# US 7,744,974 B2 · Composite structure and method of manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,744,974 B2 - Document ID: US7744974B2 - Status: Granted - Kind: B2 - Application number: 11/184,722 - Filed: 2005-07-19 - Published: 2007-01-25 - Granted: 2010-06-29 - Earliest claimed: 2005-07-19 - Assignees: Pearson Pilings, LLC - Inventors: Everett A. Pearson; Philip C. Mosher, Jr.; Michael Fyrer; Matthew Dunham - Web page: https://patentgrep.com/patent/US7744974B2 ## CPC - B29C 70/342: {using isostatic pressure} - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - Y10T 428/1372: Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes - Y10T 428/1393: Multilayer [continuous layer] - Y10T 428/24314: Slit or elongated - Y10T 428/24744: Longitudinal or transverse tubular cavity or cell - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A fiberglass laminate used in fabricating a composite pile comprising a plurality of fiberglass type layers and an impervious tube array. A tubular composite pile construction includes the laminate as well as plastic inner and outer skins and a resin injected into the laminate. A method of fabrication includes providing a mandrel, wrapping a plastic inner sleeve about a bladder on the mandrel, wrapping the fiberglass laminate and wrapping a plastic outer skin about the laminate. Lastly, a resin is injected into the laminate to substantially fill between the inner and outer skins. ## Claims ### Claim 1 A tubular composite pile construction comprising: a pre-formed laminate of a plurality of fiberglass layers that are bound together, wherein the pre-formed laminate comprises: first and second layers of a fiberglass material; a plurality of fiberglass strands extending in a spaced unidirectional matrix and disposed between said respective first and second layers, and a plurality of pervious tube members extending between respective first and second layers and uniformly arranged so as to enable injection of a resin therethrough; a plastic inner skin on one side of the laminate and constructed and arranged to form an inner surface of the tubular pile; a plastic outer skin fixed to an opposite side of the laminate and constructed and arranged to form an outer surface of the tubular pile; and a resin injected into said laminate with the skins forming a mold for retaining the resin while also forming the respective inner and outer pile surfaces. ### Claim 2 (depends on 1) The construction of claim 1 wherein the pervious tube members receive the resin and inject the resin between the first and second layers. ### Claim 3 (depends on 1) The construction of claim 1 wherein at least one of the skins is made of PET. ### Claim 4 (depends on 1) The construction of claim 1 wherein the resin is injected with a vacuum. ### Claim 5 (depends on 1) The construction of claim 1 wherein the plastic outer skin is made of polypropylene terephthalate. ### Claim 6 (depends on 1) The construction of claim 1 wherein the tube members comprise spiral slotted members from which the resin can escape therealong. ### Claim 7 (depends on 1) The construction of claim 1 wherein the laminate is subjected to passage through a needle loom to form orthogonal fiberglass filaments for binding the layers together. ### Claim 8 (depends on 1) The construction of claim 1 wherein the laminate is subjected to passage through a sewing head. ### Claim 9 (depends on 1) The construction of claim 1 wherein said first layer comprises a woven roving fiberglass cloth. ### Claim 10 (depends on 9) The construction of claim 9 wherein the fiberglass cloth has a density of from 12 oz. per square yard to 48 oz. per square yard. ### Claim 11 (depends on 9) The construction of claim 9 wherein the woven roving cloth is heavier in the hoop direction, greater than 50% and lighter in the vertical direction, less than 50%. ### Claim 12 (depends on 11) The construction of claim 11 wherein the hoop or annular strands are preferably about 80% in number and the vertical about 20% in number. ### Claim 13 (depends on 1) The construction of claim 1 wherein said second layer comprises at least one of a continuous strand fiberglass mat and distributed random fiberglass filaments. ### Claim 14 (depends on 13) The construction of claim 13 wherein said second layer has a density of from 12 oz. per square yard to 48 oz. per square yard. ### Claim 15 (depends on 1) The construction of claim 1 wherein the fiberglass strands comprise continuous fiberglass rovings with a per bundle yield between 53 yards per pound and 625 yards per pound. ### Claim 16 (depends on 15) The construction of claim 15 wherein the strands are grouped, spread and controlled to yield between 30 oz. per square yard and 250 oz. per square yard of unidirectional reinforcement. ### Claim 17 A composite pile construction comprising: a pre-formed laminate of a plurality of fiberglass layers that are bound together with a resin, wherein the pre-formed laminate comprises first and second layers of a fiberglass material, a plurality of fiberglass strands extending in a spaced unidirectional matrix and disposed between said respective first and second layers, and a plurality of pervious tube members extending between respective first and second layers and uniformly arranged so as to enable injection of the resin therethrough; and a plastic outer skin fixed to one side of the laminate and constructed and arranged to form an outer surface of the tubular pile. ### Claim 18 (depends on 17) The composite pile construction of claim 17 wherein the plastic outer skin is made of polypropylene terephthalate. ### Claim 19 (depends on 17) The composite pile construction of claim 17 wherein said first layer comprises a woven roving fiberglass cloth, wherein said second layer comprises at least one of a continuous strand fiberglass mat and distributed random fiberglass filaments, wherein the pervious tube members comprise spiral slotted members from which the resin can escape therealong, and wherein strands from said first layer are driven through said second layer to bind together the layers of the pre-formed laminate.