U.S. patent number 3,637,446 [Application Number 04/822,769] was granted by the patent office on 1972-01-25 for manufacture of radial-filament spheres.
This patent grant is currently assigned to Uniroyal, Inc.. Invention is credited to Daniel R. Elliott, Edgar Francois, Donald C. MacDonald.
United States Patent |
3,637,446 |
Elliott , et al. |
January 25, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
MANUFACTURE OF RADIAL-FILAMENT SPHERES
Abstract
Making a shell-type body of spherical curvature by various
methods which include the butt edge bonding in a spherical
configuration of segments of resin/reinforced by short length
high-modulus filaments extending substantially normal to the inner
and outer surfaces of the segments and preferably through the
entire segment thickness whereby the filaments are disposed
generally radially with respect to the curvature of the body.
Complete spheres of this construction are particularly suited for
deep submergence work under high-external hydrostatic pressures,
being characterized by a low weight to displacement ratio and a
high-compressive strength to weight ratio. The full nature and
extent of the invention is discernable only by reference to the
entire disclosure.
Inventors: |
Elliott; Daniel R. (Ridgewood,
NJ), Francois; Edgar (Wayne, NJ), MacDonald; Donald
C. (Ridgewood, NJ) |
Assignee: |
Uniroyal, Inc. (New York,
NY)
|
Family
ID: |
27060900 |
Appl.
No.: |
04/822,769 |
Filed: |
February 3, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
522675 |
Jan 24, 1966 |
3490638 |
Jan 20, 1970 |
|
|
Current U.S.
Class: |
156/69; 156/211;
156/257; 156/268; 156/297; 428/11; 156/170; 156/182; 156/217;
156/264; 156/292; 156/304.2; 428/902 |
Current CPC
Class: |
B63B
3/13 (20130101); Y10T 156/1026 (20150115); Y10T
156/1082 (20150115); Y10T 156/1075 (20150115); Y10S
428/902 (20130101); Y10T 156/1064 (20150115); Y10T
156/1089 (20150115); Y10T 156/1036 (20150115) |
Current International
Class: |
B63B
3/00 (20060101); B63B 3/13 (20060101); B29c
027/10 (); B29d 025/00 () |
Field of
Search: |
;156/211,217,292,297,69,182,257,264,304,268 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Quarforth; Carl D.
Assistant Examiner: Miller; E. A.
Parent Case Text
This application is a division of application Ser. No. 522,675,
filed Jan. 24, 1966, now U.S. Pat. No. 3,490,638, issued Jan. 20,
1970.
Claims
Having thus described our invention, what we claim and desire to
protect by Letters Patent is:
1. The method of constructing a radial-filament, spherically
curved, hollow shell-type body, comprising the steps of preparing a
plurality of sheet-like members of a unidirectional
fiber-reinforced resin in each of which members all the individual
fiber lengths are oriented substantially normal to the broad faces
of that member, building said body by assembling a plurality of
said members in laterally adjacent relation and in a spherically
curved configuration so as to dispose said fiber lengths
substantially radially of said body, filling all cracks and spaces
between said assembled members with a material comprising a
thermosetting resin to complete said body, and treating said body
to cure any still uncured resin part thereof.
2. The method of constructing a radial-filament, spherically
curved, hollow shell-type body, comprising the steps of preparing a
plurality of flat sheetlike members of a cured, unidirectional
fiber-reinforced resin in each of which members all the individual
fiber lengths are oriented substantially normal to the broad faces
of that member, building said body by assembling a plurality of
said members in laterally adjacent relation and in a spherically
curved configuration so as to dispose said fiber lengths
substantially radially of said body, filling all cracks and spaces
between said assembled members with a material comprising a
thermosetting resin to complete said body, and curing the resin
filling.
