According to certain embodiments, as best illustrated in FIGs. 9A-9B, a finished complex superstructure 130 having sub-components 132 is shown. The substrate material 134 of the sub-components 132 is covered with the reinforcing outer layer 136 and a finishing coat 138. A section plane D-D cutting one of the sub-components 132 is shown in FIG. 9A. FIG. 9B illustrates the sectional view of the cross-section generated by section plane D-D. In the sectional view, the molded sub-component 132 includes the substrate material 134 to which a reinforcing outer layer 136 has been applied by the steps of blocks 112 and 114 of FIGs. 1A-IB. Further, a finishing coat 138 has been applied over the reinforcing outer layer 136 according to the step of block 120 of FIG. IB.

[0205] According to certain embodiments, as best illustrated in FIGs. 10A-10B, a finished complex superstructure 130 having sub-components 132 is shown. The substrate material 134 of the sub-components 132 is covered with the reinforcing outer layer 136 and a finishing coat 138. A section plane E-E cutting one of the sub-components 132 is shown in FIG. 10A. FIG. 10B illustrates the sectional view of the cross-section generated by section plane E-E. In the sectional view, the molded sub-component 132 includes the substrate material 134 to which a reinforcing outer layer 136 has been applied by the steps of blocks 112 and 114 of FIGs. 1A- 1B. Further, a finishing coat 138 has been applied over the reinforcing outer layer 136 according to the step of block 120 of FIG. IB.

[0206] While the figures described above illustrate a finished complex superstructure 130 as a firearm, a tennis racket, and a bicycle frame, the person of ordinary skill in the relevant art will understand that the above process may be applied to generate any suitable superstructure 130 that may be assembled from sub-components 132 including but not limited to:• construction equipment (excavators, bulldozers, cranes, backhoes, forklifts, concrete mixers, pavers, trailers, etc.),• construction tools and components (window frames, doors, gutters, headers, flooring, wall supports, hammers, crowbars, paint guns, nail guns, etc.),• agricultural equipment (tractors, combine harvesters, plows, seeders, irrigation systems, sprayers, etc.),• nautical equipment (anchors, fishing equipment, traps, etc.),• industrial machinery (CNC machines, lathes, milling machines, industrial robots, conveyor systems, packaging machinery, etc.), medical equipment (MRI machines, X-ray machines, ultrasound machines, surgical instruments, ventilators, defibrillators, etc.),office equipment (desks, chairs, shredders, computer / printer / copier / scanner hardware, telephone / fax machines, etc.),• kitchen equipment (refrigerators, stoves, ovens, dishwashers, microwave ovens, coffee makers, food processors, etc.),• plumbing components (pipes, fittings, handles, valves, etc.),• fitness / recreational equipment (treadmills, weightlifting machines, elliptical trainers, rowing machines, baseball bats, hockey sticks, lacrosse sticks, skis, snowboards, tennis rackets, golf clubs, bicycles, camping equipment, etc.),• laboratory equipment (microscopes, spectrophotometers, centrifuges, incubators, autoclaves, fume hoods, etc.),• electrical and electronic equipment (generators, transformers, circuit breakers, oscilloscopes, multimeters, power supplies, etc.),• musical instruments (guitars, piano, drums, keyboards, violins, etc.),• transportation equipment (cars and trucks, motorcycles, ships, boats, aircraft, trains, rail cars, engine components thereof, transmission components thereof, interior cabin components thereof, seating components thereof, storage components thereof, etc.),• entertainment equipment (televisions, projectors, video game consoles, sound systems, home theaters, cameras, etc.),• mining and quarrying equipment (rock drills, haul trucks, crushers, conveyor belts, etc.),• environmental and renewable energy equipment (solar panels, wind turbines, water treatment plants, air purifiers, recycling machinery, etc.),• wear items (shoes, boots, clothing, etc.),• safety implements (bullet-proof clothing, helmets, shields, safety sticks, etc.).

