CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Non-Provisional Application No. 17/449,204, filed on September 28, 2021, entitled ‘ISO-TRUSS STRUCTURE AND COUPLING MECHANISM FOR ISO-TRUSS STRUCTURE,” which claims priority to U.S. Provisional Application No. 63/199,459, filed on December 30, 2020, entitled “ISO-TRUSS STRUCTURE INCLUDING COUPLING BAND,” and to U.S. Provisional Application No. 63/199,460, filed on December 30, 2020, entitled “COUPLING MECHANISM FOR ISOTRUSS STRUCTURE,” the disclosures of which are incorporated herein in their entireties.

FIELD

[0002] 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.

BACKGROUND

[0003] 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 / isobeam 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.

SUMMARY

[0004] 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.

[0005] 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.

[0006] 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.

[0007] 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.

[0008] 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.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] 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.

[0013] 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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. lAis a side view, FIG. IB is a perspective view, and FIG. 1C is an axial end view, of an example three-dimensional load bearing structure, in accordance with implementations described herein.

[0015] FIGs. 2A-2C are partial perspective views of example three-dimensional load bearing structures, in accordance with implementations described herein.

[0016] FIG. 3 illustrates a manufacturing fixture, in accordance with implementations described herein.

[0017] FIGs. 4A-4C illustrate example bands of example three-dimensional load bearing structures, in accordance with implementations described herein.

[0018] FIGs. 5A-5C illustrate an example coupling mechanism for example three- dimensional load bearing structures, in accordance with implementations described herein.

[0019] FIGs. 6A and 6B illustrate an example coupling mechanism for example three- dimensional load bearing structures, in accordance with implementations described herein.

[0020] FIG. 7 is a perspective view of an example coupling mechanism for example three-dimensional load bearing structures, in accordance with implementations described herein.

[0021] FIGs. 8A-8D illustrate an installation process of the example coupling mechanism shown in FIG. 7, in accordance with implementations described herein.

[0022] FIGs. 9A-9B illustrate the example coupling mechanism shown in FIG. 7, coupling example annular flanges of example three-dimensional load bearing structures, in accordance with implementations described herein.

[0023] FIGs. 10A-10B illustrate the example coupling mechanism shown in FIG. 7, coupling example annular collars of example three-dimensional load bearing structures, in accordance with implementations described herein.

[0024] FIG. 11 illustrates the example coupling mechanism shown in FIG. 7, coupling example hexagonal collars of example three-dimensional load bearing structures, in accordance with implementations described herein.

DETAILED DESCRIPTION

[0025] 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.

[0026] 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.

[0027] An example 3D load bearing structure 100, in accordance with implementations described herein, is shown in FIGs. 1A-1C. In particular, FIG. lA is a side view of the example 3D load bearing structure 100, FIG. IB is a perspective view of the example 3D load bearing structure 100, and FIG. 1C is an axial end view of the example 3D load bearing structure 100. The example 3D load bearing structure 100 shown in FIGs. 1 A- 1C is illustrated in a substantially horizontal orientation, with a central longitudinal axis A of the example 3D load bearing structure 100 extending substantially horizontally, simply for purposes of discussion and illustration. The principles to be described herein with respect to the 3D load bearing structure 100 may also be applied to substantially vertical orientations of the 3D load bearing structure 100, as well as to a plurality of other orientations of the 3D load bearing structure 100.

[0028] 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 FIGs. 1A-1C includes six longitudinal members 110. In some implementations, the 3D load bearing structure 100 may include more, or fewer, longitudinal members 110. Numerous factors may affect the number of longitudinal members 110 included in the 3D load bearing structure 100. These factors may include, for example, a length of the 3D load bearing structure 100, a load to be carried by the 3D load bearing structure 100 (including, for example, an amount of torsional loading, an amount of bending loading, an amount of tension/compression loading, and other such loads which may be applied to the 3D load bearing structure 100), and the like.

[0029] 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 FIG. 1C is just one example of a central plane extending through the central longitudinal axis A of the 3D load bearing structure 100. The longitudinal members 110 of the 3D load bearing structure 100 may be symmetrically arranged about any number of different central planes extending through the central longitudinal axis of the 3D load bearing structure 100.