3. The method of constructing a hollow radial-filament sphere,
comprising the steps preparing a plurality of flat, wedgelike
strips of precured, high-modulus, unidirectional fiber-reinforced
thermosetting resin wherein all the individual fiber lengths are
oriented substantially normal to the broad faces of said strips,
applying a double-faced pressure-sensitive adhesive tape to one
face of each strip, cutting a grid of mutually perpendicular
longitudinal and transverse incisions into and through each strip
to said tape from the other face of said strip so that the severed
bits remain attached to said tape, assembling said severed strips
on a spherically curved mandrel so that the wide end of each strip
overlies the equatorial line of the mandrel and that the narrow
ends of said strips meet at the pole of the mandrel, thereby
defining a hemisphere having all the fibers oriented substantially
radially, said adhesive tapes serving to retain said strips in
position on said mandrel, and said incisions enabling said strips
to curve in conformity with the curvature of the mandrel surface,
impregnating said assembly of strips with a thermosetting resin to
fill all incisions and cracks between adjoining bits, curing the
resin filling, preparing a second identical hemisphere and bonding
the two hemispheres to each other at their open equatorial edges to
complete the sphere.
4. The method of constructing a hollow radial-filament sphere,
comprising the steps of preparing a plurality of flat small slabs
of a precured, unidirectional high-modulus fiber-reinforced
thermosetting resin, all the individual fiber lengths in each slab
being oriented substantially normal to the opposite plane faces
thereof, assembling a plurality of said slabs into a plane
structure and clamping said slabs to each other, the number of such
slabs exceeding somewhat the number required for a one-third
quadrant segment of a hemisphere, cementing a sheet of flexible
material to one face of said assembly, cutting through said slabs
from their free faces down to but not through said flexible sheet,
thereby providing a multiplicity of small bits adhered to said
sheet but not to each other, fitting said assembly onto a
spherically curved surface with said flexible sheet engaging the
latter, filling the gaps between adjacent bits with a thermosetting
resin and curing the latter, trimming the spherically curved
assembly to the size of a one-third quadrant segment of a
hemisphere, preparing a plurality of additional identical one-third
quadrant segments sufficient in number to make up a hemisphere,
assembling said segments by threes on a spherically curved mandrel
and cementing each set of three segments to each other at their
abutting edge faces to form a respective quadrant, assembling said
quadrants by fours on said mandrel so that the wide end of each
quadrant overlies the equatorial line of the mandrel and that the
narrow ends of said quadrants meet at the pole of the mandrel,
thereby defining a hemisphere having all the fibers oriented
substantially radially, said flexible sheet engaging said mandrel,
impregnating said assembly of quadrants with a thermosetting resin
to fill all cracks between segments and quadrants, curing the resin
filling, preparing a second identical hemisphere, and bonding the
two hemispheres to each other at their open equatorial edges to
complete the sphere.
5. The method of constructing a hollow radial-filament sphere,
comprising the steps of preparing a plurality of flat small blocks
of a precured, unidirectional high-modulus fiber-reinforced
thermosetting resin, all the individual fiber lengths in each block
being oriented substantially normal to the opposite plane faces
thereof, applying a respective double-faced, pressure-sensitive
adhesive tape to one face of each of a plurality of elongated
series of said blocks to define a plurality of strips, assembling
said strips into the shape of a hemisphere on a spherically curved
mandrel y first applying at least one strip to the mandrel as an
equatorial band, then at least one strip over the pole of the
mandrel from one end to the diametrically opposite edge of said
equatorial band, then at least one strip on each side of said
edge-to-edge band transverse to the latter and extending from the
opposite sides thereof to the equatorial band, then angularly
oriented strips within each of the spherical triangles previously
defined by said bands until the triangles are completely filled,
thereby defining a hemisphere having all the fibers oriented
substantially radially, said adhesive tapes serving to retain said
strips in position on said mandrel, impregnating said assembly of
strips with a thermosetting resin to fill all cracks between
adjoining blocks and strips, curing the resin filling, preparing a
second identical hemisphere, and bonding the two hemispheres to
each other at their open equatorial edges to complete the
sphere.