[0207] In the following, further examples are described to facilitate the understanding of the invention:Example 1 : A method of designing a complex superstructure comprising the steps of: determining a shape and dimensions of the complex superstructure;subdividing the complex superstructure into at least two sub-components, wherein each of the at least two sub-components comprises: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; and an overlapping mating surface joint between the at least two subcomponents.Example 2: The method of any of the preceding or subsequent examples, wherein the step of determining a shape and dimensions of the complex superstructure comprises: determining an approximate location of a longitudinal axis of the complex superstructure, wherein the complex superstructure comprises a range of circumferential lengths measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is greater than a factor of 2.Example 3: The method of any of the preceding or subsequent examples, wherein an overlapping mating surface arrangement between the at least two sub-components comprises having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two subcomponents and into a reciprocally shaped region of an adjacent one of the at least two sub-components.Example 4: The method of any of the preceding or subsequent examples, wherein the step of subdividing the complex superstructure into at least two sub-components comprises positioning the at least two sub-components in a side-to-side arrangement.Example 5: The method of any of the preceding or subsequent examples, wherein the step of subdividing the complex superstructure into at least two sub-components comprises positioning the at least two sub-components in an end-to-end arrangement.Example 6: The method of any of the preceding or subsequent examples, wherein the step of subdividing the complex superstructure into at least two sub-components comprises creating at least one open region between the at least two sub-components.Example 7: The method of any of the preceding or subsequent examples, further comprising adding a permanent spacer into the at least one open region.Example 8: The method of any of the preceding or subsequent examples, wherein the step of subdividing the complex superstructure into at least two sub-components comprises choosing a shape for each sub-component that will allow a reinforcing outer layer of fiber that is applied over at least a portion of a molded substrate that forms a base for each the at least two sub-components to have an approximately uniform fiber density after application.Example 9: The method of any of the preceding or subsequent examples, wherein the step of subdividing the complex superstructure into at least two sub-componentscomprises choosing a material for a molded substrate base or each of the at least two sub-components that will provide required physical properties for the complex superstructure in a location of each of the at least two sub-components.Example 10: The method of any of the preceding or subsequent examples, wherein the material used for the molded substrate base of one of the at least two subcomponents is different from the material used for the molded substrate base of another of the at least two sub-components.Example 11 : A method of forming a complex superstructure, the complex superstructure comprising at least two sub-components, comprising the steps of: molding substrate material using a pre-formed mold to form a base for each of the at least two sub- components; applying a reinforcing outer layer of fiber over at least a portion of each base, wherein the applied reinforcing outer layer has an approximately uniform fiber density7after application; bonding the reinforcing outer layer to each base to form each of the at least two sub-components; placing a mating surface of one of the at least two sub-components adjacent to a mating surface of another of the at least two sub-components in an overlapping mating surface arrangement; and bonding the mating surfaces to each other.Example 12: The method of any of the preceding or subsequent examples, wherein placing a mating surface of one of the at least two sub-components adjacent to amating surface of another of the at least two sub-components in an overlapping mating surface arrangement comprises having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of the adjacent one of the at least two sub-components.Example 13: The method of any of the preceding or subsequent examples, wherein the step of applying a reinforcing outer layer of fiber over at least a portion of each base comprises placing the base through an industrial braiding machine.Example 14: The method of any of the preceding or subsequent examples, wherein the industrial braiding machine has a maximum diameter of 7 feet.Example 15: The method of any of the preceding or subsequent examples, wherein prior to applying a reinforcing outer layer of fiber over at least a portion of each base, the method comprises inserting a temporary spacer into a receptacle formed in at least one of the bases.Example 16: The method of any of the preceding or subsequent examples, wherein the temporary spacer is shaped to protrude above a surrounding outer surface of the base.Example 17: The method of any of the preceding or subsequent examples, wherein prior to bonding the reinforcing outer layer to each base to form each of the at least two sub-components, the method comprises removing the temporary spacer from thereceptacle and tucking the reinforcing outer layer material that previously covered the protruding spacer into the receptacle.Example 18: The method of any of the preceding or subsequent examples, wherein prior to molding substrate material using a pre-formed mold to form a base for each of the at least two sub-components, the method comprises positioning at least one reinforcing intermediate layer on a mold surface in a location where the subcomponent requires additional support.Example 19: The method of any of the preceding or subsequent examples, wherein prior to bonding the mating surfaces to each other, the method comprises inserting a permanent spacer into an open region between the at least two sub-components.Example 20: A complex superstructure comprising: at least two sub-components, wherein each of the at least two sub-components comprises: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; a reinforcing outer layer of fiber bonded to at least a portion of a molded substrate that forms a base for each of the at least two sub-components, wherein the reinforcing outer layer of fiber has an approximately uniform fiber density: and an overlapping mating surface joint between the at least two sub-components.Example 21: The complex superstructure of any of the preceding or subsequent examples, wherein the complex superstructure is a rifle stock.Example 22: The complex superstructure of any of the preceding or subsequent examples, wherein a material for the molded substrate base for each of the at least two sub-components is chosen to provide required physical properties for the complex superstructure in a location of each of the at least two sub-components.Example 23: The complex superstructure of any of the preceding or subsequent examples, wherein the material for the molded substrate base of one of the at least two sub-components is different from the material used for the molded substrate base of another of the at least two sub-components.Example 24: The complex superstructure of any of the preceding or subsequent examples, wherein the overlapping mating surface joint between the at least two subcomponents comprises having at least a portion of each of the at least two subcomponents extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of an adjacent one of the at least two sub-components.Example 25: The complex superstructure of any of the preceding or subsequent examples, wherein the overlapping mating surface joint is formed when the at least two sub-components are arranged side-to-side.Example 26: The complex superstructure of any of the preceding or subsequent examples, wherein the overlapping mating surface joint is formed when the at least two sub-components are arranged end-to-end.Example 27: The complex superstructure of any of the preceding or subsequent examples, wherein at least one open region is located between the at least two subcomponents.Example 28: The complex superstructure of any of the preceding or subsequent examples, wherein a permanent spacer is positioned within the at least one open region.

