Carbon fiber structure, and a method for forming the carbon fiber structure

A method of making a carbon fiber boom structure having a length and comprising:

• an elongated upper carbon fiber tube;
• at least one elongated lower carbon fiber tube;
• and
• a plurality of carbon fiber/resin matrix uniting structures spaced apart along said length, each of said plurality of carbon fiber/resin matrix uniting structures bonded to each of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube to hold said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube in a spaced apart position along said length, each of said carbon fiber/resin matrix uniting structures being formed in a winding operation by applying windings of a carbon fiber string with a liquid resin around portions of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube;
• for each of said plurality of carbon fiber/resin matrix structures, said windings and said carbon fiber/resin matrix uniting structure defining an inner primary layer and an outer primary layer of said carbon fiber/resin matrix uniting structure, wherein a portion of said inner primary layer is bonded to a surface portion of each of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube that is oriented towards an inside of said carbon fiber/resin matrix uniting structure while a portion of said outer primary layer is bonded to a remaining surface portion of each of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube to completely, or essentially completely, envelope each of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube by said portion of said inner primary layer and said portion of said outer primary layer, the method comprising:
• providing a core device having a periphery with a plurality of elongated recesses, each of said plurality of recesses configured for receiving one of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube;
• providing a supply of said carbon fiber string with a liquid resin;
• positioning one or more spacer devices along said periphery;
• winding said carbon fiber string with said liquid resin around said core device with said one or more spacer devices to form said inner primary layer, with portions of said inner primary layer bridging said plurality of elongated recesses;
• removing said one or more spacer devices;
• pressing said portions of said inner primary layer into said plurality of elongated recesses;
• positioning said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube in a respective one of said plurality of elongated recesses with a first surface portion of each of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube bearing against a respective one of said portions of said inner primary layer;
• winding said carbon fiber string around said inner primary layer and second surface portions of said elongated upper carbon fiber tube and said at least one elongated lower carbon fiber tube to form said outer primary layer;
• curing said resin to bond said inner primary layer and said outer primary layer to each other and to said first surface portion and said second surface portions;
• before or after said curing removing said core device.