6. The method of constructing a hollow radial-filament sphere,
comprising the steps of preparing a flat sheet of a precured,
unidirectional high modulus fiber-reinforced thermosetting resin,
all the individual fiber lengths in said sheet being oriented
substantially normal to the opposite plane faces thereof, making a
plurality of side-by-side transverse cuts in said sheet, with
adjacent cuts being alternatively oriented in equiangular
converging and diverging relation to each other, thereby to define
a plurality of rectilinear strips of trapezoidal cross section,
inverting alternate ones of said strips in situ and recementing all
the strips to define a cylindrically curved sector, making a
plurality of pairs of side-by-side cuts in said sector at axially
spaced locations therein, with each pair of such cuts being made on
respective equally but oppositely oblique planes oriented to
intersect at the axis of said sector along a line perpendicular to
said axis, thereby to define a plurality of curved strips having
equally inwardly angled sides, assembling said curved strips in
side-by-side engaging relation to each other to define a
spherically curved sector and cementing the abutting sides of said
curved strips to each other, trimming said spherically curved
sector to desired dimensions and configuration, in like manner
preparing a plurality of additional spherically curved sectors,
assembling said sectors so as to define a barrel having all the
fibers oriented substantially radially, cementing said assembly of
sectors, cutting polar end caps from identically made barrel
sectors to fit the polar openings of the barrel, and cementing said
caps in place to complete the sphere.
Description
This invention relates to underwater research and exploration
vessels of the type disclosed and claimed in our aforesaid
application and there named "Radial-Filament Spheres," and in
particular to methods of manufacturing such vessels.
Hollow vessels capable of withstanding extremely high external
pressures are in great demand for oceanographic and various other
types of underwater research and exploration, to serve as the
load-carrying envelopes for underwater structures, as vehicles for
men and/or instruments, and as buoyant elements for attachment to
underwater vessels. Such a vessel when made out of a solid,
monolithic metal shell has well-known superior strength
characteristics and resistance to buckling under the tremendous
compressive stresses to which it is subjected at great depths below
the surface of the water, but metallic vessels are disadvantageous
in that their strength-to-weight ratio is relatively low, while
their weight-to-displacement ratio is relatively high.
It is an important object of the present invention to provide novel
methods of manufacturing radial-filament spheres which are capable
of withstanding high external pressures and which are possessed of
relatively high ratios of compressive strength to weight and of
elastic stability to weight, and of a relatively low ratio of
weight to displacement.
It is another object of the present invention to provide methods of
making resin and fiber shell-type bodies of spherical curvature
which are characterized by the fact that all the fibers in each
such body are oriented substantially radially thereof and which can
be assembled from structural elements made of unidirectional
filament-reinforced resin.
The foregoing and other objects of the present invention, as well
as the characteristics and advantages thereof, will be more clearly
understood from the following detailed description of preferred
embodiments of the invention when read in conjunction with the
accompanying drawings, in which:
FIG. 1 is a perspective illustration of a radial-filament sphere
constructed of two identical hemispheres each built up in
accordance with one aspect of the present invention;
FIG. 2 is a fragmentary vertical section through the sphere shown
in FIG. 1;
FIG. 3 is a perspective elevational view of the starting basic
structural member employed in large numbers in the manufacture of
the sphere shown in FIGS. 1 and 2;
FIG. 4 is a similar view of the said member as modified prior to
use in the actual buildup of the hemispheres;
FIG. 5 is a plan view of the member shown in FIG. 4 and illustrates
a further structural modification thereof which is effected prior
to the hemisphere-building operation;
FIG. 6 is an elevational view of a partly built-up hemisphere which
when completed is to be used in making the sphere of FIG. 1;
FIG. 6a is a fragmentary diagrammatic illustration of the manner of
building of the hemisphere shown in FIG. 6 from the structural
members of FIG. 5;
FIG. 7 is a diagrammatic illustration of the effect of compressive
stresses on a unidirectional or parallel filament member of the
type employed in the practice of the present invention;
FIG. 8 is a perspective illustration of a radial-filament sphere
constructed of two identical hemispheres each built up in
accordance with another aspect of the present invention;
FIG. 9 is a plan view of a built-up intermediate structural member
employed in building up the hemispheres used in constructing the
sphere shown in FIG. 8;
FIG. 9a is a somewhat enlarged perspective illustration of the
starting structural member employed in building up the intermediate
member shown in FIG. 9;
FIG. 10 is a side elevational view of the said intermediate member,
taken along the line 10--10 in FIG. 9;
FIGS. 11 and 12 are schematic elevational views of a hemispherical
mandrel and illustrate the first two steps in the method of
building a radial-filament hemisphere in accordance with yet
another aspect of the present invention;
FIG. 13 is a sectional view taken along the line 13--13 in FIG.
