CARBON FIBER WRAPPED STRUCTURAL COMPONENTS FOR A MACHINE

A component for a machine is disclosed. The component may include an interior frame, a protruding member extending from the interior frame, and a carbon fiber wrapped over the interior frame and around the protruding member. A method of manufacturing a component for a machine is also disclosed. The method may include supplying an interior frame with a protruding member extending from the interior frame. The method may further include wrapping a carbon fiber around the interior frame and the protruding member, and curing the carbon fiber to the interior frame.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to machines and, more particularly, relates to structural components for machines and methods for manufacturing same.

BACKGROUND OF THE DISCLOSURE

Machines, such as excavators, tractors, dozers, loaders, mining trucks, and the like, include many structural components that are made entirely out of steel. Although strong and durable, steel components may add to an overall weight of a machine. Accordingly, there exists a need to reduce a weight of the structural components of the machine.

Recently, three-dimensional (3D) additive manufacturing methods have been explored for fabrication of structural components for machines. In 3D additive manufacturing, a 3D printer uses a metallic powder deposited in successive layers to build a structural component. However, the metallic powder is significantly more expensive than plated steel. Furthermore, to 3D print the structural component, a considerably larger quantity of the expensive metallic powder is required than an amount of powder that is actually incorporated into the finished part.

A body structure is disclosed in Japanese Patent No. JP2012131309A, entitled, “Vehicle Body Structure.” The body structure of JP2012131309A is composed of a pipe that is a substantially straight cylinder with a circular cross-section. The pipe of JP2012131309A is completely formed using a filament winding method.

While effective, there is still a need for structural components having reduced weight, high tensile strength and impact resistance, as well as the ability to attach to other components of the machine after fabrication.

SUMMARY OF THE DISCLOSURE

In accordance with one embodiment, a structural component for a machine is disclosed. The component may include an interior frame, a protruding member extending from the interior frame, and a carbon fiber wrapped over the interior frame and around the protruding member.

In accordance with another embodiment, a method of manufacturing a component for a machine is disclosed. The method may include supplying an interior frame with a protruding member extending from the interior frame. The method may further include wrapping a carbon fiber around the interior frame and the protruding member, and curing the carbon fiber to the interior frame.

In accordance with another embodiment, a machine is disclosed. The machine may include a machine frame, a ground engaging member supporting the machine frame, a prime mover supported by the machine frame, and at least one structural component forming part of the machine, the structural component including an interior frame having a tubular wall composed of steel, a protruding member extending from the interior frame and configured for attachment to another component of the machine, and a carbon fiber wrapped around the interior frame and the protruding member.

These and other aspects and features will become more readily apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings. In addition, although various features are disclosed in relation to specific exemplary embodiments, it is understood that the various features may be combined with each other, or used alone, with any of the various exemplary embodiments without departing from the scope of the disclosure.

While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof will be shown and described below in detail. The disclosure is not limited to the specific embodiments disclosed, but instead includes all modifications, alternative constructions, and equivalents thereof.

DETAILED DESCRIPTION

Referring now to the drawings, and with specific reference toFIG. 1, a machine20is shown in accordance with certain embodiments of the present disclosure. It is to be understood that although the machine20is illustrated as an excavator, the machine20may be of any other type. As used herein, the term “machine” refers to a mobile machine that performs a driven operation involving physical movement associated with a particular industry, such as, earthmoving, construction, landscaping, mining, forestry, agriculture, transportation, etc.

Non-limiting examples of machines include commercial and industrial machines, such as earth-moving vehicles, excavators, tractors, dozers, loaders, motor graders, backhoes, mining vehicles, on-highway vehicles, trains, agricultural equipment, material handling equipment, and other types of machines that operate in a work environment. It is to be understood that the machine20is shown primarily for illustrative purposes to assist in disclosing features of various embodiments, and thatFIG. 1does not depict all of the components of a machine.

The machine20may include a set of ground engaging members22that support a machine frame24. Although the ground engaging members22are shown as tracks, the members22may be wheels or of any other type. The machine frame24may support an operator cab26, linkages, such as a boom28and a stick30, and a work implement or tool32. An engine34or other power source may be operatively configured to drive the ground engaging members22, the boom28, the stick30, and/or the work tool32.

Referring now toFIGS. 2 and 3, with continued reference toFIG. 1, a structural component40of the machine20is shown, in accordance with an embodiment of the present disclosure. At least one component40may be used to comprise the frame24, the operator cab26, the boom28, the stick30, other linkages, lift arms, levers, the work tool32, brackets, a hydraulic tank, or any other component of the machine20. The component40may include an interior frame42, a protruding member44extending from the interior frame42, and a carbon fiber46wrapped around the interior frame42and the protruding member44.