[0208] Different arrangements of the sub-components depicted in the drawings or described above, as well as sub-components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the disclosure have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present disclosure is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.

Claims

CLAIMSThat which is claimed is:1 . A method of designing a complex superstructure comprising the steps of: determining a shape and dimensions of the complex superstructure; subdividing the complex superstructure into at least two sub-components, wherein each of the at least two sub-components comprises: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; and an overlapping mating surface joint between the at least two sub-components.

2. The method of claim 1, wherein the step of determining a shape and dimensions of the complex superstructure comprises: determining an approximate location of a longitudinal axis of the complex superstructure, wherein the complex superstructure comprises a range of circumferential lengths measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is greater than a factor of 2.

3. The method of claim 1, wherein an overlapping mating surface arrangement between the at least two sub-components comprises having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of an adjacent one of the at least two sub-components.

4. The method of claim 1, wherein the step of subdividing the complex superstructure into at least two sub-components comprises positioning the at least two sub-components in a side-to-side arrangement.

5. The method of claim 1, wherein the step of subdividing the complex superstructure into at least two sub-components comprises positioning the at least two sub-components in an end-to-end arrangement.

6. The method of claim 1, wherein the step of subdividing the complex superstructure into at least two sub-components comprises creating at least one open region between the at least two sub-components.

7. The method of claim 6, further comprising adding a permanent spacer into the at least one open region.

8. The method of claim 1, wherein the step of subdividing the complex superstructure into at least two sub-components comprises choosing a shape for each sub-component that will allow a reinforcing outer layer of fiber that is applied over at least a portion of a molded substrate that forms a base for each the at least two sub-components to have an approximately uniform fiber density after application.

9. The method of claim 1, wherein the step of subdividing the complex superstructure into at least two sub-components comprises choosing a material for a molded substrate base or each of the at least two sub-components that will provide required physical properties for the complex superstructure in a location of each of the at least two sub-components.