[0030] 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 FIG. IB). As noted above, the plurality of helical structures 130 may be coupled to the longitudinal members 110 to provide reinforcement to the longitudinal members 110, and/or to provide buckling resistance to the longitudinal members 110. In some situations, and/or in some arrangements of the components of the 3D load bearing structure 100, the helical structures 130 carry a torsional component of the load applied to the 3D load bearing structure 100. [0031] 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. FIG. IB highlights one of the plurality of helical structures 130, joined with the longitudinal members 110 at example nodes 150-1 through 150-13 along the length L of the 3D load bearing structure 100.

[0032] In the example arrangement shown in FIGs. 1 A-1C, the helical structures 130 are joined, at the nodes 150, to the longitudinal members 110 at portions of the helical structures 130 where a contour of the helical structure 130 changes direction, or said differently, at portions of the helical structures 130 at which the helical structure 130 forms an apex. For example, the helical structures 130 may be joined, at the nodes 150, to the longitudinal members 110 at portions of the helical structures 130 at which one transverse member 120 is joined to the next adjacent transverse member 120, causing the contour of the helical structure 130 to form an apex and change direction. In this arrangement, straight portions of the helical structures 130/transvers members 120 extend between adjacent longitudinal members 110, and between adjacent nodes 150. In the example shown in FIGs. 1A-1C, this results in a 3D load bearing structure 100 having a substantially hexagonal cross- sectional shape or contour when viewed axially, as in FIG. 1C. More, or fewer, longitudinal members 110 would produce a 3D load bearing structure having a different cross-sectional shape or contour. In some implementations, the longitudinal members 110 and the helical structures 130/transverse members 120 may be joined at straight portions of the transverse members 120, such that the nodes 150 occur at straight portions of the corresponding helical structure 130.

[0033] 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.

[0034] In the examples shown in FIGs. 1A-1C, the band 180 is substantially circular, simply for purposes of discussion and illustration. In some implementations, the band 180 may include other forms and/or shapes and/or contours. For example, in some implementations, the band 180 may extend radially outward to form a flange. In some implementations, the band 180 may extend axially along the longitudinal length of the 3D load bearing structure 100 to form a collar. In some implementations, the band 180 may incorporate a series of angles, or bends defining a polyhedral shape or cross-section. For example, in some implementations, the band 180 may bend or change direction at positions corresponding to the longitudinal members 110. In some implementations, portions of the band 180 extending between adjacent longitudinal members 110 may be substantially flat and/or straight and/or planar. In this type of arrangement, in an example 3D load bearing structure 100 including six longitudinal members 110 (as in the example shown in FIGs. 1A- 1C), the polyhedral shape or cross-section or contour of the band 180 would be a substantially hexagonal shape or cross-section or contour when viewed axially. Similarly, in an example 3D load bearing structure including eight longitudinal members, the band would have a substantially octagonal shape or contour when viewed axially.

[0035] FIGs. 2A-2C are perspective views of example bands 180 which may be included on the example 3D load bearing structure 100 shown in FIGs. 1 A-1C. As noted above, a shape and/or a contour of the bands 180 may vary based on, for example, a number of longitudinal members 110 included in the 3D load bearing structure, a magnitude of load to be borne by the 3D load bearing structure, a type of load to be carried by the 3D load bearing structure 100, connection and support requirements associated with installation of the 3D load bearing structure 100, environmental considerations associated with the installation of the 3D load bearing structure 100, and other such factors.

