The present invention provides an improved tubular structure which uses
the properties of different materials, such as stiffness, strength, and
density are exploited in a manner which combines the most attractive
characteristics of existing metal and composite tubes into a
metal/composite tube which contains performance characteristics
(stiffness, strength or weight) not possible with pure metal or composite
materials.For example, an improved tube is suitably created with a
conventional metallic tube structure (e.g., steel, aluminum, titanium or
the like). The original tube is modified with a secondary operation such
as machining, punching, laser cutting or the like to remove various
portions of the original tube wall, resulting in a tube with some pattern
of "holes" or "cutaway" sections, thus resulting in a lighter tube. The
tube is then suitably "fused" with composite material. For example, in
one embodiment of the present invention, the metal piece is placed in a
mold assembly and composite materials are molded inside the metal tube
resulting in a part metal and part composite tube that has beneficial
characteristics of each material.