Abstract:
Shaped terminations for composite tension members, as well as methods for creating such shaped terminations. A shaped termination is consolidated into a solid mass that is substantially uniform in structure. Heat and pressure are used to shape and fuse the carbon fiber composite into geometries having favorable loading characteristics. This durably fixes the components of the tension member into an optimized arrangement for the intended loading configuration such that unequal stresses are minimized. Terminal geometry can be formed by re-forming existing material, or by adding additional material, which can comprise a thermoplastic composite material or other epoxy/resin composite, metal, tow, tape, mat, or other fibers, to the inside or outside of the tension member. The terminal may be machined and/or thermoformed before and/or after the addition of material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority pursuant to 35 U.S.C. §119(e) and 37 CFR §1.78(a)(4), to provisional Application No. 61/356,992, filed Jun. 21, 2010, the content of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates to shaped terminations for composite tension members, as well as methods for creating such shaped terminations. 
       BACKGROUND OF THE INVENTION 
       [0003]    The leisure marine industry relies upon strong and lightweight tension members for a number of applications, including various types of rigging for sailboats. High-performance sailboats can benefit greatly from the use of tension members that combine high tensile strength, high modulus, resistance to corrosive salt-water environments, light weight, durability, and reduced cross section. However, optimization of these features can involve significant trade-offs, particularly between those affecting light weight and cross section vs. durability. 
         [0004]    Carbon fiber based tension members offer an attractive combination of the qualities listed above; however they suffer from the inefficiencies common to many fiber-based tension members including a vulnerability to unequal loading of the component fibers. In applications where the fiber bundle is loaded such that the majority of the load is applied only to a subset of the component fibers, the overall tensile strength of the member is reduced, and an immediate or gradual cascading failure of the fibers can result. 
         [0005]    In general, where a consolidated grouping of fibers is bent while under tension, the fibers on the outside of the bend will bear an increasing share of the load, while the innermost fibers will slacken. The application of carbon fiber tension members to sailboat rigging can create regions that are particularly susceptible to uneven loading of the component fibers. Rigging generally also ends in a terminal of some type, in addition to applications where rigging is bent continuously around a structure such as a mast. These terminals, if not thoughtfully designed, may incorporate bends, loops, or knots that result in unequal fiber loading. Accordingly, there have been a number of attempts to address this problem. 
         [0006]    A known terminal system for composite tension members is disclosed in U.S. Pat. No. 7,137,617 (Sjostedt). It includes a tension cable comprising a plurality of composite rods bundled together into a composite cable. The ends of this composite cable are splayed out and embedded into a fitting having an internal cavity that flares outwardly, where they are held by adhesives and/or in an interference fit using wedges or plugs adapted to fit the internal cavity of the fitting. However, the anchoring strength of the splayed material is dependent upon the bonding and frictional forces provided by the wedges and/or adhesives. When the included angle of the internal cavity flare is low, the tension member is subject to pulling out if the tensile forces exceed the friction imparted by the wedging forces and/or adhesive. If the included angle of the internal cavity flare is high, excessive stress can be concentrated upon individual components of the splayed material at the angle, increasing the likelihood of successive individual component breakage, and premature failure of the tension member. 
         [0007]    Another system for terminating tension members is disclosed in U.S. Pat. No. 3,660,887 (Davis). It includes a tension cable comprising a plurality of fibers. The ends of this cable are spread within a fitting having an internal cavity, and a potting compound is cast in place within the fitting in order to surround the cable with a closely conforming complimentary surface. However, like U.S. Pat. No. 7,137,617, the spread fibers are subject to pull-through and excessive individual stresses. 
         [0008]    What is desired therefore is a composite tension member having a terminal with characteristics that address these deficiencies. 
       SUMMARY OF THE INVENTION 
       [0009]    It is an object of the invention to provide a shaped terminal to a composite tension member. Ideally, this shaped terminal will be consolidated into a solid mass that is substantially uniform in structure. This arrangement has the advantage of ensuring that the components of the tension member at the terminal are durably fixed into an optimized arrangement for the intended loading configuration, such that unequal stresses are minimized. 
         [0010]    Tension members may comprise a thermoplastic rod or bundle of rods comprising a thermoplastic resin and a high strength and high modulus carbon fiber or other fiber. 
