This document relates, generally, to iso-truss structures and/or iso-grid structures and/or iso-beam structures, and in particular to coupling mechanisms for iso-truss structures and/or iso-grid structures and/or iso-beam structures.
An iso-truss and/or iso-grid and/or iso-beam structure may include a plurality of load bearing members, or force members, that are joined at a plurality of nodes to define a load bearing structure. An iso-truss and/or iso-grid and/or iso-beam structure may be employed in situations in which a support structure is to bear a considerable load across a relatively extensive span, and in a situation in which weight of the support structure itself may affect the performance of the support structure. In some situations, it may be beneficial to couple the iso-truss/iso-grid/iso-beam structure to an adjacent iso-truss/iso-grid/iso-beam structure, or other supporting structure while avoiding fastening devices which may adversely impact the structural integrity of the iso-truss/iso-grid/iso-beam structure.
In one general aspect, a coupling mechanism includes a first plate configured to be positioned on a first surface of a band of a first three-dimensional (3D) load bearing structure and a corresponding first surface of a band of a second 3D load bearing structure; a second plate configured to be positioned on a second surface of the band of the first 3D load bearing structure opposite the first surface thereof and a corresponding second surface of the band of a second 3D load bearing structure; a first plurality of openings extending from the first plate, through the band of the first 3D load bearing structure, and into the second plate; a second plurality of openings extending from the first plate, through the band of the second 2D load bearing structure, and into the second plate; a first plurality of fasteners respectively received in the first plurality of openings to secure the first 3D load bearing structure between the first and second plates; and a second plurality of fasteners respectively received in the second plurality of openings to secure the second 3D load bearing structure between the first and second plates.
In some implementations, a contour of the first plate corresponds to a contour of the first surface of the band of the first 3D load bearing structure and to the contour of the first surface of the band of the second 3D load bearing structure, and a contour of the second plate corresponds to a contour of the second surface of the band of the first 3D load bearing structure and to the contour of the second surface of the band of the second 3D load bearing structure, such that the band of the first 3D load bearing structure and the band of the second 3D load bearing structure are secured between the first and second plates.
In some implementations, the first plurality of fasteners includes one of a plurality of bolts extending through the first plurality of openings; a plurality of dowels extending through the first plurality of openings; a plurality of rivets extending through the first plurality of openings; or a plurality of pultruded pins extending through the first plurality of openings, and the second plurality of fasteners includes one of a plurality of bolts extending through the second plurality of openings; a plurality of dowels extending through the second plurality of openings; a plurality of rivets extending through the second plurality of openings; or a plurality of pultruded pins extending through the second plurality of openings.
In some implementations, the coupling mechanism is configured to be coupled on a mating section of the band of the first 3D load bearing structure that is positioned between two longitudinal members of the first 3D load bearing structure, and on a mating section of the band of the second 3D load bearing structure that is between two longitudinal members of the second 3D load bearing structure. In some implementations, the mating section of the band of the first 3D load bearing structure is arcuate, and the mating portion of the band of the second 3D load bearing structure is arcuate. In some implementations, the mating section of the band of the first 3D load bearing structure is substantially planar, and the mating portion of the band of the second 3D load bearing structure is substantially planar. In some implementations, the band of the first 3D load bearing structure and the band of the second 3D load bearing structure to which the first plate and the second plate are to be coupled are one of an annular flange, an annular collar or a polyhedral collar integrally formed at an end portion of the 3D load bearing structure.
In another general aspect, a coupling mechanism includes a first plate configured to be positioned at an inner lateral end portion of a band of a first three-dimensional (3D) load bearing structure; a second plate configured to be positioned at an inner lateral end portion of a band of a second 3D load bearing structure; a first fastener extending from a first end portion of the first plate to a first end portion of the second plate, at an outer side of the band of the first 3D load bearing structure and an outer side of the second load bearing structure; a second fastener extending from a second end portion of the first plate to a second end portion of the second plate, at an inner side of the band of the first 3D load bearing structure and an inner side of the second load bearing structure, wherein the first and second fasteners are configured to couple the first and second plates so as to secure the band of the first 3D load bearing structure and the band of the second 3D load bearing structure between the first and second plates.