12;
FIG. 14 is an elevational view of the mandrel, similar to FIG. 12,
and illustrates the next step of the method according to this
aspect of the present invention;
FIG. 15 is an elevational view of the mandrel, seen at an angle of
45.degree. to the plane of FIG. 14, and illustrates further steps
of this method;
FIG. 16 is a perspective view of a large block of undirectional
filament-reinforced resin which can be employed as the basic
starting material for the construction of radial-filament spheres
in accordance with the present invention;
FIGS. 16a and 16b are similar views illustrating, respectively,
severed parts of the block of FIG. 16 and their reassembly into a
relatively thin undirectional slab;
FIG. 17 is a fragmentary perspective illustration of the slab of
FIG. 16b as cut transversely in the first step of a
sphere-constructing method according to yet another aspect of the
present invention;
FIG. 18 is a perspective illustration of a builtup intermediate
structural member made from the cut slab shown in FIG. 17;
FIGS. 19, 19a and 19b are side elevational, top plan and end
elevational views, respectively, of further intermediate structural
members cut from the member of FIG. 18; and
FIGS. 20 and 20a are perspective illustrations, respectively, of
parts of a sphere built up from a multiplicity of the members shown
in FIGS. 19 and 19b by further steps of this method.
Generally speaking, the present invention provides methods of
manufacturing radial-filament spheres the theory underlying the
construction of which is based on the fact that, when a
three-dimensional structure composed of a cured thermosetting resin
matrix having embedded therein a multiplicity of parallel,
unidirectional, high-modulus filaments is subjected to
bidirectional compressive stresses normal to each other and to the
filament orientation, the filaments are additionally stressed in
tension. This is diagrammatically illustrated in FIG. 7 wherein B
denotes a rectangularly prismatic structure, composed of a cured
resin matrix having embedded therein a great number of filaments
(not shown) all oriented parallel to each other in the direction of
the double-headed arrow F, and subjected to balanced compressive
stresses .sigma.' and .sigma." which are perpendicular both to each
other and to the filament direction. Under such conditions, the
filaments are also stressed in tension as indicated by the arrows
T.
In a hollow spherical vessel subjected to external hydrostatic
pressure over its entire surface, the external pressure is opposed
by balanced circumferential stresses in the wall of the vessel, and
any given element of such a body can thus be considered as being
subjected to two perpendicular compressive stresses, both
essentially parallel to the surface. The general equation for the
circumferential stress in a spherical shell under external
hydrostatic pressure is
(1) .sigma.=Pr/ 12t
where P is the unit pressure, r is the mean radius of the sphere,
and t is the wall thickness of the shell. If, now, each such
element of the shell body is composed of a unidirectional filament
slab in which all the individual fibers are oriented substantially
radially of the sphere and thus normal to the plane of application
of the compressive stresses, the fibers in each element of the
shell body will be stressed in tension as well as in lateral
compression. Thus, no buckling of the filaments can occur, which
obviates the requirement of a high degree of straightness in the
fibers and effective lateral support by the resin. It will be
readily recognized that this is precisely opposite to the situation
existing in conventional filament-wound spheres, where transverse
buckling of the filament windings is resisted only by the lateral
support provided by the resin.
It can be shown that the critical pressure P.sub.c for the buckling
of a spherical shell of wall thickness t and radius r is
where E is the modulus of elasticity, .nu. is Poisson's ratio, and
k is an empirically determinable numerical constant. Deep
submergence vessels are also generally characterized by a figure of
merit M which is defined by the relation
(3) M=W/D
where W is the weight of the vessel, and D is the weight of the
water displaced thereby. For a given value of the critical pressure
for buckling, the quantity W/D, which is the weight-to-displacement
ratio, is related to the nature of the material of which the vessel
is made by the proportionality
(4) W/D .rho. / E
where .rho. is the density of the wall material. It will be evident
that a low value for the ratio W/D represents a large payload
capability for the vessel, and from equation (1) that the wall
thickness t should be in direct proportion to the radius of the
vessel, so that vessels of different sizes will have the same
pressure capabilities.