         [0011]    Objects of the invention are achieved by forming a terminal using heat and pressure to shape and fuse the carbon fiber composite into geometries having favorable loading characteristics. The forming of the terminal geometry can be completed by re-forming existing material, or by adding additional material, which can be the same thermoplastic, epoxy or other resin/fiber composite material in the form of tow, tape material, mat or bulk; to the inside, outside, or throughout the tension member. The fill of the epoxy or thermoplastic can be nano-fibers, chopped fibers, unidirectional fibers, or other fibers. The terminal may be machined and/or thermoformed before and/or after the addition of material. 
         [0012]    Terminal geometries can include, but are not limited to: frustum, concave head, convex spherical head, conical taper, eye (e.g. material wrapped around pin and fused back onto itself), threaded (male and female), overlap joint, unidirectional tube overlap joint, laminate, flatten-and-overlap, two-into-one (butt-joint, diagonals onto verticals) and so forth. 
         [0013]    The invention and its particular features and advantages will become more apparent from the following detailed description considered with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is an overview of the tension member showing the shaped terminal. 
           [0015]      FIG. 2  is a section view of a shaped terminal, showing its consolidated structure. 
           [0016]      FIG. 3  is a section view of an unconsolidated portion of a tension member, showing its unconsolidated structure. 
           [0017]      FIG. 4  is a flow chart illustrating a method for creating a consolidated shaped terminal according to a preferred embodiment of the invention. 
           [0018]      FIG. 5  is a section view of a die used in the consolidation of tension members. 
           [0019]      FIG. 6  is a view of the die shown in an arrangement where it may be transported to different regions of a tension member. 
           [0020]      FIG. 7  is a section view of the arrangement of the die as in  FIG. 6 . 
           [0021]      FIG. 8  is a view of a consolidated end of a tension member that may result from the action of the die according to various embodiments of the invention. 
           [0022]      FIG. 9  is a view of a drilled consolidated end of a tension member that has been drilled axially according to various embodiments of the invention. 
           [0023]      FIG. 10  is a section view of a splitting die that may be used to split the drilled consolidated end of a tension member according to various embodiments of the invention. 
           [0024]      FIG. 11  is a view of a split end of a tension member that may result from use of the splitting die of  FIG. 10 . 
           [0025]      FIGS. 12   a - c  are section views illustrating the steps of inserting materials into a void created in the end of a tension member according to various embodiments of the invention. 
           [0026]      FIG. 13  is a view of a consolidated shaped terminal according to embodiments of the invention. 
           [0027]      FIG. 14  is a flow chart illustrating a method for creating a consolidated shaped terminal according to an alternative embodiment of the invention. 
           [0028]      FIGS. 15   a - e  are section views illustrating the creation of a void and insertion of materials into the end of a tension member according to an alternative embodiment of the invention. 
           [0029]      FIGS. 16   a - d  are section views illustrating the insertion of a material part into the end of a tension member according to an alternative embodiment of the invention. 
           [0030]      FIG. 17  is a flow chart illustrating a method for creating a consolidated shaped terminal according to an alternative embodiment of the invention. 
           [0031]      FIG. 18  is a section view of an arrangement of a tension member and a collar piece for surrounding the end of the tension member according to an alternative embodiment of the invention. 
           [0032]      FIGS. 19   a - d  are section views of various bends and joins of tension members according to an alternative embodiment of the invention. 
           [0033]      FIGS. 20   a - c  are section views of the formation of a shaped terminal using two coordinating dies according to an alternative embodiment of the invention. 
           [0034]      FIG. 21  is a section view of an application of a shaped terminal where the terminal is connected to a fitting. 
           [0035]      FIGS. 22   a - h  are section views of example geometries into which shaped terminals may be formed, and corresponding collar shapes which may be used in order to create the geometries. 
           [0036]      FIGS. 23   a - c  illustrate an arrangement for creating a shaped terminal by adding material prior to initial consolidation according to an alternative embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0037]      FIG. 1  illustrates an overview of a tension member  1 , which may be elongated in shape. Tension member  1  comprises a plurality of composite rods, fibers, tow, or tape arranged to form a bundle  2 . Bundle  2  comprises a first end  3  and a second end  4 . The composite rods  2  may comprise a thermoplastic resin and high strength and/or high modulus carbon fibers or other fibers. A shaped terminal  5  is formed at first end  3 . Shaped terminal  5  may be consolidated such that its composition is solid and substantially unified in structure. Shaped terminal  5  comprises an inner end  6  that is disposed toward the center of tension member  1 , and an outer end  7  that is disposed toward, or substantially coincident with, first end  3 . Outer end  7  may have a dimension that is greater than a corresponding dimension of the inner end  6 . 