In some implementations, an inner facing surface of the first plate abuts the inner lateral end portion of the band of the first 3D load bearing structure, and an inner facing surface of the second plate abuts the inner lateral end portion of the band of the second 3D load bearing structure. In some implementations, the first fastener includes a bolt that extends through a first opening in the first plate and through a first opening in the second plate, with a head portion of the first fastener positioned on an outer facing surface of the first plate, and a nut securing the bolt relative to the first and second plates abutting an outer facing surface of the second plate, and the second fastener includes a bolt that extends through a second opening in the first plate and through a second opening in the second plate, with a head portion of the second fastener positioned on the outer facing surface of the first plate, and a nut securing the bolt relative to the first and second plates abutting the outer facing surface of the second plate.
In another general aspect, a three-dimensional (3D) load bearing structure includes a longitudinal frame including six longitudinal members arranged in parallel with respect to a central longitudinal axis of the load bearing structure, and extending longitudinally along a length of the load bearing structure; a transverse frame integrally coupled with the longitudinal frame at a respective plurality of nodes, the transverse frame including a plurality of 3D polyhedral structures sequentially arranged along the central longitudinal axis of the load bearing structure, wherein the plurality of nodes are respectively defined at a plurality of points of intersection between the plurality of longitudinal members and the plurality of 3D polyhedral structures, at points of the plurality of 3D polyhedral structures at which a contour of the plurality of 3D polyhedral structures forms an apex such that each apex of each of the plurality of polyhedral structures is coupled to a corresponding longitudinal member; and at least one band formed at a longitudinal end portion of the integrally coupled longitudinal frame and transverse frame, wherein the at least one band is configured to interface with a coupling mechanism to provide for coupling of the 3D load bearing structure to an adjacent structure.
In some implementations, the at least one band is integrally coupled with the integrally coupled longitudinal frame and transverse frame. In some implementations, the at least one band includes a first band integrally formed at a first longitudinal end portion and a second band integrally formed at a second longitudinal end portion of the integrally coupled longitudinal frame and transverse frame. In some implementations, the at least one band is one of an annular flange, an annular collar, or a polyhedral collar. In some implementations, each of the plurality of 3D polyhedral structures follows a helical pattern relative to the central longitudinal axis, with straight portions of the plurality of polyhedral structures extending between adjacent nodes of the plurality of nodes such that a cross-sectional contour of the load bearing structure is substantially hexagonal. In some implementations, each of the plurality of nodes includes an interweaving of longitudinal fibers of a longitudinal member of the plurality of longitudinal members, with transverse fibers of a transverse member of a polyhedral structure of the plurality of 3D polyhedral structures.
In another general aspect, a three-dimensional (3D) load bearing structure includes a longitudinal frame including a plurality of longitudinal members arranged in parallel with respect to a central longitudinal axis of the 3D load bearing; a transverse frame integrally coupled with the longitudinal frame, the transverse frame including a plurality of sequentially arranged 3D polyhedral structures each following a helical pattern with respect to the central longitudinal axis of the 3D load bearing structure; a band integrally coupled to a first end portion of the integrally coupled transverse frame and longitudinal frame; a plurality of mating sections defined on the band, at portions of the band positioned between two adjacent longitudinal members, wherein the plurality of mating sections are configured to be coupled to a coupling mechanism for coupling the 3D load bearing structure to an adjacent structure.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
An iso-truss structure and/or an iso-grid structure and/or an iso-beam structure, hereinafter referred to as a three-dimensional (3D) load bearing structure, may include a plurality of load bearing members joined at a plurality of nodes, and arranged so that the assembled plurality of load bearing members act together, as a single load bearing structure. In some implementations, the load bearing members may be arranged, and joined at the plurality of nodes, so that the load bearing members and nodes are positioned in multiple different planes, defining the 3D load bearing structure. In some implementations, the 3D load bearing structure may include a plurality of longitudinal members to provide for bending and axial strength of the 3D load bearing structure. In some implementations, the 3D load bearing structure may include a plurality of transverse members to carry shear and torsional forces applied to the 3D load bearing structure.