[0036] In particular, FIG. 2 A illustrates the 3D load bearing structure 100 including a substantially annular band that extends radially outward so as to form a flange 180A. FIG. 2B illustrates the 3D load bearing structure 100 including a substantially annular band that extends axially along the longitudinal direction of the 3D load bearing structure 100 so as to form a collar 180B. In the example shown in FIG. 2B, portions of the annular collar 180B extending between adjacent longitudinal members 110 have a curved, or arcuate shape, thus forming a substantially annular collar 180B. FIG. 2C illustrates the 3D load bearing structure 100 including a band that extends in the axial direction of the 3D load bearing structure 100, and that incorporates bends at portions corresponding to each of the longitudinal members 110 so as to form a polyhedral collar 180C. In the example shown in FIG. 2C, the polyhedral collar 180C is applied to the example 3D load bearing structure 100 having six longitudinal members 110, and thus the polyhedral collar 180C is substantially hexagonal, with portions of the polyhedral collar 180C extending between adjacent longitudinal members 110 being substantially planar so as to define the hexagonal shape or contour of the polyhedral collar 180C when viewed axially. In contrast, portions of the flange 180A shown in FIG. 2A extending between adjacent longitudinal members 110 have a curved, or arcuate shape corresponding to the annular configuration of the flange 180A. In some implementations, a band that includes bends such as the polyhedral collar 180C shown in FIG. 2C may be formed to extend radially outward so as to form a flange having a hexagonal shape, or a shape corresponding to a number of longitudinal members 110 as appropriate. .

[0037] 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.

[0038] 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.

[0039] 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.

[0040] A portion of an example manufacturing fixture 300 is shown in FIG. 3. As noted above, in some implementations, the strands of the material of the longitudinal member(s) 110 and the strands of the material of the transverse members 120 forming the helical structures 130 and the strands of the material of the band(s) 180 may be laid up, or woven, on the manufacturing fixture 300. The manufacturing fixture 300 may include guide structures 310 defining each of the longitudinal members 110, guide structures 330 defining each of the helical structures 130 formed by the transverse members 120, joints 350 defining points of intersection of the guide structures 310 of the longitudinal members 110 and the guide structures 330 of the helical structures 130 defined by the transverse members 120 corresponding to the nodes 150 (i.e., a joint 350 corresponding to each node 150), and a guide structure 380 at one or both end portions defining the band(s) 180. The guide structures 380 defining the bands 180 may define an internal shape or contour corresponding to the desired shape or contour of the resulting band 180. For example, the guide structure 380 may define an arcuate, or substantially circular contour to produce the annular flange 180A shown in FIG. 2A, or the annular collar 180B shown in FIG. 2B. More, or additional carbon fiber material may be laid on or filled in the guide structure 380 in the radial direction to produce the annular flange 180A shown in FIG. 2A. More or additional carbon fiber material may be laid on or filled in the guide structure 380 in the axial direction to produce the annular collar 180B shown in FIG. 2B. The interior contour of the guide structure 380 may incorporate bends with flat or planar portions extending therebetween to produce the hexagonal collar 180C shown in FIG. 2C.

[0041] 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.

[0042] 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.

[0043] In one example implementation, strands of material, for example, strands of pre-impregnated carbon fiber material, are wound in a first guide structure 380 A 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.

[0044] 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 FIG. 2A, to extend the band 180 further axially outward to produce the annular collar 180B shown in FIG. 2B or the hexagonal collar 180C shown in FIG. 2C, and the like. This allows the 3D load bearing structure 100 to be formed from a substantially continuous layup of strands of material to produce the interwoven, integral 3D load bearing structure 100, while producing a band 180 that is suitable for a desired application and/or installation of the 3D load bearing structure 100.

[0045] 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.

[0046] 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 FIGs. 4A-4C, in some implementations, openings 410, or holes 410 may be formed in the bands 180. The openings 410 may facilitate the insertion of fastening devices into the bands 180 of adjacent 3D load bearing structures 100, to secure the mating surfaces of the structures 100, and couple the adjacent structures 100 to each other. In some implementations, the openings 410 formed in the bands 180 may facilitate connection of mounting surfaces and the like to the 3D load bearing structures 100. In some implementations, the openings 410 in the bands 180 may facilitate the mounting of the 3D load bearing structures 100 to other support structures.

