# US 9,435,060 B2 · Continuous wound composite truss structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,435,060 B2 - Document ID: US9435060B2 - Status: Granted - Kind: B2 - Application number: 13/874,865 - Filed: 2013-05-01 - Published: 2013-11-07 - Granted: 2016-09-06 - Earliest claimed: 2012-05-01 - Assignees: University of Maryland - Applicants: University of Maryland - Inventors: Benjamin K. S. Woods; Benjamin Otto Berry; Vladimir Bohdan Stavnychyi - Web page: https://patentgrep.com/patent/US9435060B2 ## CPC - D04C 1/06: Braid or lace serving particular purposes - B29C 53/58: helically - B64C 3/185: {Spars} - B64C 3/22: Geodetic or other open-frame structures - B64C 27/473: Constructional features - D04C 3/48: Auxiliary devices - E04C 3/291: {with apertured web} - B64C 2027/4736: {from composite materials} - D04C: BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE (machines for making soles from strips of material A43D29/00; cane working B27J1/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B64C: AEROPLANES; HELICOPTERS - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract Ultra-efficient composite truss structures and methods for manufacturing the same using low cost and high throughput winding processes are presented. The present disclosure describes combining the high structural efficiency of truss structures with the excellent mechanical properties of composite materials using processes that mitigate the high manufacturing costs typical of composite materials. The present disclosure further describes creating the members of the truss structure through continuous winding of either thermoset or thermoplastic matrix, fiber reinforced composite members around a central mandrel. The longitudinal chord members of the truss are held in position by the mandrel, and the web members are wrapped under the chord members, over them, or both. The web members are bonded to the chord members during manufacture to produce a single consolidated truss structure. ## Claims ### Claim 1 A truss structure manufactured using a winding process, the process comprising the steps of: fastening at least two chord members in proximity to each other around at least one mandrel; operatively connecting the at least one mandrel and the at least two chord members to a winding apparatus; actuating the winding apparatus to rotate the at least one mandrel and the at least two chord members to wind material around at least the two chord members from a first location to a second location which is spaced apart from the first location wherein winding the material around the at least two chord members creates a portion of the truss structure; and removing each of the at least one mandrel after completion of the actuating step. ### Claim 2 (depends on 1) The truss structure according to claim 1, wherein, during the actuating step, the material continuously winds around the at least two chord members and makes contact with the at least two chord members at repeating intervals. ### Claim 3 (depends on 1) The truss structure according to claim 1, wherein a plurality of continuous wound web members is formed along the truss structure from a continuous section of the material. ### Claim 4 (depends on 1) The truss structure according to claim 1, wherein the truss structure comprises the at least two chord members extending the length of the truss structure and contacting a plurality of continuous web members wrapped around the at least two chord members. ### Claim 5 (depends on 3) The truss structure according to claim 3, wherein the plurality of continuous wound web members wrap around the at least two chord members in a quasi-helical fashion. ### Claim 6 (depends on 1) The truss structure according to claim 1, in which the at least one mandrel extends substantially the length of the truss structure. ### Claim 7 (depends on 1) The truss structure according to claim 1, wherein the truss structure includes fiber reinforced composite materials. ### Claim 8 (depends on 1) The truss structure according to claim 1, wherein the first location is in proximity to a first end of the at least two chord members and the second location is in proximity to a second end of the at least two chord members. ### Claim 9 (depends on 1) The truss structure according to claim 1, wherein the actuating step comprises actuating the winding apparatus in one of manually and automatically. ### Claim 10 A truss structure comprising: at least two chord members extending the length of the truss structure; and material wound around the at least the two chord members from a first location to a second location which is spaced apart from the first location, wherein the material wound around the at least two chord members forms a plurality of continuous wound web members between the first location and the second location, and wherein the at least two chord members and the material wound around the at least two chord members define an internal volume that is free of structure therewithin. ### Claim 11 (depends on 10) The truss structure according to claim 10, wherein the plurality of continuous wound web members contact the at least two chord members at repeating intervals from the first location to the second location. ### Claim 12 (depends on 10) The truss structure according to claim 10, wherein the material forming the plurality of continuous wound web members is wound around the at least two chord members in a quasi-helical fashion. ### Claim 13 (depends on 10) The truss structure according to claim 10, wherein the internal volume is configured to accommodate and subsequently remove a mandrel or a plurality of mandrels that extend in proximity to the at least two chord members. ### Claim 14 (depends on 10) The truss structure according to claim 10, wherein the internal volume is configured to accommodate and subsequently remove a mandrel that extends or a plurality of mandrels that extend the length of the truss structure. ### Claim 15 (depends on 10) The truss structure according to claim 10, further comprising a plurality of reinforcement members each attached to a respective member of the plurality of continuous wound web members. ### Claim 16 (depends on 10) The truss structure according to claim 10, wherein the first location is in proximity to a first end of the at least two chord members and the second location is in proximity to a second end of the at least two chord members. ### Claim 17 (depends on 10) The truss structure according to claim 10, wherein the truss structure includes fiber reinforced composite materials. ### Claim 18 (depends on 10) The truss structure according to claim 10, wherein the truss structure is manufactured using a continuous winding process for winding the material around the at least two chord members. ### Claim 19 (depends on 13) The truss structure according to claim 13, wherein the internal volume defines a cross-section that is identical to a cross-section of a mandrel around which the truss structure is manufactured. ### Claim 20 A method for manufacturing a truss structure comprising the steps of: fastening at least two chord members in proximity to each other around at least one mandrel; operatively connecting the at least one mandrel and the at least two chord members to a winding apparatus; actuating the winding apparatus to rotate the at least one mandrel and the at least two chord members to wind material around at least the two chord members from a first location to a second location which is spaced apart from the first location, wherein each pass of the material wound around the at least two chord members creates a portion of the truss structure; and removing each of the at least one mandrel after completion of the actuating step. ### Claim 21 (depends on 20) The method according to claim 20, wherein during the actuating step, the material continuously winds around the at least two chord members and makes contact with the at least two chord members at repeating intervals. ### Claim 22 (depends on 20) The method according to claim 20, wherein a plurality of continuous wound web members is formed along the truss structure from a continuous section of the material. ### Claim 23 (depends on 20) The method according to claim 20, wherein the truss structure comprises the at least two chord members extending the length of the truss structure and is in contact with a plurality of continuous wound web members wrapped around the at least two chord members. ### Claim 24 (depends on 22) The method according to claim 22, wherein the material forming the plurality of continuous wound web members is wrapped around the at least two chord members in a quasi-helical fashion. ### Claim 25 (depends on 20) The method according to claim 20, wherein the step of fastening at least two chord members in proximity to each other around at least one mandrel includes fastening at least one mandrel that extends the length of the truss structure. ### Claim 26 (depends on 20) The method according to claim 20, wherein the step of fastening at least two chord members in proximity to each other around at least one mandrel includes fastening a plurality of mandrels along the length of the truss structure. ### Claim 27 (depends on 20) The method according to claim 20, further comprising providing at least one reinforcement member at least one selected location of the wound material. ### Claim 28 (depends on 20) The method according to claim 20, wherein the first location is in proximity to a first end of the at least two chord members and the second location is in proximity to a second end of the at least two chord members. ### Claim 29 (depends on 20) The method according to claim 20, wherein the actuating step comprises actuating the winding apparatus in one of manually and automatically.