A 3D load bearing structure, in accordance with implementations described herein, may include a plurality of longitudinal members extending along a longitudinal length of the 3D load bearing structure. A plurality of transverse members may extend between the longitudinal members. In some implementations, the transverse members may be joined end to end so as to form one or more tetrahedral shapes defining a plurality of helical structures. Portions of the transverse members defining these tetrahedral shapes may be respectively joined to the longitudinal members at a plurality of nodes, to form a lattice type structure. In some implementations, the plurality of longitudinal members and the plurality of transverse members may be formed by a series of interwoven fibers, for example, carbon fibers, impregnated with epoxy. The interweaving of these fibers, particularly at the nodes, may join the longitudinal members and the transverse members. This interweaving at the nodes may provide for structural integration of the longitudinal members and the transverse members defining the 3D load bearing structure.
An example 3D load bearing structure 100, in accordance with implementations described herein, is shown in
The example 3D load bearing structure 100 may include a plurality of longitudinal members 110 extending axially, along a length L of the 3D load bearing structure 100. The plurality of longitudinal members 110 may define a longitudinal frame portion of the 3D load bearing structure 100. This longitudinal frame defined by the plurality of longitudinal members 110 may carry an axial load portion of a force exerted on, or a load borne by the 3D load bearing structure 100. The example 3D load bearing structure 100 shown in
The plurality of longitudinal members 110 defining the longitudinal frame portion of the 3D load bearing structure 100 may be arranged in parallel to each other, and in parallel with the central longitudinal axis A of the 3D load bearing structure 100. The arrangement of the longitudinal members 110 may be symmetric about any one of a plurality of different central planes extending through the central longitudinal axis A of the 3D load bearing structure 100. The exemplary central plane B extending through the central longitudinal axis A of the 3D load bearing structure 100 shown in
The longitudinal members 110 may carry an axial, or compressive, or bending load applied to the 3D load bearing structure 100. A plurality of polyhedral structures may be coupled to the longitudinal members 110 to provide reinforcement and buckling resistance to the longitudinal members 110. In some implementations, the polyhedral structures may follow a substantially helical pattern relative to the arrangement of longitudinal members 110. In some implementations, the polyhedral structures may follow another type of pattern relative to the longitudinal members 110. Hereinafter, for purposes of discussion and illustration, the polyhedral structures will be referred to as helical structures 130, and correspondingly described. The plurality of helical structures 130 may include a plurality of transverse members 120 arranged end to end to define the helical structures 130 (see
The plurality of helical structures 130 including the transverse members 120 may define a transverse frame portion of the 3D load bearing structure 100. This transverse frame portion of the 3D load bearing structure 100 defined by the plurality of helical structures 130/transverse members 120 may carry a torsional load portion of a force exerted on, or a load borne by the 3D load bearing structure 100. The transverse frame may be coupled to, or joined with, or intersect, or be integrally formed with, the longitudinal frame to form the 3D load bearing structure 100. That is, the helical structures 130 may be coupled to, or joined with, or intersect, or be integrally formed with, the longitudinal members 110 at a respective plurality of nodes 150.