         [0038]    In all figures and embodiments, second end  4  can be formed into a consolidated shaped terminal (not shown) in the same manner as described for first end  3 . 
         [0039]      FIG. 2  illustrates a cross-section  8  of a shaped terminal, showing its consolidated structure.  FIG. 3  illustrates a cross-section  9  of an unconsolidated portion of a tension member, showing its unconsolidated structure. 
         [0040]      FIG. 4  illustrates a preferred embodiment of the invention describing a method of creating a consolidated shaped terminal to a composite tension member. In a first step  10 , a plurality of composite rods, fibers, tow or tape are first arranged to form a bundle having a first end and a second end. In second step  11 , the first end is consolidated by placing it into a die and applying heat and pressure to the end while it is within the die to create a consolidated end comprising a unified structure. In an alternate embodiment, the first end is consolidated by wrapping it with a heat-shrink tape prior to placement within the die. In another alternate embodiment, an initial pre-consolidation is applied to the first end where it is compressed and reformed using heat and pressure such that an exterior profile of the bundle is given a smaller cross-section and/or a desired shape, and such that at least some interstitial spaces between the resin/fiber composite rods, fibers, tow or tape are removed or reduced; In third step  12 , the first end is drilled axially to create a drilled consolidated end, having an axial drill hole disposed therein. In fourth step  13 , the drilled, consolidated end is split axially to create a split end by indexing the tension member by a desired number of degrees around its axis, inserting the drilled consolidated end into a splitting die, and optionally, repeating the splitting a desired number of times. In a fifth step,  14 , the split end is filled to create a filled end by adding thermoplastic and/or composite material to the void that was created by drilling and splitting. In a sixth step,  15 , the filled end is consolidated by placing the filled end into an appropriately shaped die; and applying heat and pressure to the end while it is within the die to create a shaped terminal that is consolidated and unified in structure, and where the shaped terminal has an outer end disposed at the end of the tension member; an inner end disposed toward the center of the tension member; and where the outer end of the shaped terminal has a dimension that is greater than a corresponding dimension of the inner end of the shaped terminal. 
         [0041]      FIG. 5  illustrates a die  16  to be used in a consolidation step of the preferred embodiment in order to form a consolidated end (not shown). Die  16  is adapted to accept a plurality of composite rods, fibers, tow, or tape that may comprise a thermoplastic resin and high strength and/or high modulus carbon fibers or other fibers and is arranged to form a bundle  17  having a central portion  18 , a first end  19 , and a second end  20 . Die  16  may be used to create consolidated regions  21  in portions of bundle  17  which have a substantially unified structure, including the first end  19 , second end  20 , sub-portions of, or the entirety of, central portion  18 , by applying heat and pressure to the portion as it is held within die  16 . 
         [0042]      FIG. 6  illustrates the arrangement of the die  16  such that it may be transported to different regions of bundle  17  in order to create consolidated regions. In an alternate embodiment, die  16  may be transported along the regions of bundle  17  while applying continuous heat and pressure in order to form a continuous consolidated region of arbitrary length (not shown). In alternate embodiments, die  16  may be held fixed to the center axis of bundle  17 , or may rotate around the centerline axis of bundle  17  during all or part of the consolidation process. 
         [0043]      FIG. 7  illustrates a section view of the arrangement of the die  16  with respect to bundle  17 . 
         [0044]      FIG. 8  illustrates a resulting consolidated end  22  of the bundle  17  which has been consolidated by the action of a die (not shown) as described with respect to  FIGS. 5-7  and  FIG. 4  ( 11 ). 
         [0045]      FIG. 9  illustrates a drilled consolidated end  23  of bundle  17 , showing axial drill hole  24 , such as may result from axial drilling as described with respect to  FIG. 4  ( 12 ). 
         [0046]      FIG. 10  illustrates a splitting die  25  which can be used to split the drilled consolidated end  23  of tension member  17 , as described with respect to  FIG. 4  ( 13 ). Splitting die  25  comprises a channel  26  adapted to accept drilled consolidated end  23 , and blade  27 . A suitable wedge, saw, or other splitting or slicing means known in the art may be used in place of blade  27 . Blade  27  intersects with channel  26  and is adapted and disposed such as to split drilled consolidated end  23 . Bundle  17  is first indexed by a desired number of degrees about its primary axis as shown by arrow  28 . Drilled consolidated end  23  is then inserted into the channel  26  to a desired depth and using a desired force such that drilled consolidated end  23  is split to a desired extent by the blade  27 . The resulting split end (not shown) is then removed from channel  26 , and can optionally be indexed and split one or more subsequent times to create additional discrete splits. 
