WO2001064570A1

WO2001064570A1 - Composite structural members

Info

Publication number: WO2001064570A1
Application number: PCT/US2001/003678
Authority: WO
Inventors: Michael W. Hanagan
Original assignee: Corbin Pacific, Inc.
Priority date: 2000-02-29
Filing date: 2001-02-06
Publication date: 2001-09-07

Abstract

A fiber reinforced resin composite structural member is made by coating elongated fibers (50) with fluid synthetic resin (46) and leading the coated fibers (50) between at least four spaced turning points (28, 30, 34) defining the configuration of the desired structural member and completely about at least some of the turning points until the desired cross section for the structural member has been produced. The resin (46) on the fibers (50) is cured to form the desired structural member and the structural member is removed from the support from the turning points. Generally, posts (12, 14, 16) provide at least some of the turning points, and they may have spools (28, 30, 34) thereon about which the resin coated fibers (50) extend and which are bonded with the resin coated fibers into the structural member.

Description

COMPOSITE STRUCTURAL MEMBERS BACKGROUND OF THE INVENTION

The present invention relates to methods for making stmctural members and, more particularly, to methods for making such stmctural members from fiber/resin composite material.

As the automotive industry has moved towards producing lower weight vehicles to reduce fuel consumption, there has been increasing reliance upon synthetic resins to provide

various components for such vehicles. Unfortunately, synthetic resins do not necessarily

provide the stmctural strength required for many applications such as the frame or chassis elements unless reinforced with metal or made in a relatively large cross section.

It has been recognized that future efforts to reduce the weight of vehicles might focus on the use of composite materials, i.e., composites of resin and reinforcing fibers. Moreover, use of such composite materials would not only produce high strength parts but also provide superior corrosion resistance and, in some instances, the ability to absorb impact forces. Another proposed advantage to utilizing composite materials would be the ability to fabricate relatively complex configurations and thus facilitate styling as well as improved transfer of

stresses and loads.

Accordingly, it is the object of the present invention to provide a novel method for

making fiber/resin composite stmctural components.

It is also an object to provide such a method which is adapted to producing such

stmctural components of various configurations on relatively simple forms or fixtures so that the expense of producing complex molds can be eliminated. Another object is to provide such a method which is relatively economical and relatively fast.

A further object is to provide such a method in which the resin coated fiber is laid about desired turning points on a form by one or more robotic arms, thus minimizing the labor content for making such components.

Yet another object is to provide novel stmctural members formed by the foregoing methods.

SUMMARY OF THE INVENTION

It has now been found that the foregoing and related objects may be readily attained in a method for making a fiber reinforced resin composite stmctural member in which there is provided a form with at least four spaced turning points thereon defining the configuration of

the desired stmctural element. Elongated fibers are coated with fluid synthetic resin, and the coated fibers are led between the turning points and completely about at least some of the turning points until the desired cross section for the stmctural member has been produced. The resin on the fibers extending between and about the turning points is cured to form the desired stmctural member, which is then removed from the form.

Generally, posts provide at least some of the turning points, and the posts may have spools thereon about which the resin coated fibers extend and which are bonded with the resin coated fibers of the stmctural member. The fiber leading step includes winding the resin coated fibers about the periphery of at least one of the spools so as to substantially embed it in the resin coated fibers.

Desirably, structural inserts are mounted on the form, and the fiber leading step embeds the inserts in the resin coated fibers. The form may include channel members between at least some of the turning points and the fiber leading step lays the resin coated fibers in the channels between the turning points. The channel members may extend arcuately between pairs of the turning points.

The step of removing the stmctural member from the form will generally comprise collapsing or retracting parts of the form to move the turning points away from the stmctural member, or it may involve disassembling the form. In some instances, the stmctural member may be simply slid off the form.

In one embodiment of the process, the form includes longitudinally spaced end posts to provide turning points at the ends of the elongated stmctural member and intermediate posts between the longitudinally spaced end posts, and the intermediate posts are transversely spaced to define the sides of the stmctural member to provide a skeleton of generally ovoidal cross section. The fiber leading step provides longitudinally extending ribs along two sides of the stmctural member and ribs extending transversely therebetween.

The form may include channel members between at least some of the turning points and the fiber leading step lays the resin coated fibers in the channels between the turning

points.