[0047] In particular, FIG. 4A illustrates the coupling of a first 3D load bearing structure 100 A coupled to a second 3D load bearing structure 100B. In the example shown in FIG. 4 A, the first and second load bearing structures 100 A, 100B include bands 180 formed as annular flanges 180 A. A plurality of openings 410A are formed in the flange 180 A of the first load bearing structure 100 A. A plurality of openings 410A are formed in the flange 180 A of the second load bearing structure 100B, at positions corresponding to the openings 410A in the flange 180A of the first load bearing structure 100A. The openings 410A in the flange 180 A of the first load bearing structure 100 A may be aligned with the openings 410 A in the flange 180 A of the second load bearing structure 100B, and fasteners (not shown in FIG. 4 A) may be inserted through the aligned openings 410Ato couple the first and second load bearing structures 100 A, 100B. In some implementations, the fasteners may be made of a non-corrosive material. For example, in some implementations, a fastening mechanism employing quasi-isotropic laminate materials together with pultruded carbon pins may be used to join the first and second load bearing structures 100 A, 100B shown in FIG. 4 A.

[0048] In the example shown in FIG. 4B, the first and second load bearing structures IOO A, 100B include bands 180 formed as annular collars 180B. A plurality of openings 41 OB are formed in the annular collar 180B of the first load bearing structure 100 A and the second load bearing structure 100B. In mating the first and second load bearing structures 100 A,

IOOB, the first and second load bearing structures 100 A, 100B may be aligned so that, for example, the respective longitudinal members 110, and mating sections 185B of the annular collar 180B therebetween, are aligned, as shown in FIG. 4B. A coupling mechanism may extend between mating sections 185B of the adjacent annular collars 180B to couple the first load bearing structure 100 A and the second load bearing structure 100B. Coupling mechanisms will be described in more detail below with respect to FIGs. 5A-5C.

[0049] In the example shown in FIG. 4C, the first and second load bearing structures

IOOA, 100B include bands 180 formed as hexagonal collars 180C. A plurality of openings 410C are formed in the collar 180C of the first load bearing structure 100 A and the second load bearing structure 100B. In mating the first and second load bearing structures 100 A,

IOOB, the first and second load bearing structures 100 A, 100B may be aligned so that, for example, the respective longitudinal members 110, and mating sections 185C of the collar 180C therebetween, are aligned, as shown in FIG. 4C. A coupling mechanism may extend between mating sections 185C of the adjacent collars 180C to couple the first load bearing structure 100 A and the second load bearing structure 100B. Coupling mechanisms will be described in more detail below with respect to FIGs. 5A-5C.

[0050] FIG. 5 A is an isometric view of coupling of the first load bearing structure 100A and the second load bearing structure 100B by a coupling mechanism 500. FIG. 5B is a top view of the first and second load bearing structures 100 A, 100B shown in FIG. 5 A. FIG. 5C is a cross-sectional view taken along line C-C of FIG. 5B. In this example, the first and second load bearing structures 100 A, 100B include bands 180 in the form of a hexagonal collar 180C, with openings 410C formed therein as shown in FIG. 4C, simply for purposes of discussion and illustration. The principles to be described may be applied to other types of bands 180, and in particular bands 180 having a collar configuration including the annular collar 180B described above, as well as other configurations.

[0051] In the example shown in FIGs. 5A and 5B, a coupling mechanism 500 is provided at each mating section 185 of the collars 180 of the first and second load bearing structures 100A, 100B. In some implementations, fewer coupling mechanisms 500 may be used to couple the first and second load bearing structures 100 A, 100B. For example, in some implementations, coupling mechanisms 500 may be omitted for one or more mating sections 185 of the collars 180, i.e., coupling mechanisms 500 may be provided at only some of the mating sections 185 of the collars 180 of the first and second load bearing structures 100A, 100B.

[0052] 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 100 A 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 100 A 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 100 A 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 100 A 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 100 A 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 100 A 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 100 A 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 100 A, 100B.

[0053] 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 FIGs. 5A-5C, in which the mating sections 185 of the collar 180 extending between adjacent longitudinal members 110 is substantially flat, or substantially planar, the first and second plates 510, 520 may be substantially planar. Similarly, in an example in which the mating sections 185 of the collar 180 extending between adjacent longitudinal members 185 is arcuate (as in the annular collar 180B shown in FIG. 2B), the first and second plates 510, 520 may be substantially arcuate, to correspond to the contour of the mating sections 185 of the collars 180 of the first and second load bearing structures 100 A, 100B.