         [0047]      FIG. 11  illustrates a portion of bundle  17  and split end  29  of previously consolidated end of bundle  17  which has resulted from the action of the splitting die (not shown) as described with respect to  FIG. 10  and  FIG. 4  ( 13 ), showing a void  30  that has been created in split end  29 . 
         [0048]      FIG. 12   a  illustrates a die  31  adapted to accept the split end  29  which is described with respect to  FIG. 11 . First, split end  29  is placed within die  31 . Material  32 , which may be thermoplastic resin and/or composite material, is then inserted into void  30  of split end  29  to create a filled end (not shown). In alternative embodiments, the material  32  can comprise a metal or metal alloy, or other suitable material. 
         [0049]      FIG. 12   b  illustrates a filled end  33  which is created as described with respect to  FIG. 12   a  and  FIG. 4  ( 14 ). Heat and pressure are applied to filled end  33  as it is held within a die to create a consolidated shaped terminal (not shown). 
         [0050]      FIG. 12   c  illustrates a consolidated shaped terminal  34  created as described with respect to  FIG. 12   b  and  FIG. 4  ( 15 ). 
         [0051]      FIG. 13  further illustrates a consolidated shaped terminal  34  created as described with respect to  FIG. 12   b  and  FIG. 4  ( 15 ). Shaped terminal  34  is consolidated such that its composition is solid and substantially unified in structure, and comprises an inner end  35  that is disposed toward the center of bundle  17 , and an outer end  36  that is disposed toward, or substantially coincident with, tension member end  37 . Outer end  36  may have a dimension that is greater than a corresponding dimension of the inner end  35 . 
         [0052]      FIG. 14  illustrates an alternative embodiment of the invention, describing a method of creating a consolidated shaped terminal to a composite tension member. This embodiment is similar to the preferred embodiment described above with respect to  FIG. 4 , except in that the creation of a void in a drilled consolidated end of a tension member is achieved using a spiked plunger step  41  rather than by the splitting step of the preferred embodiment that is described with respect to  FIG. 4  ( 13 ). 
         [0053]    Here, in a first step  38 , a plurality of composite rods, fibers, tow or tape are first arranged to form a bundle having a first end and a second end. In second step  39 , the first end is consolidated by placing it into a die and applying heat and pressure to the end while it is within the die to create a consolidated end comprising a substantially unified structure. In an alternate embodiment, the first end is consolidated by wrapping it with a heat-shrink tape prior to placement within the die. In another alternate embodiment, an initial pre-consolidation is applied to the first end where it is compressed and reformed using heat and pressure such that an exterior profile of the bundle is given a smaller cross-section and/or a desired shape, and such that at least some interstitial spaces between the resin/fiber composite rods, fibers, tow or tape are removed or reduced; In other alternative embodiments, the die may also be transported along the length of the bundle to form continuous consolidated regions of arbitrary length, as in the preferred embodiment. In third step  40 , the consolidated end is drilled axially to create a drilled consolidated end. 
         [0054]    In fourth step  41 , a spiked plunger is inserted into the drilled, consolidated end axially to create a voided end having a void by applying heat and pressure. Here, the drill hole may serve as a pilot hole for insertion of the spiked plunger. 
         [0055]    In a fifth step,  42 , the voided end of the previously consolidated end of the bundle is filled to create a filled end by adding thermoplastic and/or composite material to the void that was created by drilling and plunging. In an alternative embodiment, the material added to the void can comprise a metal or metal alloy, or other suitable material. In a sixth step,  43 , the filled end is consolidated by placing the filled end into an appropriately shaped die; and applying heat and pressure to the end while it is within the die to create a shaped terminal that is consolidated and substantially unified in structure, and where the shaped terminal has an outer end disposed toward, or substantially coincident with, the end of the tension member; an inner end disposed toward the center of the tension member; and where the outer end of the shaped terminal has a dimension that is greater than a corresponding dimension of the inner end of the shaped terminal. 
         [0056]      FIGS. 15   a - e  illustrate the alternative embodiment of the invention, wherein a void is created in a drilled consolidated end of a tension member using a spiked plunger. 