One resultant integrally formed fiber-reinforced resin composite stmctural member has at least four spaced spools at changes in direction in the periphery of the stmctural member and an armature of fiber/resin composite material extending between the spools which are embedded therein. A multiplicity of stmctural inserts may also be embedded in the armature at spaced points thereabout. Some of the spools are disposed at the ends of the stmctural member and others are provided therebetween and spaced transversely to define a skeleton of generally ovoidal cross section with longitudinally extending ribs along two sides of the stmctural member and ribs extending transversely therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a collapsible form for use in the method of the present invention to make a motorcycle box frame;

Figure 2 is a diagrammatic illustration of a single fiber laying head on a robotic arm laying fibers about four spools;

Figure 3 is a diagrammatic illustration of the path of fiber about four spools;

Figure 4 is a perspective view of the finished stmctural element being formed in Figure 3;

Figure 5 is a diagrammatic illustration of the path of the fiber about three spools and an arcuate channel support or frame;

Figure 6 is a diagrammatic illustration of a fiber being laid on a skeleton by five robot arms;

Figure 7 is a perspective view of a five spool bracket with multiple passes of fiber wound about the spools;

Figure 8a, 8b and 8c are semi-diagrammatic views of a personal vehicle utilizing stmctural frame elements which may be fabricated by the method of the present invention;

Figure 9 is an exploded view of the elements of the frame of Figure 8;

Figures lOa-lOf are diagrammatic views of different elements used in fabricating forms and fragmentarily illustrated molded sections;

Figures 11a, lib, lie and lid diagrammatically illustrate the method of producing the wheels of the vehicle of Figure 8; Figure 12 is a perspective view of another form with fiber wound thereabout; and

Figure 13 is a view of the stmctural element in Figure 12 removed from the form. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning first to Figure 1 , there is shown apparatus for conducting the method of the present invention in making a motorcycle box frame. Supported on the base 10 are three aligned pedestals 12, 14 and 16 of increasing height. The pedestals 12, 14 have retractable telescoping cross arms 18, 20 which support at their outer ends convexly arcuate channel members 22, and the pedestal 16 has an upper portion 24 which is inclined upwardly and in the direction of the pedestals 12, 14.

The shorter pedestal 12 also has a retractable telescoping support arm 26 which is inclined downwardly in the direction away from the pedestal 14, and an elongated and mounted thereon is a relatively large diameter swing arm spool 28 which extends perpendicularly to the arm 26 and parallel to the cross arms 18, 20. Seated on a retractable arm (not shown) at the upper end of the inclined upper portion of the pedestal 16 is an elongated and large diameter fork tube spool 30. Seated on bosses 32 along the length of the channel members 22 are spools 34, one of which is shown separated and in enlarged size. The cross arms 18, 20 are held in extended position by the lock pins 36.

Conveniently, release or engagement of the lock pins and extension and retraction of the arms 18, 20 and the arm (not shown) of the pedestal 16 may be effected by pneumatic or

hydraulically operated piston/cylinder assemblies (not shown) actuated by the controller 38.

Turning next to Figure 2, there is shown another type of form and a fiber laying head assembly generally designated by the numeral 40 with a six axis robotic arm generally designated by the numeral 42 which carries the resin bladder or chamber 46 and the guide nozzle 48 at its write 44. Elongated fiber 50 is fed from supply spools (not shown) about the guide roller 52 and into the resin chamber 46 wherein it is saturated with resin flowing from a supply (not shown) through the tubes 54. In many instances, the resin system employed will require a catalyst for polymerization and curing.

As seen, three smaller diameter spools 56 are supported on pedestals 58 and a larger diameter spool 60 is supported on the pedestal 62. The fiber 50 is wound about and between different pairs of the several spools 56, 60. When the fiber 50 has been laid to the desired thickness, the fiber laying operation can be ended and the resin cured. In some instances, curing may progress swiftly so that the fiber/spool stmcture can be lifted from the pedestals 58, 62 for oven curing and further processing. However, generally the fixture and stmcture will be placed in the oven for full curing since the fixture holds the desired configuration during the complete curing process.

Figure 3 illustrates diagrammatically the path of the fiber around different pairs of four spools 64, 66, 68 and 70.

Figure 4 illustrates the fully formed stmctural element with the spools 64, 66, 68 and 70 substantially embedded therein.