Extending from a first end48to a second end50, the interior frame42may include a tubular structure52. For example, the tubular structure52may comprise a tube including a substantially thin wall, although other configurations for the interior frame42may be used. A cross-section of the tubular structure52may be circular, oval, triangular, square, rectangular, hexagonal, octagonal, polygonal, or any other shape.

In one example, the first end48and the second end50of the interior frame42may be configured for attachment to other components of the machine20. Each of the first end48and the second end50may be attached to the other components of the machine20, such as via bolting, welding, and the like. For instance, the first end48and the second end50may be used in pivot joints or other types of joints. In this example, each of the first end48and the second end50may include bores54for receiving bolts or other means of attachment. However, other attachment features than bores54may be used. Furthermore, the interior frame42may not include attachment features on the first end48and/or the second end50.

The interior frame42may be composed of steel. However, aluminum, titanium, other metallic materials, and non-metallic materials may also be used for the interior frame42. For example, the wall of the interior frame42may have a thickness between an inclusive range of approximately three millimeters to six millimeters, although other thicknesses may be used. Compared to prior art steel components having a thickness of ten millimeters to fifteen millimeters, the thickness of the wall of the interior frame42in accordance with the present invention may be reduced to about one third of that of the prior art. In so doing, a weight of the component40and a weight of the machine20may be significantly reduced as well.

Protruding outward from the interior frame42, the protruding member44may be configured for attachment to other components of the machine20. For instance, the protruding member44may comprise a boss, a bushing, or any other type of feature for attachment to another component of the machine20. In one example, the protruding member44may extend radially outward from the tubular structure52. Although shown, inFIGS. 2-3, as positioned proximate a middle56of the interior frame42, the protruding member44may be positioned anywhere along the interior frame42. Furthermore, in other embodiments, the component40may not include a protruding member44.

The protruding member44may be composed of steel, aluminum, titanium, other metallic materials, and non-metallic materials. For example, the protruding member44may be composed of a same material as the interior frame42, although the protruding member44may also be composed of a different material than the interior frame42. Furthermore, the protruding member44may be formed as part of the interior frame42at a same time the interior frame42is being formed, such as during casting or any other fabrication method. In another example, the protruding member44may be attached to the interior frame42, such as via welding, brazing, soldering, and the like, after each of the protruding member44and the interior frame42has been formed separately.

As shown inFIG. 3, the carbon fiber46may be wrapped over the interior frame42and around the protruding member44such that the first end48, the second end50, and an end58of the protruding member44are uncovered or exposed for attachment to other components of the machine20. The carbon fiber46may add reinforcement, tensile strength, and stiffness to the interior frame42without adding substantial weight to the component40. Moreover, the carbon fiber46may consist of fibers composed mostly of carbon atoms and bundled together to form a single, continuous filament or a tow60of carbon fiber46, as shown inFIG. 4. For example, a diameter of the single filament of carbon fiber46may be ten microns to twenty microns. However, other diameters for the single filament of carbon fiber46may be used. Furthermore, other types of fiber besides carbon fiber may be used in addition to or instead of carbon fiber46.

A carbon fiber wrapping machine62, as shown inFIG. 5, may be used to wrap the carbon fiber46around the interior frame42and the protruding member44. In one example, the wrapping machine62may wind the single filament of carbon fiber46around the interior frame42and the protruding member44without covering the ends48,50,58. By leaving the ends48,50,58exposed, the component40may be attached to another component after being wrapped in carbon fiber. However, the component40may also be attached to the other component(s) first and the entire configuration may be subsequently wrapped, as well. An overall thickness of the carbon fiber46may depend on the type of component40being manufactured.

In another example, the wrapping machine62may wind multiple filaments of carbon fiber46at a same time around the interior frame42and the protruding member44. For instance, the wrapping machine62may be configured to interlace the multiple filaments of carbon fiber46, such as via weaving, braiding, or other processes, as the interior frame42and the protruding member44are being wrapped. More specifically, the wrapping machine62may interlace the multiple filaments of carbon fiber together as the wrapping machine62winds the carbon fiber46around the interior frame42and the protruding member44.

In yet another example, the carbon fiber46may be provided in a pre-woven arrangement, such as a sleeve64, shown inFIG. 6. The sleeve64may comprise filaments of the carbon fiber46interlaced together, such as via weaving, braiding, or other processes, to form a layer of carbon fiber46. The sleeve64of carbon fiber46may be applied around the interior frame42and the protruding member44as one cohesive layer. A thickness of the sleeve64may depend on the type of component40being manufactured.

In order for the interior frame42to fit within the sleeve64, the sleeve64may have to accommodate for the ends48,50and the protruding member44, which may be larger than a diameter of the tubular structure52. For example, the sleeve64may be compressed in an axial direction such that a diameter of the sleeve64increases. The sleeve64may then be placed over the interior frame42and the protruding member44. Once positioned over the interior frame42, the sleeve64may be stretched out such that the diameter of the sleeve64decreases and the sleeve64is fit tightly around the interior frame42. In addition, the sleeve64may have features, such as an opening66, to accommodate the exposure of the end58of the protruding member44. However, other configurations for the sleeve64and other configurations for wrapping of the carbon fiber46may be used.