         [0057]      FIG. 15   a  illustrates a drilled consolidated end  44  of a tension member  45  showing drill hole  46 . Drill hole  46  may serve as a pilot hole for the insertion of a spiked plunger  47 . Spiked plunger  47  is aligned axially with drilled consolidated end  44  such that it may be plunged axially into drilled consolidated end  44  in order to create a void (not shown). 
         [0058]      FIG. 15   b  illustrates the end  50  of the tension member  45  which is held within a die  48 . Spiked plunger  47  has been plunged axially into the end  50  of the tension member such that upon removal, a void (not shown) will have been created in the drilled consolidated end (shown in  FIG. 14   a    44 ), creating a voided end (not shown). 
         [0059]      FIG. 15   c  illustrates a voided end  49  of the tension member  45  which is held within die  48 . A plunger has previously been applied to the drilled consolidated end (not shown) as described with respect to  FIG. 14   b  in order to create voided end  49 . Material  51  is shown in preparation for insertion into void  52  of voided end to create a filled end (not shown). In various embodiments, Material  51  comprises one or more of a thermoplastic and/or composite material, a metal or metal alloy, or other suitable material. 
         [0060]      FIG. 15   d  illustrates a filled end  53  of a tension member which is held within die  48 . A material has previously been inserted into a voided end as described with respect to  FIG. 14   c  in order to create filled end  53 . Heat and pressure are applied to filled end while it is held within die in order to create a shaped terminal (not shown). 
         [0061]      FIG. 15   e  illustrates a shaped terminal  54  to a tension member which was created as described with respect to  FIG. 14   d . Shaped terminal  54  is consolidated such that its composition is unified in structure, and comprises an inner end  55  that is disposed toward the center of tension member  45 , and an outer end  56  that is disposed toward, or coincident with, tension member end  57 . Outer end  56  may have a dimension that is greater than a corresponding dimension of the inner end  55 . 
         [0062]      FIGS. 16   a - d  illustrate an alternative embodiment of the invention wherein a preformed material is plunged axially into the tension member. This arrangement, or any portions of this arrangement, may be used in combination with any of the embodiments described herein to replace or compliment steps for adding material to the tension member end. 
         [0063]      FIG. 16   a  illustrates the arrangement of a die  58 , a material  59 , which may have a spiked shape and in various embodiments may comprise one or more of a thermoplastic and/or composite material, a metal or metal alloy, or other suitable material, and a plunging arm  60 , which is adapted to position material  59 .  FIG. 16   b  illustrates the arrangement of the die  58 , material  59 , and plunging arm  60 . A tension member  61  having a tension member end  62 , which has been prepared in advance of this step to create a void using methods such as those described with respect to  FIG. 4  or  14 , or by using other methods known in the art, is disposed within the die  58 , and the material  59  is disposed within the plunging arm  60 , in preparation for insertion of the material  59  into tension member end  62 .  FIG. 16   c  shows the arrangement of the die  58 , material  59 , plunging arm  60 , and tension member  61 , where the tension member  61  has been advanced through the die  58  in order to contact the material  59  axially, in preparation for insertion.  FIG. 16   d  shows the arrangement of the die  58 , material  59 , plunging arm  60 , and tension member  61 , where the die  58  has been advanced over the tension member end  62  to create a press fit between the material  59  and the tension member end  62 . Heat and pressure may be applied at this stage or a subsequent stage to incorporate material into tension member end  62  in order to create a shaped terminal having a consolidated structure (not shown). 
         [0064]      FIG. 17  illustrates an alternative embodiment of the invention which includes adding material to the outside of the tension member end. This embodiment is similar to the preferred embodiment described above with respect to  FIG. 4 , except in that the addition of composite or thermoplastic material to the consolidated end of a tension member is achieved by using an insertion step  65  rather than by using the drilling, splitting, and filling steps of the preferred embodiment that are described with respect to  FIG. 4  ( 12 ,  13 ,  14 ). This arrangement, or any portions of this arrangement, may be used in combination with any of the embodiments described herein to replace or compliment steps for adding material to the tension member end. 
         [0065]    Here, in a first step  63 , a plurality of composite rods, fibers, tow or tape are first arranged to form a bundle having a first end and a second end. In second step  64 , the first end is consolidated by placing it into a die and applying heat and pressure to the end while it is within the die to create a consolidated end comprising a unified structure. In an alternate embodiment, the first end is consolidated by wrapping it with a heat-shrink tape, and applying heat to the end while it is wrapped with the heat-shrink tape. 
