Patent ID: 8790565
Filing Date: 2014-07-29
Classification: B29B,B29C,D04B,D10B,Y10T

Abstract:
1. A method of forming a composite structure having a range of higher to lower load-bearing regions within its three-dimensional geometry, the method comprising the steps of: using a three-dimensional knitting machine to knit fibers into a seamless three-dimensional preform having walls closing around at least one interior space, the preform having a shape commensurate with that of said composite structure, and the preform being knit with a tailored fiber gauge, orientation, density, and interface resulting in said higher to lower load-bearing regions which in turn provide resistance to loads and stresses applied to the composite structure; providing into said interior space a foam material and then expanding the preform shape into said three-dimensional geometry using the foam material; and fixing the three-dimensional geometry by infusing resin binder throughout the expanded preform and then curing or setting the infused resin binder.