From equations (2) to (4) it can be seen, therefore, that for a
sphere of a given size and intended for a specified critical
pressure, better performance (lower W/D ) results from a higher
modulus E, which permits a decreased wall thickness t, and from a
lower density .rho.. Effective implementation of the principles
outlined above thus entails the use of unidirectional fiber and
resin building elements having an optimally low value of .rho./ E,
a ratio which decreases as E increases, E in this case being he
transverse modulus of the element (i.e. the modulus perpendicular
to the filament direction). It is preferred to employ both resin
and fiber components of high modulus, since both contribute to the
transverse modulus of the composite element. Nevertheless, it will
be understood that other factors, e.g. permissible density, weight,
etc., may place limitations on the choice of resin and/or fiber for
the elements.
Merely by way of example, we have found that excellent results are
achieved by using glass filaments (having a modulus in the range of
about 10 million to 12 1/2 million p.s.i.) as the fiber component
in a resin matrix composed of an epoxy resin system marketed by
Minnesota Mining and Manufacturing Company under the designation
"1,009" (having a modulus of about 430,000 psi). Alternatively, the
fiber component of the building elements may include asbestos
fibers (modulus in the range of about 24 million to 25 million
p.s.i.), boron filaments (modulus in the range of about 50 million
to 60 million p.s.i.), carbon filaments (modulus in the range of
about 20 million to 70 million p.s.i.), sapphire whiskers, tungsten
whiskers, etc. The resin component may be such epoxy resin systems
as are marketed by Union Carbide Corporation under the designations
"ERL-2256" (modulus about 550,000 p.s.i.), "ERRA-0300" (modulus
about 720,000 p.s.i.) and "EP-2114" (modulus about 1 3/10 million
p.s.i.), as well as other epoxies, and various other resins such as
phenolics, melamines, and the maleic alkyd/styrene copolymer types
of polyester resins, characterized by relatively low values of
.rho. E. We have found, for example, that an element such as shown
in FIG. 7 and composed of an epoxy resin matrix (Minnesota Mining
and Manufacturing Company's type "1009") having embedded therein
unidirectional filaments of "S" glass (77 percent of the total
volume) can withstand balanced compressive stresses of 165,000 psi
in each of the .sigma.' and .sigma." directions.
FIGS. 1 and 2 show a radial-filament hollow sphere 25 constructed
of two hemispheres 25a and 25b each built up in accordance with the
principles of the present invention. The method here employed,
which we term the "lune" or "wedge" method, uses as the starting
material precured unidirectional sheet composed of a resin matrix,
e.g. epoxy resin, and glass or other filaments embedded therein,
the filaments extending parallel to each other and to the wide
faces of the sheet. The sheet is first severed into a plurality of
thin strips 26 (FIG. 3), the direction of cutting being
perpendicular to both the direction of the filaments and the plane
of the sheet. Each strip 26 thus has a multitude of short, closely
packed filament lengths extending perpendicularly to its wider
faces, as indicated diagrammatically at 26a. The thickness of the
strips 26 will, of course, depend on the intended structural and
strength characteristics of the sphere to be constructed.
Each strip 26 is then cut into the shape of a half-lune or
wedgelike member 27 (FIG. 4), and a double-faced,
pressure-sensitive adhesive tape 28 is applied to one face of each
member 27. As the final preparatory step, each member 27 is cut in
a gridlike pattern (FIG. 5), severing it to, but not enough, the
adhesive tape backing. The bits 27a thus remain adhered to the
backing tape, and the assembly thereby has a two-dimensional
formability, i.e. the ability to bend somewhat both longitudinally
and transversely.
The manner in which the various members 27 are built up into the
form of a hemisphere 25a (or 25b ) is best shown in FIGS. 6 and 6a.
The only equipment required for this operation is a destructible
spherical mandrel 29 of the appropriate outer diameter, made
conveniently of a low-melting alloy, e.g. Wood's metal. As is
clearly apparent, the building method involves laying the
individual wedgelike members onto the mandrel with their respective
adhesive tape backings in contact with the mandrel. Thus, each such
member is applied to the mandrel by initially positioning the wide
end 27b parallel to the "equator" of the mandrel, as indicated in
solid lines in FIG. 6a, and then bending the wedgelike strip over
into its final, curved, mandrel-conforming position, as indicated
in broken lines in FIG. 6a, so that the apex 27c of the member or
strip 27 essentially reaches the "pole" of the mandrel. It should
be understood that in actual practice it will be preferable to use
half-lunes or wedgelike members 27 of such sizes that when they are
adhered to the mandrel, their wider ends 27b are located slightly
below the mandrel "equator," for a reason which will become clear
as the description proceeds.