         [0066]    In third step  65 , the consolidated end is inserted into a thermoplastic or composite part having the shape of a collar or other shape such that the material surrounds the consolidated end to create a surrounded end. 
         [0067]    In fourth step  66 , the surrounded end is consolidated by placing the surrounded end into an appropriately shaped die; and applying heat and pressure to the end while it is within the die to create a shaped terminal that is consolidated and substantially unified in structure, and where the shaped terminal has an outer end disposed toward, or substantially coincident with, the end of the tension member; an inner end disposed toward the center of the tension member; and where the outer end of the shaped terminal has a dimension that is greater than a corresponding dimension of the inner end of the shaped terminal. 
         [0068]      FIG. 18  illustrates the step of the alternative embodiment of the invention which includes adding material to the outside of the tension member end that is described with respect to  FIG. 16  ( 65 ). Here, a tension member  67 , tension member end  68 , and material sleeve  69 , that is comprised of a thermoplastic or composite material, are shown. 
         [0069]      FIGS. 19   a - f  illustrate further embodiments of the invention wherein the consolidation techniques described herein are applied to other sections of the tension member, or to multiple tension members. 
         [0070]      FIG. 19   a  illustrates a tension member  70  comprising a bundle  71  of thermoplastic or composite rods, fibers, tape, or tow, that has been consolidated in one or more mid-span portions  72  by the application of heat and pressure using a die (not shown) as described with respect to  FIGS. 5-7 . 
         [0071]    Because a bundle of individual, small-diameter thermoplastic rods is more flexible than a comparatively large-diameter solid thermoplastic rod; in some embodiments, one or more mid-span lengths of tension member  1  can be left as individual, separate thermoplastic rods, while other mid-span lengths are consolidated. This has the advantage of providing one or more bending locations to coil the entire assembly for shipping, storage, or other purposes. In alternate embodiments, heat and pressure can be applied to sections of the bundle, using a die or heat-shrink tape as developed above, using a degree of heat and/or pressure that is lower than that used to fuse and consolidate the bundle. The temperature and/or pressure used are selected such that the thermoplastic rod components of the bundle are not fused. Rather, the components are caused to deform to a degree such that the exterior profile of the tension member is given a smaller cross-section and/or a desired shape, and such that some, or all interstitial spaces between the components are removed. This is performed in such a way that the components of the tension member retain their independent movement and remain under equal tension. This can have the combined advantage of providing a section that is flexible for bending as above, but also exhibits desirable drag and windage characteristics. 
         [0072]      FIG. 19   b  illustrates the use of heat and pressure  73  to join consolidated end portions  74  of two separate tension members  75  such that the joint comprises a consolidated and substantially unified structure. 
         [0073]      FIG. 19   c  illustrates the use of heat and pressure  76  to join the consolidated end portion  77  of one tension member to the consolidated mid-span portion  78  of a separate tension member such that the joint  79  comprises a consolidated and substantially unified structure. 
         [0074]      FIG. 19   d  illustrates the use of heat and pressure  80  to bend an unconsolidated mid-span portion of a tension member  84 , having components under equal tension, around a form  82  having a radiused surface  83 . This method creates a radiused mid-span portion  81  comprising a consolidated and substantially unified structure. In alternative embodiments, heat and pressure  80  is applied using methods developed herein incorporating a die (not shown) or using heat-shrink tape (not shown). By forming a radiused mid-span portion  81  in this way, the resulting tension member  84  can be fastened around similarly radiused objects such as mast spreader bends with a reduction or substantial elimination of weakening due to imbalanced loading of the composite structure of the tension member at the site of the radius. This can have the advantage of increasing the tensile strength of a tension member used for such applications. 
         [0075]      FIG. 20   a  illustrates an alternative embodiment of the invention where tension member  85  is placed into a die  86 , such that the region of tension member  85  closest to tension member end  87  is within the die  86 , and a portion of tension member end  87  protrudes from die  86 . In  FIG. 20   b , a second die  88  is applied to tension member end  87  and die  86  from the direction of tension member end  87 , and heat and pressure are applied to the arrangement such that a shaped terminal is formed, having a consolidated and substantially uniform composition. Second die  88  can be rotated axially with respect to tension member end  87  during forming. This can have the advantage of inducing a desired order to the fiber orientation.  FIG. 20   c  illustrates the arrangement after the formation of shaped terminal  89 . Shaped terminal  89  is consolidated such that its composition is unified in structure, and comprises an inner end  90  that is disposed toward the center of tension member  85 , and an outer end  91  that is disposed toward, or coincident with, tension member end  87 . Outer end  91  may have a dimension that is greater than a corresponding dimension of the inner end  90 . 