[0054] 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.

[0055] FIGs. 6A and 6B are isometric views of the coupling mechanisms 500, as described above with respect to FIG. 5 A, coupled to a single 3D load bearing structure 100 A. Attachment of the coupling mechanisms 500 to the single 3D load bearing structure 100 in this manner may allow for coupling of other support structure(s) to the 3D load bearing structure 100 to, for example, mount components on the 3D load bearing structure 100 and the like. In some implementations, attachment of the coupling mechanisms to the single 3D load bearing structure 100 in this manner may allow for the direct mounting of components to the 3D load bearing structure 100. In some implementations, attachment of the coupling mechanisms to the single 3D load bearing structure 100 in this manner may allow for mounting of the 3D load bearing structure 100 to an external support structure. In the example shown in FIGs. 6A and 6B, the coupling mechanisms 500 are coupled to a 3D load bearing structure 100 having a band 180 formed as an annular collar 180B, as described above with respect to FIG. 2B, simply for purposes of discussion and illustration. The principles to be described may be applied to 3D load bearing structures including bands having other configurations as described above.

[0056] In the examples shown in FIGs. 5A-5C and 6A-6B, each of the coupling mechanisms 500 is positioned at corresponding mating sections 185 of the bands 180 of the respective 3D load bearing structure 100. In these example implementations, each coupling mechanism 500 is positioned within the mating sections 185 of the bands 180 defined between two adjacent longitudinal members 110, such that the first and second plates 510, 520 do not extend to a portion of the bands 180 corresponding to the longitudinal members 110. Accordingly, in this arrangement, a gap is formed between adjacent coupling mechanisms 500 as shown. [0057] In the examples shown in FIGs. 5A-5C and 6A-6B, the first plate 510 and the second plate 520 are substantially square, or rectangular, and have substantially the same configuration (size and/or shape and/or thickness), simply for purposes of discussion and illustration. In some examples, the first plate 510 and/or the second plate 520 can have different sizes and/or shapes and/or thicknesses than shown. In some examples, some or all of the plates 510, 520 can have different configurations than others of the plates 510, 520. In some examples, more than one first plate 510 and more than one second plate 520 may be positioned at a particular mating section 185 of the 3D load bearing structure(s) 100. In some examples, not all of the mating sections 185 of the 3D load bearing structure(s) 100 may be coupled or mated by a coupling mechanism 500.

[0058] In the examples shown in FIGs. 5A-5A-5C and 6A-6B, each of the example coupling mechanisms 500 includes both the first plate 510 and the second plate 520. In some examples, the bands 180 of adjacent 3D load bearing structures 100 may be coupled by just the first plate 510, or just the second plate 520, with fasteners extending through the aligned openings in the first or second plate 510, 520 and the mating sections 185 of the first and second load bearing structures 100. In this type of example arrangement, the fasteners may be fixed directly in, or on, the surface of the band 180 on which a plate 510/520 is not positioned.

[0059] FIG. 7 is a side view of a coupling mechanism 700 which may be used to couple first and second 3D load bearing structures, in accordance with implementations described herein. The example coupling mechanism 700 includes a first plate 710 and a second plate 720. Fasteners 730 extend through the first plate 710 and into the second plate 720. In the example shown in FIG. 7, the fasteners 730 (730A, 730B) are in the form of bolts each including a shaft portion 732, a head portion 734 at a first end portion of the shaft portion 732, and a nut 736 threadably engaged at a second end portion of the shaft portion 732. In the example arrangement shown in FIG. 7, the head portion 734 abuts an upper surface portion of the first plate 710, and the nut 736 abuts a lower surface portion of the second plate 720. The bands 180 of first and second 3D load bearing structures 100 A, 100B to be coupled by the coupling mechanism 700 may be received and retained in the space defined by the first and second plates 710, 720 and the fasteners 730. This will be described in more detail with respect to FIGs. 8A-8D.

