Lightweight beam structure

• US 8,347,572 B2
• Filed: 04/19/2011
• Issued: 01/08/2013
• Est. Priority Date: 04/19/2011
• Status: Active Grant

• Current Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: Piedmont, Gregory
• Primary Examiner(s): WENDELL, MARK R
• Application Number:
  US13/090,185
• Publication Number:
  US 20120266561A1
• Time in Patent Office: 630 Days
• Field of Search: 523/091, 523/094, 523/097
• US Class Current: 52/309.4
• CPC Class Codes: E04C 3/28 of materials not covered by groups E04C3/04 - E04C3/20
• CPC Class Codes: E04C 3/29 built-up from parts of different material, i.e. composite structures
• CPC Class Codes: E04C 3/291 with apertured web
• CPC Class Codes: Y10T 29/49634 Beam or girder

Abstract

A lightweight beam may have a triangular prism core and a triaxial fabric cover wrapped around the core, with at least one rod proximate an apex of the core. The rod may extend substantially parallel to a centerline of the core. Multiple lightweight beams may be joined to form a larger lightweight structure.

Claims

1. A beam comprising:

a triangular prism core comprising a first material, the core having a longitudinal centerline, a plurality of apexes, and a length;

at least one rod extending substantially parallel to the centerline of the core and proximate to one of the plurality of apexes; and

a cover woven of a yarn comprising a second material different from the first material, the cover disposed about the core and the at least one rod.

2. The beam of claim 1, wherein the second material comprises carbon fibers.

3. The beam of claim 2, wherein the first material comprises a foam.

4. The beam of claim 2, further comprising a bonding enhancement substance disposed between the cover and the core.

5. The beam of claim 1, wherein the cover is woven in an alternating over and under pattern.

6. The beam of claim 1, wherein the at least one rod extends substantially the length of the core.

7. The beam of claim 1, wherein the woven yarn forms a fabric, the cover comprises a plurality of layers of the fabric, and the at least one rod lies between the layers of the fabric.

8. The beam of claim 1, comprising two rods extending substantially parallel to the centerline of the core, and respectively proximate two of the plurality of apexes of the core.

9. The beam of claim 8, comprising three rods extending substantially parallel to the centerline of the core and respectively proximate three of the plurality of apexes of the core.

10. A lightweight beam structure comprising:

a plurality of lightweight beams joined to form a structure;

wherein each of the lightweight beams comprises;

a triangular prism core comprising a first material, the core having a longitudinal centerline and a plurality of apexes;

at least one rod extending substantially parallel to the centerline of the core and proximate to one of the plurality of apexes; and

a cover woven of a yarn comprising a second material different from the first material, the cover disposed about the core and the at least one rod.

11. A method of forming a beam, the method comprising the steps of:

providing a triangular prism core comprising a first material and having a longitudinal centerline;

providing at least one rod respectively proximate to at least one of the plurality of apexes of the core and extending substantially parallel to the centerline of the core; and

wrapping a cover woven of a yarn comprising a second material different from the first material about the core.

12. The method of claim 11, wherein the step of providing the at least one rod occurs prior to the step of wrapping the cover.

13. The method of claim 11, wherein:

the step of wrapping the cover comprises a step of wrapping a first layer of the cover around the core and a subsequent step of wrapping a second layer of the cover around at least a portion of the first layer of the cover; and

the step of providing the at least one rod occurs between the step of wrapping a first layer of the cover and the step of wrapping a second layer of the cover.

14. The method of claim 11, further comprising the step of applying a bonding enhancement substance to the core prior to wrapping the cover.

15. The method of claim 11, further comprising the step of treating the cover after the cover is wrapped about the core.

16. The method of claim 11, wherein the step of providing the core comprises fabricating the core from a foam.

17. The method of claim 16, wherein fabricating the core comprises extruding the foam longitudinally, so as to form the triangular prism.

18. The method of claim 11, wherein the step of providing the rod comprises fabricating the rod from carbon.

19. The method of claim 11, wherein the step of providing the rod comprises providing a second rod proximate a second apex of the plurality of apexes of the core and extending substantially parallel to the centerline of the core.

20. The method of claim 19, wherein the step of providing the rod comprises providing a third rod proximate a third apex of the plurality of apexes of the core and extending substantially parallel to the centerline of the core.