Figure 5 diagrammatically illustrates the paths of fiber laying about three spools 72, 74 and 76 and an arcuate channel member 78 with the spools being substantially embedded in the fiber which is merely formed in the channel member 78.

In Figure 6, the form has a pedestal 80 with a horizontal arm 82 upon which is mounted a skeletal member generally designated by the numeral 84 and having a first leg 86 and a second leg 88 which extends generally perpendicularly to the leg 86 at a point spaced inwardly from its outer end which is configured as a spool 90. Extending angularly from the second leg 88 adjacent its midpoint is a first short leg 92 which has its outer end configured as a spool 94. At the outer end of the second leg 88 is an elongated spool 96 which has its axis extending generally transversely of the principal axis of the leg 88. As seen, the second leg 88 has an arcuate bend adjacent its outer end and a second short leg 98 extends angularly therefrom and has a transversely extending spool 100 at its outer end.

In this illustration, five multiple axis robotic arms generally designated by the numerals 102, 104, 106, 108 and 110 carry fiber laying head assemblies 112, 114, 116, 118 and 120 to generate the stmcture more quickly. The head assembly 112 wraps the first leg 86 and its spool end 90, and it also lays fiber over the juncture with the second leg 88. The head assembly 114 wraps the inner end portion of the second leg 88 and the first short leg 92 and its spool end 94. The head assembly 120 wraps the remainder of the second leg 88 while the head assembly 116 wraps the second short leg 98 and its spool 100. Lastly, the head assembly 118 wraps the elongated spool 96. Each robot can dispense the same or different combinations of fibers and resins.

The robotic arms 102, 104, 106, 108 and 110 are computer controlled so that fiber being laid by adjacent head assemblies is overlapped. After at least partial curing of the resin

in the applied fiber layers, the entire stmcture is removed from the horizontal arm 82 of the pedestal 80 for further processing.

Figure 7 is a diagrammatic illustration of another stmctural member employing four small spools 122, 124, 126 and 128, and one large spool 130. This also illustrates the paths of fiber laying between different pairs of spools to substantially embed the spools 122-130 and

provide a rigid stmcture. Figures 8a, 8b and 8c are semi-diagrammatical views of a three-wheeled vehicle for a single occupant, and Figure 9 is an exploded view of the principal stmctural members of the vehicle. Figure 10 fragmentarily illustrates the various components of the form used in making the stmctural members.

Turning first to Figure 10 for generally understanding of the types of form components, Figure 10a illustrates a form element generally designated by the numeral 154 and channel elements 156 which have bosses 158 supporting nut inserts 160 which are embedded in the fiber stmcture 162 formed thereon. As can be seen, the element 154 includes a support arm 164 which is retractable and extensible. After the fiber stmcture 162 has set, the arm 164 is retracted therefrom.

Figures 10b and 10c show an elongated channel member 166 of concave cross section with bosses 168 along the length thereof upon which nut inserts 170 are seated. The channel member 166 is supported upon multiple retractable arms 172. The fiber/resin composite 174 laid in the channel member 166 assumes a hemispherical cross section and embeds the nut inserts 170.

Figure lOd shows a channel member 178 with a boss 180 and a nut insert 182 of the type which is preferably used since the radial spokes 184 firmly lock it in the fiber/resin composite formed thereabout.

Figure lOe illustrates a channel member 186 of more complex cross section with a convex center portion 188.

Figure lOf shows the directions of laying fiber in intersecting channel members.

Returning to Figure 9, the spheroidal member generally designated by the numeral 132 is produced as a unitary element by a form (not shown) comprised of pedestals and retractable arms which support arcuate channel members, spool supports and nut supports, all as generally illustrated in Figure 10. Multiple fiber laying head assemblies lay fiber in the arcuate channel members to provide the elongated ribs and st ts of the member 132 and to embed nuts 134 and spools 136. After laying the fiber, the supports are moved inwardly to allow the spheroidal member 132 to be lifted therefrom.

The door skeleton member 138 is similarly formed on a form which supports channel members and spools, and the channel members support nuts along their length. As a result, the skeleton member 138 is formed as a unitary member with a spool 140 at its forward end and nuts 142 along the length of the ribs 144.

The swing arm 146 is formed on the form shown in Figure 1. The A-arms 148 for supporting the front wheels are made substantially as shown in Figures 3 and 4.