10. The method of claim 9, wherein the material used for the molded substrate base of one of the at least two sub-components is different from the material used for the molded substrate base of another of the at least two sub-components.

11. A method of forming a complex superstructure, the complex superstructure comprising at least two sub-components, comprising the steps of: molding substrate material using a pre- formed mold to form a base for each of the at least two sub-components; applying a reinforcing outer layer of fiber over at least a portion of each base, wherein the applied reinforcing outer layer has an approximately uniform fiber density after application; bonding the reinforcing outer layer to each base to form each of the at least two subcomponents; placing a mating surface of one of the at least two sub-components adjacent to a mating surface of another of the at least two sub-components in an overlapping mating surface arrangement; and bonding the mating surfaces to each other.

12. The method of claim 11 , wherein placing a mating surface of one of the at least two sub-components adjacent to a mating surface of another of the at least two sub-components in an overlapping mating surface arrangement comprises having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of the adjacent one of the at least two sub-components.

13. The method of claim 11, wherein the step of applying a reinforcing outer layer of fiber over at least a portion of each base comprises placing the base through an industrial braiding machine.

14. The method of claim 13, wherein the industrial braiding machine has a maximum diameter of 7 feet.

15. The method of claim 11, wherein prior to applying a reinforcing outer layer of fiber over at least a portion of each base, the method comprises inserting a temporary spacer into a receptacle formed in at least one of the bases.

16. The method of claim 15, wherein the temporary spacer is shaped to protrude above a surrounding outer surface of the base.

17. The method of claim 16, wherein prior to bonding the reinforcing outer layer to each base to form each of the at least two sub-components, the method comprises removing the temporary spacer from the receptacle and tucking the reinforcing outer layer material that previously covered the protruding spacer into the receptacle.

18. The method of claim 11, wherein prior to molding substrate material using a preformed mold to form a base for each of the at least two sub-components, the method comprises positioning at least one reinforcing intermediate layer on a mold surface in a location where the sub-component requires additional support.

19. The method of claim 11, wherein prior to bonding the mating surfaces to each other, the method comprises inserting a permanent spacer into an open region between the at least two sub-components.

20. A complex superstructure comprising: at least two sub-components, wherein each of the at least two sub-components comprises: a longitudinal axis; a range of circumferential lengths between 0.5 inches to 8 inches measured along the longitudinal axis, wherein a difference between a largest circumferential length and a smallest circumferential length is no greater than a factor of 2; a reinforcing outer layer of fiber bonded to at least a portion of a molded substrate that forms a base for each of the at least two sub-components, wherein the reinforcing outer layer of fiber has an approximately uniform fiber density; and an overlapping mating surface joint between the at least two sub-components.

21. The complex superstructure of claim 20, wherein the complex superstructure is a rifle stock.

22. The complex superstructure of claim 20, wherein a material for the molded substrate base for each of the at least two sub-components is chosen to provide required physical properties for the complex superstructure in a location of each of the at least two subcomponents.

23. The complex superstructure of claim 22, wherein the material for the molded substrate base of one of the at least two sub-components is different from the material used for the molded substrate base of another of the at least two sub-components.

24. The complex superstructure of claim 20, wherein the overlapping mating surface joint between the at least two sub-components comprises having at least a portion of each of the at least two sub-components extend through a plane formed between the mating surfaces of the at least two sub-components and into a reciprocally shaped region of an adjacent one of the at least two sub-components.

25. The complex superstructure of claim 20, wherein the overlapping mating surface joint is formed when the at least two sub-components are arranged side-to-side.

26. The complex superstructure of claim 20, wherein the overlapping mating surface joint is formed when the at least two sub-components are arranged end-to-end.

27. The complex superstructure of claim 20, wherein at least one open region is located between the at least two sub-components.

28. The complex superstructure of claim 27, wherein a permanent spacer is positioned within the at least one open region.

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