[0060] As shown in FIGs. 8 A and 8B, with the band 180 of the first 3D load bearing structure 100 A aligned with the band 180 of the second 3D load bearing structure 100B, the first plate 710, for example with the first end portions of the fasteners 730 inserted through openings in the first plate 710, is positioned so as to abut an edge portion of the band 180 of the first 3D load bearing structure 100 A. As shown in FIGs. 8C and 8D, once the first plate 710 and fasteners 730 are positioned, the second plate 720 may be positioned so as to abut an edge portion of the band 180 of the second 3D load bearing structure 100B. The nuts 736 may be coupled onto the threaded second end portions of the shaft portions 732 of the fasteners 730, so as press the second plate 720 against the edge portion of the band 180 of the second 3D load bearing structure 100B and secure a relative position of the first and second 3D load bearing structures 100 A, 100B.

[0061] In the example shown in FIGs. 8A-8D, the fasteners 730 are in the form of bolts including a shaft portion 732, a head portion 734 at a first end portion of the shaft portion 732, and a bolt threadably coupled to a second end portion of the shaft portion 732, simply for ease of discussion and illustration. Other types of fasteners may be used to secure a position of the bands 180 of the first and second 3D load bearing structures 100 A, 100B between the first and second plates 710, 720 of the example coupling mechanism 700.

[0062] FIG. 9Ais an isometric view, and FIG. 9B is a side view, illustrating the coupling of a first 3D load bearing structure 100 A and a second 3D load bearing structure 100B, each having bands 180 in the form of annular flanges 180 A, by the coupling mechanism 700 described above with respect to FIGs. 7 and 8A-8D. The example arrangement shown in FIGs. 9A and 9B includes a plurality of the coupling mechanisms 700, located at positions corresponding to the longitudinal members 110 of the first and second 3D load bearing structures 100A, 100B, simply for ease of discussion and illustration. The first and second load bearing structures 100 A, 100B may be coupled at their respective annular flanges 180Aby more, or fewer, coupling mechanisms 700 than shown in FIGs. 9A and 9B, and/or coupling mechanisms 700 arranged differently than shown in FIGs. 9A and 9B.

[0063] The example coupling mechanism 700 shown in FIGs. 8A-8D and 9A-9B includes two fasteners 730 connecting the first and second plates 710, 720, simply for purposes of discussion and illustration. In some examples, more, or fewer fasteners 730 may couple the first and second plates 710, 720. In some examples, a single fastener in the form of, for example, a U-bolt may extend around mating sections 185 of the bands 180 of adjacent load bearing structures 100 to couple the load bearing structures 100, either with or without one or both of the plates 710 in place as shown.

[0064] FIG. lOAis an isometric view, and FIG. 10B is a side view, illustrating the coupling of a first 3D load bearing structure 100A and a second 3D load bearing structure 100B, each having bands 180 in the form of annular collars 180B, by the coupling mechanism 700 described above with respect to FIGs. 7 and 8A-8D. The example arrangement shown in FIGs. 10A and 10B includes a plurality of the coupling mechanisms 700, located at positions corresponding to the longitudinal members 110 of the first and second 3D load bearing structures 100A, 100B, simply for ease of discussion and illustration. The first and second load bearing structures 100 A, 100B may be coupled at their respective annular collars 180B by more, or fewer, coupling mechanisms 700 than shown in FIGs. 10A and 10B, and/or coupling mechanisms 700 arranged differently than shown in FIGs. 10A and 10B.

[0065] FIG. 11 is an isometric view illustrating the coupling of a first 3D load bearing structure 100A and a second 3D load bearing structure 100B, each having bands 180 in the form of a hexagonal collar 180C, by the coupling mechanism 700 described above with respect to FIGs. 7 and 8A-8D. The example arrangement shown in FIG. 11 includes a plurality of the coupling mechanisms 700, located at positions corresponding to the longitudinal members 110 of the first and second 3D load bearing structures 100 A, 100B, simply for ease of discussion and illustration. The first and second load bearing structures 100 A, 100B may be coupled at their respective hexagonal collars 180C by more, or fewer, coupling mechanisms 700 than shown in FIG. 11, and/or coupling mechanisms 700 arranged differently than shown in FIG. 11.

[0066] 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.

[0067] 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.

[0068] 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.