# US 10,864,697 B2 · Composite members and methods of manufacturing same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,864,697 B2 - Document ID: US10864697B2 - Status: Granted - Kind: B2 - Application number: 15/756,323 - Filed: 2016-08-24 - Published: 2018-09-06 - Granted: 2020-12-15 - Earliest claimed: 2015-08-28 - Assignees: RTL Materials Ltd. - Applicants: RTL Materials Ltd. - Inventors: Andrew Daton-Lovett - Web page: https://patentgrep.com/patent/US10864697B2 ## CPC - B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)} - B32B 1/08: Tubular products - B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)} - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/024: {Woven fabric} - B32B 5/026: {Knitted fabric} - B32B 5/142: {Variation across the area of the layer} - B32B 27/08: of synthetic resin - B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers} - B32B 27/36: comprising polyesters - B32B 27/38: comprising epoxy resins - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/023: Two or more layers - B32B 2260/046: Synthetic resin - B32B 2262/0269: Aromatic polyamide fibres - B32B 2262/101: Glass fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2307/514: Oriented - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2597/00: Tubular articles, e.g. hoses, pipes - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract The present application relates to composite members and to methods of manufacturing a composite member. In an aspect, a composite member (10) is formed as a longitudinal structure capable of being coiled about an axis transverse to the longitudinal axis of the member. The composite member (10) comprising plural layers (p1-p5) of material bonded together to form a laminate. At least one layer (p3) of material has a boundary (30) partway along the longitudinal extent of the member and extending between the sides of the member. The boundary (30) is angled with respect to the transverse axis (18) of the member. ## Claims ### Claim 1 A composite member formed as a longitudinal structure capable of being coiled about an axis transverse to the longitudinal axis of the member, the composite member comprising plural fibre reinforced layers of material configured and bonded together to form a laminate, wherein the laminate has a different configuration in a first portion of the member from the configuration of the laminate in a second portion of the member, the first and second portions being at different longitudinal positions along the longitudinal extent of the member, such that the member has different mechanical characteristics along its longitudinal axis. ### Claim 2 (depends on 1) A composite member according to claim 1, where one or more layers comprise a fibre reinforced composite. ### Claim 3 (depends on 1) A composite member according to claim 1, wherein the member is constructed and arranged so as to be bistable. ### Claim 4 (depends on 1) A composite member according to claim 1, wherein the layer boundary comprises a zig-zag shape having plural points or a curved shape having at least one maxima and at least one minima. ### Claim 5 (depends on 1) A composite member according to claim 1, wherein the different configuration is provided at least in part by the fibres in a first layer of material in the first portion of the member being more angled with respect to the longitudinal axis of the structure than the fibres in the first layer of material in the second portion of the member, the first and second portions of the first layer being within the same laminar plane and contiguous in a longitudinal direction. ### Claim 6 (depends on 1) A composite member according to claim 1, wherein coiling is initiated at a first end of the member, the different configuration providing additional bending stiffness to the member so as to increase the natural diameter of the coil. ### Claim 7 (depends on 1) A composite member according to claim 1, wherein the member forms a mast or boom. ### Claim 8 (depends on 1) A composite member according to claim 1, wherein the different configuration is provided at least in part by at least one of said layers of material in the laminate extending has a boundary partway along the longitudinal extent of the member and having a boundary extending between the longitudinal sides of the member which separates the first and second portions of the member. ### Claim 9 (depends on 8) A composite member according to claim 8, wherein the boundary is angled with respect to the transverse axis of the member. ### Claim 10 (depends on 9) A composite member according to claim 9, wherein the layer boundary comprises a V-shape or inverted V-shape. ### Claim 11 (depends on 9) A composite member according to claim 9, wherein the layer boundary comprises a U-shape or inverted U-shape. ### Claim 12 (depends on 9) A composite member according to claim 9, wherein the layer boundary comprises a zig-zag shape having plural points or a curved shape having at least one maxima and at least one minima. ### Claim 13 (depends on 8) A composite member according to claim 8, wherein at least one layer having a boundary is provided at a central longitudinal portion of the member and does not extend to at least one end of the member, the at least one layer providing additional bending stiffness to the member at the central portion but not the at least one end portion so as to require less force to initiate coiling of the member at that end. ### Claim 14 (depends on 1) A composite member according to claim 1, the different configuration of the member achieving different local bending stiffnesses of the member, such that the member has plural natural frequencies along its length to aid in damping vibrations that arise in the member. ### Claim 15 (depends on 8) A composite member according to claim 8, comprising plural layers having respective plural boundaries wherein the boundaries are offset along member so as to create gradual increase in stiffness and/or coil diameter along at least a portion of the member. ### Claim 16 (depends on 8) A composite member according to claim 8, wherein the at least one layer is a braided or woven fibre reinforced layer, wherein the fibres local to the boundary are combed out to align the fibre ends increasingly with the longitudinal axis so as to provide strain relief at the boundary when coiling or extending the member. ### Claim 17 (depends on 16) A composite member according to claim 16, wherein a first layer has a boundary partway long the member and a second layer within the same laminar plane as the first layer and has a boundary that matches the boundary of the first member such that the first and second layers are contiguous in a longitudinal direction, wherein both first and second layers are braided or woven fibre reinforced layers having their longitudinal fibres local to their respective boundaries combed out and intermingled with each other to increase the amount of intermeshing of the fibres in the respective first and second layers at the boundary. ### Claim 18 (depends on 1) A method of manufacturing a composite member according to claim 1, the method comprising: stacking the plural layers of material; and bonding the layers of material to form a laminate. ### Claim 19 (depends on 18) A method according to claim 18, wherein the at least one layer is a braided or woven fibre reinforced layer, the method comprising, prior to bonding the layers of material, combing out the fibres local to the boundary so as to reduce the amount of intermeshing of the fibres and to align the fibre ends increasingly with the longitudinal axis so as to provide strain relief at the boundary when coiling or extending the member. ### Claim 20 (depends on 19) A method according to claim 19, wherein stacking the plural layers comprises placing a first layer of material having a boundary partway long the member and placing a second layer of material within the same laminar plane as the first layer and has a boundary that matches the boundary of the first member such that the first and second layers are contiguous in a longitudinal direction, wherein both first and second layers are braided or woven fibre reinforced layers and the method further comprises combing out the fibres of the first and second layers local to their respective boundaries and intermingled the combed out fibres with each other.