After this building operation has been completed, the assembly is
vacuum-impregnated on the mandrel with an appropriate thermosetting
resin, e.g. epoxy resin, to fill the respective spaces between
adjoining members 27 and between adjoining bits 27a, and is cured
on the mandrel to complete the setting of the filling resin.
Thereafter, the mandrel is removed, as by melting it out, and the
interior of the hemisphere is cleaned, at which time the tape 28 is
also removed. The annular equatorial surface of the hemisphere is
then cut and ground true, so it can mate with another like
hemisphere. Two identical hemispheres are finally equatorially
joined together by means of an epoxy resin adhesive, for example
that marketed by Shell Oil Company under the designation EPON-934.
The so-assembled sphere is then again subjected to a curing
operation to set the adhesive.
For a radial-filament sphere of this type, having a 3-inch inner
diameter, we have found a wall thickness of 0.180 inch (the
component strips being transversely cut to that thickness from a
3/8 -inch thick unidirectional sheet of epoxy-bonded glass
filaments obtained from the Minnesota Mining and Manufacturing
Company and available in various thicknesses) to be sufficient to
provide a collapse pressure in excess of 13,000 p.s.i. at a
weight-to-displacement ratio of 0.53. A comparable filament-wound
and internal ring-stiffened construction having a collapse pressure
of 13,600 p.s.i. is found to have a weight-to-displacement ratio of
0.62, the increase of about 17 percent in weight representing a
correspondingly reduced payload capability.
A somewhat different method, herein termed the "one-third octant"
method, of building a radial-filament sphere from unidirectional
resin and filament sheets is illustrated in FIGS. 8 to 10. As
before, the sphere 30 (FIG. 8) is constructed by joining two
identical hemispheres 30a and 30b. Each hemisphere is, however,
made up of four quadrant sectors 31, each of which is an octant of
a sphere, and each quadrant of the hemisphere is made up of three
substantially identical, four-sided, spherically curved segments 32
(see also FIGS. 9 and 10) the areas and contours of which can be
easily calculated from known geometrical considerations.
As the first step of the hemisphere-building method according to
this aspect of the present invention, a number of elongated planar
strips 33 (FIG. 9a) somewhat greater than the number required for
the segment 32 to be formed is assembled in side-by-side relation
and clamped together against a flat surface, with the fibers
oriented normal to said surface. A thin sheet 34 of rubber or other
flexible material capable of being formed smoothly over a doubly
curved surface is then cemented to the entire exposed face of this
assembly of strips. The assembled strips are then cut transversely
to their lines of juncture, down to but not through the flexible
sheet 34, resulting in the formation of a relatively large number
of small bits 33a which are cemented only to the rubber sheet but
not to each other. This assembly is then laid onto a spherically
curved mandrel of proper radius (with the sheet 34 against the
mandrel surface) and is impregnated with epoxy resin to fill the
numerous essentially V-shaped cracks between the bits. After the
resin filling is cured, the segment is cleaned of the sheet backing
and excess resin, and cut and trimmed to proper contours as shown
in FIG. 9. Three such cured segments 32 are then assembled on a
hemispherical mandrel and fitted together to constitute a quadrant
31 of the hemisphere, and epoxy resin is applied to the mating or
abutting surfaces of the segments and cured to complete the
quadrant. Four such quadrants, properly trimmed, are assembled on a
spherical mandrel, and epoxy resin is applied to their mating
surfaces and cured, to complete the hemisphere (30a or 30b). Two
such hemispheres are thereafter equatorially joined as before by an
epoxy resin bond to complete the sphere.