         [0076]      FIG. 21  illustrates an application of a shaped terminal  92  that has been formed according to the invention where the tension member  93  is connected to a fitting  94  or other attachment. The connection between tension member  93  and fitting  94  is effected by the geometries of the exterior surface  95  of the shaped terminal  92  and the interior surface  96  of the fitting  94  or other attachment. These geometries can be arbitrarily optimized to locate the distribution of forces to desired portions of shaped terminal  92  and/or fitting  94 . In the example arrangement of  FIG. 21 , tension member  93  is held fast within fitting  94  when they are in tension. Because of the solid and uniform structure of the terminal, the tension member is advantageously able to resist pull-through and individual stresses upon the component fibers at the fitting. In an alternative arrangement, tension member  93  could be adapted to be held within fitting  94  in the absence of tension by the addition of a stopper (not shown). Alternatively, the geometries of exterior surface  95  and interior surface  96  could be formed with complementary threaded, notched, grooved, frictional, or other similarly functioning surface features (not shown). 
         [0077]      FIGS. 22   a - h  illustrate various example geometries into which consolidated shaped terminals may be formed using the methods described above, and corresponding collar shapes which may be used in order to create these geometries according to alternative embodiments of the invention as described above. These shaped terminal geometries ( FIGS. 22   e - h ), which comprise various heads and threaded ends, may be applied as a pre-formed collar pieces ( FIGS. 22   a - d ) using the methods described and shown with respect to  FIGS. 17 and 18 , may be formed by conforming the exterior surface of the shaped terminal to a suitably shaped interior surface (not shown) of a die (not shown) using the methods described and shown with respect to  FIG. 4 , or a combination of any or all of the methods described herein. 
         [0078]      FIGS. 23   a - c  illustrates an alternative embodiment of the invention which includes adding material to the tension member end prior to consolidation. This embodiment is similar to the preferred embodiment described above with respect to  FIG. 4 , except in that the addition of composite or thermoplastic material to the end of a tension member is achieved during the initial consolidation rather than by using the drilling, splitting, and filling steps of the preferred embodiment that are described with respect to  FIG. 4  ( 12 ,  13 ,  14 ). This arrangement, or any portions of this arrangement, may be used in combination with any of the embodiments described herein to replace or compliment steps for adding material to the tension member end. 
         [0079]      FIG. 23   a  illustrates an arrangement where a plurality of composite rods, fibers, tow or tape are first arranged to form a bundle  97  having a first end  98  and a second end  99 . First end  98  is placed within a die  100 , and the component materials forming the bundle  97  within the die  100  are arranged in a suitable pattern such as a distributed, conical, or other pattern, such that interstitial spaces exist within the first end  98 . The materials may be arranged by feeding them through a disk with a suitable arrangement of holes, a loom, or another suitable method (not shown). Bundle  97  is then tensioned such that its individual components are under equal tension. The tensioning may be achieved through the application of weights to the individual components, or by another suitable method (not shown). A channel  102  is disposed within die  100  such that materials (not shown), which may comprise composites, thermoplastic resins, or other materials, may be added to the interstitial spaces within first end  98 . 
         [0080]      FIG. 23   b , illustrates the arrangement where materials have been added to the interstitial spaces within the first end  98  via channel  102 . First end  98  is consolidated by applying heat and pressure to while it is within the die  100  to create a consolidated end comprising a unified structure. Surplus end materials  103  which protrude from the die may subsequently be sliced or removed in a suitable manner from the first end  98  in order to form a shaped terminal (not shown) that is consolidated and substantially uniform in structure. 
         [0081]      FIG. 23   c  illustrates the resulting consolidated shaped terminal  104  formed as described regarding  FIGS. 23   a - b . Shaped terminal  104  is consolidated and substantially uniform in structure, and has an outer end  105  disposed toward, or substantially coincident with, the end of the tension member; an inner end  106  disposed toward the center of the tension member; and where the outer end  105  of the shaped terminal  104  has a dimension that is greater than a corresponding dimension of the inner end  106  of the shaped terminal  104 .