In the example arrangement shown in
In some implementations, a band 180 is formed (e.g., attached, integrally formed) at each axial end of the 3D load bearing structure 100. In some implementations, the band 180 facilitates the connection of two adjacent 3D load bearing structures 100. For example, the band 180 of a first load bearing structure 100 may be positioned against, or abut, the band 180 of a second, adjacent 3D load bearing structure 100. The first and second load bearing structures 100 may be coupled by, for example, fasteners coupling the mating bands 180, brackets coupling the mating bands 180, and other methods of fastening and/or coupling. In some implementations, the bands 180 facilitate the coupling of the 3D load bearing structure 100 to other support structures such as, for example, mounting platforms, buildings, and the like. Coupling of adjacent 3D load bearing structures 100 to each other, and/or to other support structures, in this manner may provide for the construction of a larger structure, while maintaining the requisite load bearing capability and/or shear strength, and without the use of welding and/or corrosive materials which may otherwise compromise the integrity of the resulting structure. Coupling of adjacent 3D load bearing structures 100 to each other and/or to other support structures in this manner may allow for multiple smaller 3D load bearing structures 100 to be transported for configuration as necessary at an installation site, rather than the transport of a single, larger structure. Coupling of adjacent 3D load bearing structures 100 in this manner may provide flexibility in tailoring to accommodate space requirements, load bearing requirements and the like for a particular installation.
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In some implementations, a material from which the longitudinal members 110 and/or the helical structures 130/transverse members 120 are made may be selected, taking into account various different characteristics of the material (such as, for example, strength, weight, cost, availability and the like), together with required characteristics of the truss structure 100 (such as, for example, size, load bearing capability and the like). For example, in some implementations, the longitudinal members 110 and/or the transverse members 120 may be made of a carbon type material, a glass type material, a basalt type material, a kevlar type material, and other such materials.
The 3D load bearing structure 100 including longitudinal members 110 and/or helical structures 130/transverse members 120 made of, for example, a carbon fiber material may be relatively light in weight relative to, for example, a comparable support structure made of, for example, a metal material such as steel, while being capable of bearing the same (or a greater) load than the comparable support structure made of a metal material. In another comparison, the 3D load bearing structure 100 including longitudinal members 110 and/or helical structures 130/transverse members 120 made of this type of carbon fiber material may be considerably stronger than, for example, a comparable support structure made of, for example, a metal material, of essentially the same weight and/or size.
In some implementations, the 3D load bearing structure 100 including longitudinal members 110, the transverse members 120 defining the helical structures 130 and the bands 180 made of a carbon fiber material may be integrally formed. As noted above, the longitudinal members 110 may join, or intersect with, or be integrally formed with the transverse members 120 defining the helical structures 130 at the nodes 150. In an example in which the longitudinal members 110 and the helical structures 130/transverse members 120 are made of a carbon fiber material, the carbon fiber material may include, for example, a plurality of strands that woven together to form a node 150 that integrally couples, or joins, the corresponding longitudinal member 110 and helical structure 130. For example, strands of the longitudinal member(s) 110 may be alternately arranged with the strands of the helical structures 130/transverse members 120 at the nodes 150, thus providing for an interweaving of carbon fibers strands at the nodes 150, and creating a substantially integral 3D load bearing structure 100 from the longitudinal members 110 and the helical structures 130. In this example, the bands 180 at the axial ends of the 3D load bearing structure 100 (including the example flange 180A, the example annular collar 180B, the example hexagonal collar 180C and other such configurations) may be integrally formed with the longitudinal members 110 and the helical structures 130 of the 3D load bearing structure 100. In some implementations, this arrangement of the strands of the material of the longitudinal members 110, the strands of the material of the helical structures 130, and the strands of the material of the bands 180, may be guided by features of a manufacturing fixture, or a manufacturing jig, or a mandrel.
A portion of an example manufacturing fixture 300 is shown in
In some implementations, the guide structures 310, 330, 380 may include a series of pins and/or forks that guide the lay-in of the strands of carbon fiber material in a particular pattern and/or contour and/or shape. In some implementations, the guide structures 310, 330, 380 may include channels or grooves defining the desired pattern and/or shape and/or contour. In some implementations, each of the joints 350 may be formed by one or more pins or forks positioned at intersections of the guide structures 310, 330. In some implementations, the joints 350 may be formed at intersections of channels or grooves defining the guide structures 310, 330.