Yet another method of building radial-filament spheres according to
the present invention is illustrated in FIGS. 11 to 15. In this
method, herein termed the "strip" method, elongated strips 35 of
unidirectional bits 36 are employed, each strip consisting of an
end-to-end arrangement of a number of such bits adhered at one face
to a double-faced, pressure-sensitive adhesive tape 37 (similar to
the tape 28 shown in FIGS. 2, 4 and 6). The filaments are, as
before, perpendicular to the tape backing. The method involves
first forming an equatorial region, one or more strips in width,
along the "equator" of the spherical mandrel 29 (FIG. 11), the
strips 35 being secured to the mandrel by the tape. Thereafter, one
or more strips 35a are laid along a great circle path across the
"pole" of the mandrel, joining two diametrically opposite sections
of the uppermost edge of the topmost equatorial strip 35 (FIGS. 12
and 13). Two quarter-circle strips 35b are then laid onto the
mandrel, spaced 90.degree. from strips 35a and extending from
opposite sides of polar strips 35a down to the corresponding
diametrally opposed sections of the upper edge of the topmost
equatorial band 35 (FIG. 14). At this stage, therefore, there are
still open four spherically triangular sections of the hemisphere.
These are then filled in progressively by applying further strips
35c etc. (FIG. 15) cut to suitable shape where they meet corners of
the respective triangles. It is again noted that in actual practice
the lowermost strip 35 will preferably extend somewhat below the
"equator" of the mandrel 29. After the hemisphere has been
completed in this manner, the cracks are filled in with epoxy resin
as previously described, and the entire assembly is cured and,
after removal of the mandrel and the tape, machined accurately in
the equatorial plane. A complete sphere is then formed, as above,
by cementing two such hemispheres to each other along their
equatorial edges.
Still another method of constructing radial-filament spheres
according to the present invention, herein designated the "barrel"
method, employs as the starting material a block 38 of
unidirectional, resin-bonded filaments (FIG. 16), of appropriate
transverse dimensions, in which the filaments run lengthwise of the
block. The block is cut in planes transverse to the filament
direction, as indicated by the lines 39, into a plurality of
relatively thin strips 40 which are then laid on their sides (FIG.
16a ), assembled in side-by-side relation (FIG. 16b), and cemented
to one another at their abutting edges 40a to form a thin panel 41
(similar, but for the joints, to the strip 26 shown in FIG. 3). It
will be understood that the thickness of each of the strips 40 cut
from the block 38 will be equal to the desired wall thickness of
the ultimate spherical shell body.
The flat panel 41, having all filaments oriented normal to its
broad faces, is then severed along oblique planes, as indicated by
the lines 42 (FIG. 17), to provide a plurality of relatively narrow
strips 43 of essentially trapezoidal cross section. These strips
are then separated, alternate ones are inverted, and all are
reassembled and cemented along their abutting faces 43a (FIG. 18),
resulting in the formation of a sector 44 of a right circular
cylinder (FIG. 18). Merely by way of example, for the member 44
enough strips 43 are employed to form a 90.degree. sector. (It
should be understood that the elements 43 are drawn to a greatly
enlarged scale in FIGS. 17 and 18 and that actually many more than
five strips will be required to make up such a sector 44.) The
cylindrically curved sector 44, having the individual fiber lengths
extending perpendicularly to the inner and outer surfaces of the
sector, is then severed into a plurality of strips 45 (FIGS. 19,
19a and 19b ) by making suitable paired oblique planar cuts through
the sector 44 in the circumferential direction thereof, as
indicated by the dot-dash lines 46-46a in FIG. 18, the paired
planes of cutting being so oriented as to intersect at the axis of
curvature of the sector 44.
A sufficient number of such strips 45 is then reassembled and
cemented to each other in side-by-side relation (after the removal
of the waste material resulting form the cutting operation) and the
cement cured to form a barrellike body 47 (FIG. 20) essentially
having the shape of a spherical segment of two bases but differing
therefrom slightly in that the annular edge surface 47a of each
cutoff area is a zone of a cone having its apex at the center of
the sphere. It will be clear, of course, that the body 47 may be
formed by first building up a plurality of intermediate members in
the shape of spherical sectors (now shown) from the strips 45 and
then assembling such sectors into the final configuration shown in
FIG. 20. By virtue of the initial formation of a 90.degree.
cylindrical sector 44, therefore, the body 47 extends 45.degree.
from either side of the "equator" of the sphere, but this can
obviously be varied as desired. Finally, a second such barrellike
body or a substantial lesser part thereof, e.g. a spherical sector
of sufficient areal size, is assembled and cured in the same manner
to provide two blanks from which two complementary polar caps 48
(only one is shown in FIG. 20a ) having boundary edge surfaces 48a
mated in size and orientation to the surfaces 47a of the body 47
can be derived, e.g. machined, these caps then being cemented and
cured to the body 47 to complete the sphere, as indicated in
phantom outline in FIG. 20.