The engine and suspension mounting module generally designated by the numeral 150 is preferably formed as a unitary stmcture on a form which has telescoping or collapsible arms and by use of multiple fiber laying heads. Alternatively, it may be assembled from three

separately formed components which are bolted together.

The wheel centers 152 are formed as illustrated in Figure 11.

As will be readily appreciated, the several elements may be bolted together and the skins (not shown) mounted thereon by fasteners secured in the nuts disposed along the ribs. Other components may also be bolted thereon.

Turning to Figure 11, the method of the present invention may be utilized to form the spokes of a hub and center insert for a wheel rim 192 which has a rib 194 extending about its inner periphery. The hub 196 is mounted on a support arm (not shown) and a ring member generally designated by the numeral 198 and having a circular configuration is also supported on retractable arms (not shown). Spaced about the ring member 198 are pairs of projecting posts 200, each of which has a laterally extending arm at its outer end. The hub 196 also has projecting posts 204 with laterally extending arms spaced about its circumference.

As seen in Figures lie and lid, the coated fiber 50 is wound about the posts 200,204 below the arms and extends from a post on one of the hub 196 and ring member 198 to a pair of posts on the other of the ring member and hub. After the composite has cured, the center insert is seated in the rim 192, and fasteners (not shown) secure the periphery of the center insert 198 to the rib 194.

Turning lastly to Figures 12 and 13, the form generally designated by the numeral 206 has a pair of arms 208, 210 upon which are slidably mounted stmctural spools 212, and a pair of arcuate blades 214 are supported on the rods 216. The fiber 50 is wound about the spools 212 and the blades 214 to produce a stmctural member with an extensive reinforcing internal rib configuration for the outer peripheral portion.

As will be readily appreciated from the foregoing illustrations and description, the forms or fixtures upon which spools and other forming elements are supported will generally be customized for the particular part to be fabricated, and ideally the forms have piston/cylinder assemblies to allow retraction of the supporting elements from the formed stmctural member to facilitate its removal therefrom. However, in some instances, the stmctural member may be simply slid off the supporting posts of the form or fixture.

As indicated in Figure 10, various types of forming elements can be utilized as a pan of the form in order to provide the desired configuration and to enable insertion of stmctural elements into the fiber armature which is to be formed thereabout. Moreover, the form may support stmctural inserts of various types such as the nuts which are illustrated, and the spools which conveniently not only provide the turning points and the radius for the fiber to be formed thereabout, but also provide stmctural components in the ultimate assembly. Exemplary of the use of such spools are various of the illustrated structures. Although the incorporated stmctural elements may be formed from synthetic resin, generally steel and aluminum will be the material from which they are fabricated construction.

When channel members or other forming elements are provided to form a desired arcuate contour or to support the fiber, it is desirable to have them highly polished or plated and to provide thereon a release coating to minirnize any potential for the resin coated fiber to bond thereto.

Although various high strength resins and various fibers such as fiberglass, carbon and aromatic poly amides (aramid) may be employed, the preferred combinations are polyester for use with glass fibers and epoxy resins for use with carbon and aramid fibers. As is well known, aramid fibers will flex and are used for where some flexure is desired and carbon fibers are relatively rigid and are preferred for areas in compression. Stmctural resin foam

(such as polycarbonate, polyurethane and polypropylene resin) is conveniently used to provide skeletons about which the coated fiber is wound.

As used herein, the term "resin" includes polymers, oligomers and monomers, as well as catalysts and crosslinking agents. Polymerization and curing can be actuated by added

catalysts or autocatalysis and catalysts may be activated by heat and light and electron beams.

The particular combination reinforcing fiber and resin is driven by the design and the desired stmctural characteristics. At various points in a stmcture, a system good in compression may be desired whereas a system providing flexure is desired in other pans. Bedding nut inserts along the stmctural elements allows other components to be fastened thereto quickly and securely by conventional threaded fasteners. Moreover, the stmctural elements themselves may be formed to include interfitting portions to facilitate their assembly and transfer loads therebetween.

As will be appreciated, the number of robotic arms and fiber laying heads can vary depending upon the complexity and size of the part.

Programming of the motion of the robotic arms can be done by use of "teaching software" wherein the arms are moved manually through the necessary motions and the computer program is developed therefrom. The computer controlling the motion of the robotic arms can also be utilized to extend and retract or otherwise move portions of the form.

