Sailboat Rigging Monolithic Composite Member
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Solution Overview
Problem
Existing sailboat rigging systems using pultruded composite rods have interstitial spaces that contribute to a larger cross-sectional area and weight, which can be reduced by consolidating fiber bundles and resin matrices into a single monolithic tension member.
Innovation Solution
The use of prepreg roving or tow, with uncured and unconsolidated resin, is employed to create a continuous and discontinuous rigging system where fibers are optimized for strength and weight savings by equalizing tension and consolidating them into a single, monolithic composite member with an over-wrapping material to prevent peeling and enhance strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pultruded composite rods are used to construct rigging members, then the rigging can be manufactured with discrete rods that are easy to assemble, but interstitial spaces between the rods increase the cross-sectional area and weight
Solution Approach 1:
The patent merges multiple discrete pultruded rods into a single consolidated monolithic member by infiltrating molten metal into the interstitial spaces between the rods, creating a unified structure that eliminates gaps and reduces overall cross-sectional area and weight
Solution Approach 2:
The patent creates a composite structure by combining the pultruded rods with an infiltrated metal matrix, forming a hybrid material system that integrates multiple materials to achieve superior mechanical properties and reduced weight
2Stability of the object's composition
If pultruded composite rods are used to construct rigging members, then the rods can be produced with consistent properties, but the interstitial spaces between rods increase the overall cross-sectional area
Solution Approach 1:
The patent consolidates multiple discrete rods into a single monolithic member by infiltrating molten metal into the spaces between rods, eliminating interstitial gaps and reducing the overall cross-sectional area while maintaining structural integrity
Solution Approach 2:
The patent utilizes the porous structure created by the discrete rod arrangement as a mold for metal infiltration, where the interstitial spaces are intentionally filled with molten metal to create a dense consolidated structure
3Weight of stationary object
If fiber bundles are consolidated into a single monolithic tension member, then the cross-sectional area and weight are reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary actions by first arranging the pultruded rods in the desired configuration and then infiltrating molten metal into the interstitial spaces before final consolidation, simplifying the overall manufacturing process by breaking it into sequential steps
Solution Approach 2:
The patent changes the physical state of the infiltrant from liquid (molten metal) to solid through cooling and solidification, enabling the consolidation of fiber bundles into a monolithic structure with controlled mechanical properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a reduced cross-sectional area and weight, optimizing the sailboat rigging system while maintaining strength, and can be applied to other applications requiring a smaller profile and reduced weight.
Implementation Method 1
The rod bundles are infiltrated with molten metal to consolidate the rod bundles into a monolithic composite member
Implementation Method 2
consolidating the fiber bundles and the resin matrix that holds the fibers together (and protects the fibers from the elements)
Data Source
AI summary
The invention is a sailboat rigging system and method for forming same. It is formed from a plurality of resin prepreg high strength fiber strands, tows or roving. The fiber are laid out in a preferred rigging configuration with the fiber strands, tows or roving being placed under generally equal tension. The resin in the prepreg fibers bonds the fiber strands, tows or roving to consolidate them together substantially without open spaces therebetween. If desired, the fiber strands, tows or roving can be branched out at branching points to provide for continuous rigging, and selective fibers can be dropped at various sections of the rigging for weight savings.