Alternatively, a spherically curved sector (not shown) built up
from the strips 45 may be trimmed, cut, precision ground, etc. in
any desired manner, for example to the dimensions of a one-third
quadrant of a hemisphere as explained hereinbefore in connection
with FIGS. 8 to 10, or it may be employed as any other portion of a
spherical shell which can be bonded to suitably mated shell
segments to complete the desired sphere.
Despite differences in the various above-described methods of
construction, all spheres built up in accordance with the
principles of the present invention will perform substantially
equally well under identical environmental conditions, subject to
the qualification that the presence of the resin-filled V-joints or
spaces between adjoining elements in the spheres produced by the
"lune," "one-third octant" and "strip" methods of construction
dilutes slightly the effective modulus of the shell and thus
effects a corresponding decrease in its critical pressure It will
be apparent, however, that such V-spaces may be filed with tapered
pieces of unidirectional fiber-reinforced resin cut from the same
material as the other elements, which pieces would be cemented in
place with the fiber lengths therein also oriented substantially
radially of the sphere, whereby the aforesaid slight decrease in
the effective modulus and critical pressure could be avoided. In
the barrel method, of course, no such considerations arise since
the building elements 43 and 45 are cut obliquely so that the
abutting faces meet without substantial cracks or spaces
therebetween. In any event, the effectiveness of all these spheres
in sustaining extremely high external pressures stems directly from
the radial orientation of the filaments which provides, under
conditions of balanced biaxial stress, strength and elastic
stability far beyond those of conventional filament-wound
constructions. Stated in other words, the radial-filament
configuration of the present invention is circumferentially
isotropic, i.e. it is equally effective in all circumferential
directions, whereas in conventional filament-wound structures a
given filament provides support primarily in a single direction,
which makes it approximately one-half as effective as the filaments
in the structures according to the present invention.
It should also be noted that the uncured unidirectional filament
and resin material, which is used to make the basic building
elements of the spheres, generally is relatively resin-rich (resin
about 35 to 50 percent of the total volume) and thus has a maximum
filament content of about 65 percent. We have found it
advantageous, however, to use a filament content above about 65
percent and preferably in the range of about 75 to 90 percent of
the total volume. This condition can be readily achieved by
squeezing out some of the resin from the uncured material prior to
the curing thereof. The reason is that with a higher filament
content in the shell wall, the sphere can withstand higher external
hydrostatic pressures. Nevertheless, the principles of the present
invention can also be implemented by using the original material of
unreduced resin content, it being understood that the critical
pressure rating of a sphere so produced will be somewhat lower than
that of a sphere having a reduced resin content and thus an
increased fiber content.
As an example of the present invention, we have constructed a
radial-filament sphere 3 inches in diameter, by the method of FIGS.
11 to 15 described herein, from fiberglass-epoxy prepreg tape
having a resin of modulus 430,000 p.s.i. and glass of modulus 12
4/10 million p.s.i. (supplied by Minnesota Mining and Manufacturing
Company under the designation 1009-26S). The volume fraction of
filaments present in the sphere was 77 percent, and the sphere had
a weight-to-displacement ratio (W/D ) of 0.50. In actual tests,
this sphere sustained an external hydrostatic pressure of 25,000
p.s.i. without failure.
Still further advantages of the radial-filament spheres or shell
bodies constructed by the methods of the present invention are set
forth in our aforesaid application, and reference may be had to
said application for details.
It is to be understood that the foregoing description is for
purposes of illustration only, and that the structural and
procedural features and relationships as well as the types, ranges
and proportions of component materials disclosed herein are merely
representative and are susceptible to various changes and
modifications none of which entails a departure from the spirit and
scope of the present invention as defined in the hereto appended
claims.
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