Composite material support structures with sinusoidal webs and method of fabricating same

A support structure, comprising:

• a laminated web formed from composite materials and having a longitudinal edge and an undulated profile extending in a longitudinal direction;
• a preform formed from composite materials, having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform is formed from tows of fiber that extend continuously through the base and legs;
• wherein
• the longitudinal edge of the web is mounted in the channel;
• and wherein
• the web tapers in height in the longitudinal direction such that the structure is greater in height on one end than an opposite end.

A support structure, comprising:

• a laminated web formed from composite materials and having a longitudinal edge and an undulated profile extending in a longitudinal direction;
• a preform formed from composite materials, having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform is formed from tows of fiber that extend continuously through the base and legs;
• wherein
• the longitudinal edge of the web is mounted in the channel;
• and wherein
• the base of the preform is inclined at a non-orthogonal angle relative to the web.

A structure, comprising:

• a laminated web formed from composite materials and having a pair of straight longitudinal edges and an undulated profile with an alternating bead configuration extending in a longitudinal direction that is spaced apart from both of the straight longitudinal edges in a direction transverse to the longitudinal direction;
• a generally pi-shaped composite preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform is formed from tows of fiber that extend continuously through the base and legs;
• a laminate member mounted to the base of the preform opposite the web;
• and wherein
• the channel of the preform captures the longitudinal edge of the web such that the legs of the preform are free of contact with the undulated profile.

A structure, comprising:

• a laminated web formed from composite materials and having a pair of longitudinal edges, the web and a longitudinal edge having an undulated profile with contours extending in a longitudinal direction;
• a generally pi-shaped composite preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform is formed from tows of fiber that extend continuously through the base and legs;
• a laminate member mounted to the base of the preform opposite the web;
• wherein
• the channel of the preform captures the longitudinal edge of the web such that the legs of the preform are shaped to the contours of the undulated profile of the longitudinal edge;
• and wherein
• the web tapers in the longitudinal direction such that the structure is greater in height on one end than an opposite end.

A structure, comprising:

• a laminated web formed from composite materials and having a pair of longitudinal edges, the web and a longitudinal edge having an undulated profile with contours extending in a longitudinal direction;
• a generally pi-shaped composite preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform is formed from tows of fiber that extend continuously through the base and legs;
• a laminate member mounted to the base of the preform opposite the web;
• wherein
• the channel of the preform captures the longitudinal edge of the web such that the legs of the preform are shaped to the contours of the undulated profile of the longitudinal edge;
• and wherein
• the laminate member is inclined at a non-orthogonal angle relative to the web.

A method for fabricating a support structure, comprising the steps of:

• (a) providing a laminated web formed from composite materials and having a longitudinal edge and an undulated profile extending in a longitudinal direction;
• (b) forming a preform from composite materials, the preform having a base with a pair of legs extending integrally therefrom to define a channel therebetween, wherein the preform has woven or braided tows of fiber that extend continuously through the base and legs in a resinous matrix;
• (c) mounting the longitudinal edge of the web in the channel of the preform such that the legs of the preform straddle the longitudinal edge of the web;
• and
• (d) shaping the legs of the preform to the longitudinal edge of the web to form a support structure.

A method for fabricating a support structure, comprising the steps of:

• (a) providing a laminated web formed from composite materials and having a longitudinal edge and an undulated profile extending in a longitudinal direction;
• (b) forming a preform from composite materials, the preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform has tows of fiber that extend continuously through the base and legs in a resinous matrix;
• (c) mounting the longitudinal edge of the web in the channel of the preform such that the legs of the preform straddle the longitudinal edge of the web;
• (d) shaping the legs of the preform to the longitudinal edge of the web to form a support structure;
• and
• (e) tapering the web in a longitudinal direction such that the beam is greater in height on one end than an opposite end.

A method for fabricating a support structure, comprising the steps of:

• (a) providing a laminated web formed from composite materials and having a longitudinal edge and an undulated profile extending in a longitudinal direction;
• (b) forming a preform from composite materials, the preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform has tows of fiber that extend continuously through the base and legs in a resinous matrix;
• (c) mounting the longitudinal edge of the web in the channel of the preform such that the legs of the preform straddle the longitudinal edge of the web;
• (d) shaping the legs of the preform to the longitudinal edge of the web to form a support structure;
• and
• (e) inclining the base of the preform at a non-orthogonal angle relative to the web.