Depending upon the resin employed, curing may take place rapidly enough upon the form so that the resin is substantially cured in place following which the part may be removed from the form and transferred to an oven for further curing. Alternatively, the form with the resin/fiber wound thereabout may be placed in an oven to expedite curing.

Thus, it can be seen from the foregoing detailed description and attached drawings that the method of the present invention enables facile fabrication of relatively complex fiber/resin composite stmctural members. This method of forming enables the production of stmctural elements of high strength and light weight, and the stmctural members are substantially free from corrosion.

Claims

CLAIMS Having thus described the invention, what is claimed is:

1. In a method for making a fiber reinforced resin composite stmctural member, the steps comprising:

(a) providing a form with at least four spaced turning points thereon defining the configuration of the desired stmctural element;

(b) coating elongated fibers with fluid synthetic resin;

(c) leading said coated fibers between said turning points and completely about at least some of said turning points until the desired cross section for the stmctural member has been produced;

(d) curing said resin on said fibers extending about said turning points to form the desired stmctural member; and

(e) removing said stmctural member from said form.

2. The method of making a fiber-reinforced resin composite stmctural member in

accordance with Claim 1 wherein there are posts providing at least some of said turning points.

3. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 2 wherein said posts have spools thereon about which said resin coated fibers extend and which are bonded with said resin coated fibers of said stmctural member.

4. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 3 wherein there is included a step of winding said resin coated fibers about the periphery of at least one of said spools.

5. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 4 wherein said at least one spool is substantially embedded in said resin coated fibers.

6. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein there is included the step of mounting stmctural inserts on said form and said fiber leading step embeds said inserts in said resin coated fibers.

7. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein said step of providing said form includes providing channel members between at least some of said turning points and in which said fiber leading step lays

said resin coated fibers in said channels between said turning points.

8. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 5 wherein at least one of said channel members extends arcuately between a pair of said points.

9. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein said step of removing said form comprises collapsing said form to move said turning points away from said stmctural member.

10. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein said step of removing said form comprises disassembling said form.

11. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein said step of providing said form includes providing longitudinally spaced end posts to provide turning points at the ends of the elongated stmctural member and intermediate posts between said longitudinally spaced end posts, said intermediate posts being transversely spaced to define the sides of said stmctural member, said stmctural member providing a skeleton of generally ovoidal cross section.

12. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 11 wherein said fiber leading steps provide longitudinally extending ribs along two sides of said stmctural member and ribs extending transversely therebetween.

13. The method of making a fiber-reinforced resin composite stmctural members in accordance with Claim 1 wherein said step of providing said form includes providing channel members between at least some of said turning points and in which said fiber leading step lays said resin coated fibers in said channels between said turning points.

14. The method of making fiber-reinforced composite resin stmctural members in accordance with Claim 2 wherein there is included the step of mounting stmctural inserts on said form assembly and said leading step embeds said inserts in said resin coated fibers, said step of providing said form includes providing longitudinally spaced end posts to provide the ends of the elongated stmctural member, and providing intermediate posts between said longitudinally spaced end posts, said intermediate posts being transversely spaced to define the sides of said stmctural member and provide a skeleton of generally ovoidal cross section, said fiber leading steps providing longitudinally extending ribs along two sides of said stmctural member and ribs extending transversely therebetween.

15. An integrally formed fiber-reinforced resin composite stmctural member comprising:

(a) at least four spaced spools at changes in direction in the periphery of

said structural member; and (b) an armature of fiber/resin composite material extending between said spools, said spools being embedded in said armature.

16. An integrally formed fiber-reinforced resin composite stmctural member in accordance with Claim 15 wherein a multiplicity of stmctural inserts are embedded in said

armature at spaced points thereabout.

17. An integrally formed fiber-reinforced resin composite stmctural member in

accordance with Claim 15 wherein some spools are disposed at the ends of said stmctural

member and others are provided therebetween and spaced transversely to define a skeleton of generally ovoidal cross section.

18. An integrally formed fiber-reinforced resin composite stmctural member in accordance with Claim 17 having longitudinally extending ribs along two sides of said stmctural member and ribs extending transversely therebetween.

19. An integrally formed fiber-reinforced resin composite stmctural member having

changes in direction at least four turning points about the periphery thereof, said stmctural

member having:

(a) an armature of fiber/resin composite material extending between said

turning points and defining the periphery thereof; and

(b) stmctural members substantially embedded in said armature at a multiplicity of points spaced about said periphery.