The strands of the material of the longitudinal member(s) 110, the strands of the material of the helical structure(s) 130 defined by the transverse member 120 may be alternately arranged in the joints 350 to achieve interweaving of the strands of the longitudinal member(s) 110 and the strands of the transverse member(s) 120/helical structure(s) at the nodes 150. Strands of the material of the longitudinal member(s) 110 and/or the strands of the material of the transverse member(s) 120/helical structure(s) 130 may similarly be wound into the guide structure 380 defining the band(s) 180 to achieve an interweaving of the bands 180 with the helical structures 130. This interweaving may in turn produce the resulting integral structure of the 3D load bearing structure 100.
In one example implementation, strands of material, for example, strands of pre-impregnated carbon fiber material, are wound in a first guide structure 380A defining the band 180 at a first end of the structure 100, to initiate a build-up of the band 180 at the first end of the structure 100. From the first guide structure 380A, strands of material can be fed into one of the guide structures 310 defining one of the longitudinal members 110, and into a second guide structure 380B defining the band 180 at a second end of the structure 100. After winding in the second guide structure 380B, the material can be fed into another of the guide structures 310 defining another of the longitudinal members 110. In this manner, each of the guide structures 310 respectively defining the longitudinal members 110 may have strands of material laid therein. In a similar manner, strands of material may be sequentially fed from one of the guide structures 380 defining the bands 180 into one of the guide structures 330 defining the helical structures 130. As strands of material are laid into the guide structures 330 defining the helical structures 130, the newly laid strands of material overlap previously laid strands of longitudinal material at the joints 350. The process of alternately laying strands of material into the guide structures 310 defining the longitudinal members 110 and the guide structures 330 defining the helical structures 130 may be repeated until an amount of material laid in the guide structures 310, 330 will produce a desired size and/or shape and/or contour of the longitudinal members 110 and the transverse members 120 defining the helical structures 130. In this manner, the longitudinal members 110, the helical structures 130 and the bands 180 may be formed of interwoven strands of material to form the integrally woven 3D load bearing structure 100.
Winding of the strands of material in the guide structures 380 defining the bands 180 may be continued, for example, after the desired amount of material has been laid in the guide structures 310, 330 to produce the longitudinal members 110 and transverse members 120 defining the helical structures. That is, strands of material may continue to be wound in the guide structures 380 defining the bands 180 to for example, extend the band 180 further radially outward to produce the annular flange 180A shown in
In some implementations, the strands of material received in the guide structures 310, 330, 380 and joints 350 formed in the manufacturing fixture 300 in this manner may be compressed in the manufacturing fixture 300, to, for example, facilitate the reduction and/or elimination of voids. In some implementations, for example, when the material is pre-impregnated with an epoxy/resin material, the material received in the manufacturing fixture 300 in this manner may then be processed, for example, cured, to form the interwoven, or integral 3D load bearing structure 100.