Furthermore, the carbon fiber46may be fused to the interior frame42, such as via a curing process. A hardener and resin, such as in an epoxy, may be applied to the carbon fiber46. Examples of resins may include, but not be limited to, vinyl ester and urethane. The resin may be applied to the carbon fiber46as it is being wrapped around the interior frame42. For example, the resin may be applied to the filament(s) of carbon fiber46as it is being wound around the interior frame42.

In another example, the resin may be applied after one layer of carbon fiber46has been wrapped around the interior frame42and onto each subsequent layer thereafter. There may also be an application of the resin only after all of the carbon fiber46has been wrapped around the interior frame42. Heat, radiation, ultraviolet radiation, and the like may be used to cure the carbon fiber46to the interior frame42after application of the resin to the carbon fiber46. However, other curing processes may be used.

Referring now toFIG. 7, with continued reference toFIGS. 1-6, the component40may further include a protective layer68around the carbon fiber46. The protective layer68may provide increased protection and impact resistance to the component40. Encasing the carbon fiber46and the interior frame42, the protective layer68may be composed of nylon, steel, or other suitable materials. The protective layer68may have a thickness between an inclusive range of approximately one millimeters to two millimeters, although other thicknesses may be used. In one example, the protective layer68may be three-dimensionally printed over the carbon fiber46using a three-dimensional printer and powdered material.

In another example, the protective layer68may comprise a sheathing70, as shown inFIG. 8, that is placed over the carbon fiber46. The sheathing70may include an opening72to accommodate the exposure of the end58of the protruding member44. For instance, the sheathing70may be provided in a pipe or tube form, although other preformed shapes may be used. To cover the carbon fiber46, the sheathing70may be split into longitudinal halves, placed around the carbon fiber46, and re-attached. However, other configurations for covering the carbon fiber46with the sheathing70or protective layer68may be used.

In addition, the sheathing70may be attached to the interior frame42, such as via bolting, welding, or other suitable processes. For instance, the sheathing70may be attached to the ends48,50of the interior frame42. In one example, the interior frame42may include attachment bosses, and the sheathing70may comprise bolt-on steel cladding that encases the carbon fiber46and is attached to the interior frame42using the attachment bosses. Furthermore, the component40may include more than one protective layer68. For example, as shown inFIG. 9, a nylon protective layer74may encase the carbon fiber46, and a bolt-on steel cladding76may encase the nylon protective layer74. However, other configurations for the protective layers may be used.

INDUSTRIAL APPLICABILITY

By applying the disclosed component to a machine, a weight of the components of the machine, and thereby a weight of the machine, may be significantly reduced. The disclosed component provides a lightweight configuration that has a same durability, tensile strength, and ability to attach to other components as a prior art component made entirely out of steel. Furthermore, the disclosed component facilitates an easy method of replacement. More specifically, the disclosed component includes attachment points, such as the ends and the protruding feature, which may be bolted to other machine components. Therefore, if the disclosed component needs to be replaced, it simply has to be unbolted and a new component of the disclosed configuration can be bolted on in its place.

Turning now toFIG. 10, with continued reference toFIGS. 1-9, a flowchart illustrating an example process80for manufacturing a structural component for a machine is shown, in accordance with another embodiment. At block82, an interior frame with a protruding member extending from the interior frame may be supplied. The protruding member may be configured for example, for attachment to another component of the machine. A carbon fiber may be wrapped around the interior frame and the protruding member, at block84. A hardener and a resin, such as in an epoxy, may be optionally applied to the carbon fiber as it is being wrapped or after it is wrapped around the interior frame and the protruding member as shown at block85. At block86, the carbon fiber may be cured to the interior frame. After the carbon fiber is fused to the interior frame, a protective layer for increased protection and impact resistance may be optionally added to the carbon fiber as shown at block88.

It is to be understood that the flowchart inFIG. 10is shown and described as an example only to assist in disclosing the features of the disclosed system, and that more or less steps than that shown may be included in the processes corresponding to the various features described above for the disclosed system without departing from the scope of the disclosure.

While the foregoing detailed description has been given and provided with respect to certain specific embodiments, it is to be understood that the scope of the disclosure should not be limited to such embodiments, but that the same are provided simply for enablement and best mode purposes. The breadth and spirit of the present disclosure is broader than the embodiments specifically disclosed and encompassed within the claims appended hereto. Moreover, while some features are described in conjunction with certain specific embodiments, these features are not limited to use with only the embodiment with which they are described, but instead may be used together with or separate from, other features disclosed in conjunction with alternate embodiments.