20. An integrally formed fiber-reinforced resin composite stmctural member in

accordance with Claim 19 wherein said armature has arcuate portions extending between at

least some of said turning points. O 01/64570

17

21. An integrally formed fiber-reinforced resin composite stmctural member in accordance with Claim 19 wherein some of said tuming points are disposed at the ends of said stmctural member and others are provided therebetween and spaced transversely to define a skeleton of generally ovoidal cross section.

22. An integrally formed fiber-reinforced resin composite stmctural member in accordance with Claim 21 having longitudinally extending ribs along two sides of said stmctural member and ribs extending transversely therebetween.

AMENDED CLAIMS

[received by the International Bureau on 3 July 2001 (03.07.01); original claims 7, 11, 17, 20 and 21 cancelled; original claims 1, 8, 12, 15 and 19 amended; remaining claims unchanged (4 pages)]

Having thus described the invention, what is claimed is:

1. In a method for making a fiber reinforced resin composite stmctural member of

generally ovoidal configuration, the steps comprising:

(a) providing a form with at least four spaced turning points thereon and arcuate channel members between at least some of said turning points, said form also including longitudinally spaced end posts to provide turning points at the ends of the stmctural member and intermediate posts between said longitudinally spaced end posts, said intermediate posts being transversely spaced to define the sides of said structural member, said stmctural member providing a skeleton of generally ovoidal cross section, said form defining generally ovoidal configuration for the desired stmctural

element;

(b) coating elongated fibers with fluid synthetic resin;

(c) leading said coated fibers between said turning points and in said

channel member and completely about at least some of said turning points until the desired cross section for periphery of the stmctural member has been produced;

(e) removing said generally ovoidal stmctural member from said form.

2. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein there are posts providing at least some of said turning points.

8. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein at least some of said channel members extends arcuately between pairs of said turning points.

9. The method of making a fiber-reinforced resin composite stmctural member in

accordance with Claim 1 wherein said step of removing said form comprises collapsing said form to move said turning points away from said stmctural member.

12. The method of making a fiber-reinforced resin composite stmctural member in accordance with Claim 1 wherein said fiber leading steps provide longitudinally extending ribs

along two sides of said stmctural member and ribs extending transversely therebetween.

14. The method of making fiber-reinforced composite resin stmctural members in accordance with Claim 2 wherein there is included the step of mounting stmctural inserts on said form assembly and said leading step embeds said inserts in said resin coated fibers, said step of providing said form includes providing longitudinally spaced end posts to provide the

ends of the elongated stmctural member, and providing intermediate posts between said longitudinally spaced end posts, said intermediate posts being transversely spaced to define the sides of said stmctural member and provide a skeleton of generally ovoidal cross section, said fiber leading steps providing longitudinally extending ribs along two sides of said stmctural member and ribs extending transversely therebetween.

15. An integrally formed fiber-reinforced resin composite stmctural member of generally ovoidal configuration comprising:

(a) at least four spaced spools at changes in direction in the periphery of

said stmctural member, some spools being disposed at the ends of said stmctural member and others are provided therebetween and spaced transversely, said aperture having portions extending arcuately between spools; and (b) an armature of fiber/resin composite material extending between said spools, said spools being embedded in said armature.

16. An integrally formed fiber-reinforced resin composite stmctural member in

accordance with Claim 15 wherein a multiplicity of stmctural inserts are embedded in said armature at spaced points thereabout.

19. An integrally formed fiber-reinforced resin composite stmctural member of generally ovoidal configuration having changes in direction provided by at least four turning points about the periphery thereof, said stmctural member having:

(a) an armature of fiber/resin composite material extending between said turning points and defining the periphery thereof, said armature having arcuate portions extending between at least some of said turning points, some of said turning points

being disposed at the ends of said stmctural member and others being provided

therebetween and spaced transversely to define a skeleton of generally ovoidal cross section; and

(b) stmctural members substantially embedded in said armature at a multiplicity of points spaced about said periphery and at the ends thereof.

22. An integrally formed fiber-reinforced resin composite stmctural member in accordance with Claim 21 having longitudinally extending ribs along two sides of

said stmctural member and ribs extending transversely therebetween.