IP Verse

Fiber Composite And Process Of Manufacture

Patent No. US11806584 (titled "Fiber Composite And Process Of Manufacture") was filed by Xene Corp on Nov 19, 2018.

What is this patent about?

’584 is related to the field of manufacturing composite materials, specifically graphite resin composite members used in sports equipment like racquet frames, golf club shafts, and bicycle frames. Traditional methods involve manual labor, molds, and air injection to form these components, which can lead to inconsistencies and limitations in design and automation.

The underlying idea behind ’584 is to use a foamable material within a sealed layup to generate pressure during the curing process, replacing the need for air injection. This is achieved by incorporating microcapsules containing a foaming agent into the layup. When heated, these microcapsules expand, applying uniform pressure to the composite material and forcing it against the mold walls, resulting in a consistent and strong final product.

The claims of ’584 focus on a method of making a fiber composite member by wrapping fiber permeated with resin to form a tubular member, placing a foam plastic forming material inside, closing the ends to create a bladder, introducing the bladder into a mold, heating the material to form a foam plastic and apply pressure, and hardening the resin. The claims also specify that the foam plastic forming material has an expansion ratio of greater than 30 .

In practice, the process involves wrapping layers of carbon fiber and resin around a mandrel, inserting the microcapsules containing the foaming agent, sealing the layup, and placing it in a mold. The mold is then heated to a temperature that cures the resin and activates the foaming agent, causing the microcapsules to expand and exert pressure. This pressure ensures that the composite material conforms to the mold's shape and that the layers are tightly bonded together.

This method differs from traditional air injection techniques by eliminating the need for manual nozzle attachment and the associated inconsistencies. The use of a foamable material allows for a more automated and uniform manufacturing process, potentially enabling mass production. Furthermore, the resulting solid frame structure can offer improved strength, reduced vibration, and a larger sweet spot compared to conventional hollow graphite racquets.

How does this patent fit in bigger picture?

Technical landscape at the time

In the late 2000s when ’584 was filed, graphite composite structures such as sports racquet frames were typically manufactured using manual labor in molds with air injection. At a time when systems commonly relied on manually placed air nozzles to inflate a bladder within the layup, the process was difficult to mechanize. When hardware or software constraints made automation non-trivial, the manual attachment of air nozzles led to inconsistencies in the manufacturing process.

Novelty and Inventive Step

The examiner allowed the claims based on a preponderance of evidence, considering a change in inventorship, an approved terminal disclaimer, and prior art cited in a previous case (U.S. Patent 10,500,447).

Claims

This patent contains 14 claims, with independent claims numbered 1, 4, 10, and 11. The independent claims are directed to methods of making fiber composite members or layups using expandable materials. The dependent claims generally refine or add specific features to the methods described in the independent claims.

Key Claim Terms New

Definitions of key terms used in the patent claims.

Term (Source)Support for SpecificationInterpretation
Bladder forming member
(Claim 4)		“The inventive resin and fiber composite may comprise an outer shell defining a cavity, the outer shell comprising a plurality of layers of fibers. A first resinous material is disposed between the fibers and secures the fibers to each other. A second resinous material is disposed inside the cavity, the second resinous material being configured and dimensioned to define voids within the cavity between portions of the second resinous material.”A component positioned adjacent to the wall portion of the unitary member, used to form a bladder when closed.
Expansion ratio
(Claim 1, Claim 4, Claim 10)		“The expansion coefficient of the foam plastic forming material used in accordance with the invention, Expancell 152 is believed to be about 60 to 1. Solid foam materials which have expansion ratios in the range of about 2 to 1 have been found not to produce racquets of sufficient strength. Jellied type foam materials having expansion ratios in the range of about 10 to 1, while measurably improved, are also less than ideal.”The ratio of the volume of the foam plastic after expansion to the volume of the foam plastic forming material before expansion.
Foamable microcapsules
(Claim 11)		“In accordance with the invention, one fills the layup with the powder microcapsule foaming plastic material, which does not begin to expand, in the examples set forth below, until the temperature reaches 120-130 degrees Centigrade, for example 130° C. At the same time, the gas generate pressure, inside the layup bladder which is sealed at both ends, due to the foaming action of the micro encapsulated material inside the bladder.”Small capsules that encapsulate a foaming agent and undergo volumetric expansion by foaming when heated to a predetermined temperature.
Foam plastic forming material
(Claim 1)		“The process of making the racquet in accordance with the invention uses a micro encapsulated plastic material, including a foaming agent in the form of a powdered material, to form the foam plastic. This material is put into the tubular layup bladder which is sealed at both ends. The bladder is then put in an iron mold which is then heated. This results in the material being heated, causing it to melt and expand under the pressure of a foaming agent contained therein.”A material that contains capsules filled with a heat expandable material, which when heated, expands to form a foam plastic.
Substantially closed bladder
(Claim 1, Claim 4)		“In accordance with the invention, one fills the layup with the powder microcapsule foaming plastic material, which does not begin to expand, in the examples set forth below, until the temperature reaches 120-130 degrees Centigrade, for example 130° C. At the same time, the gas generate pressure, inside the layup bladder which is sealed at both ends, due to the foaming action of the micro encapsulated material inside the bladder.”A bladder formed by closing the ends of the wrapped flat members, creating a sealed or nearly sealed enclosure.

Litigation Cases New

US Latest litigation cases involving this patent.

Case NumberFiling DateTitle
1:25-cv-02066Nov 17, 2025Xene Innovations, LLC v. The Boeing Company

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US11806584

XENE CORP
Application Number
US16195277
Filing Date
Nov 19, 2018
Status
Granted
Expiry Date
Aug 7, 2033
External Links
Slate, USPTO, Google Patents