A band 180, such as the flange 180A and/or collars 180B, 180C described above, may facilitate the connection of two 3D load bearing structures 100 with the requisite shear strength without welding or the use of corrosive materials. For example, as shown in
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Each example coupling mechanism 500 may include a first plate 510, or a first bracket 510, and a second plate 520, or a second bracket 520. The first plate 510 may be, for example, an outer plate 510 that is positioned against an outward facing surface of the collar 180 of the first load bearing structure 100A and a corresponding outward facing surface of the collar 180 of the second load bearing structure 100B. That is, the first plate 510 spans or extends between a portion of the outward facing surface of the collar 180 of the first 3D load bearing structure 100A and a corresponding portion of the outward facing surface of the collar 180 of the second 3D load bearing structure 100B. The second plate 520 may be, for example, an inner plate 520 that is positioned against an inner facing surface of the collar 180 of the first load bearing structure 100A and a corresponding inner facing surface of the collar 180 of the second load bearing structure 100B. That is, the second plate 520 spans or extends between a portion of the inner facing surface of the collar 180 of the first 3D load bearing structure 100A and a corresponding portion of the inner facing surface of the collar 180 of the second 3D load bearing structure 100B. The first (outer) plate 510 may include openings 512 corresponding to the openings 410 in the collar 180 of the first load bearing structure 100A and the collar 180 of the second load bearing structure 100B. Similarly, the second (inner) plate 520 may include openings 522 corresponding to the openings 410 in the collar 180 of the first load bearing structure 100A and the collar 180 of the second load bearing structure 100B, and to the openings 512 in the first plate 510. Fasteners 550 may be inserted in the openings 512 in the first plate 510, through the openings 410 in the corresponding mating section 185 of the collar 180, and into the openings 522 in the second plate 520. Securing of the first and second plates in this manner, with a first portion secured to the first 3D load bearing structure 100A and a second portion secured to the second load bearing structure 100B, may limit or restrict relative lateral movement of the first and second 3D load bearing structures 100A, 100B.
In some implementations, a contour of the first plate 510 and a contour of the second plate 510 corresponds to a contour of the mating sections 185 of the collars 180 of the first and second load bearing structures 100A, 100B. In the example shown in
In some implementations, the openings 410 in the mating sections 185 of the collar 180 are formed after fabrication of the 3D load bearing structure 100. In some implementations, the fasteners 550 are bolts. In some implementations, epoxy may be filled in the openings 512 in the first plate 510, the openings 410 in the mating sections 185 of the collars 180 and the openings 522 in the second plate 520, and dowels may be fit into the openings 512, 410, 522. In some implementations, the dowels may be carbon fiber dowels. In some implementations, the first and second plates 510, 520 may be riveted to the mating sections 185 of the collars 180 of the first and second 3D load bearing structures 100A, 100B.
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The example coupling mechanism 700 shown in
In the foregoing disclosure, it will be understood that when an element, such as a layer, a region, or a substrate, is referred to as being on, connected to, or coupled to another element, it may be directly on, connected or coupled to the other element, or one or more intervening elements may be present. In contrast, when an element is referred to as being directly on, directly connected to or directly coupled to another element or layer, there are no intervening elements or layers present. Although the terms directly on, directly connected to, or directly coupled to may not be used throughout the detailed description, elements that are shown as being directly on, directly connected or directly coupled can be referred to as such. The claims of the application may be amended to recite exemplary relationships described in the specification or shown in the figures.
As used in this specification, a singular form may, unless definitely indicating a particular case in terms of the context, include a plural form. Spatially relative terms (e.g., over, above, upper, under, beneath, below, lower, and so forth) are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. In some implementations, the relative terms above and below can, respectively, include vertically above and vertically below. In some implementations, the term adjacent can include laterally adjacent to or horizontally adjacent to.
While certain features of the described implementations have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the scope of the implementations. It should be understood that they have been presented by way of example only, not limitation, and various changes in form and details may be made. Any portion of the apparatus and/or methods described herein may be combined in any combination, except mutually exclusive combinations. The implementations described herein can include various combinations and/or sub-combinations of the functions, components and/or features of the different implementations described.
This application claims priority to U.S. Provisional Application No. 63/199,459, filed on Dec. 30, 2020, entitled “ISO-TRUSS STRUCTURE INCLUDING COUPLING BAND,” and to U.S. Provisional Application No. 63/199,460, filed on Dec. 30, 2020, entitled “COUPLING MECHANISM FOR ISO-TRUSS STRUCTURE,” the disclosures of which are incorporated herein in their entireties.
Number | Date | Country | |
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63199459 | Dec 2020 | US | |
63199460 | Dec 2020 | US |