Lightweight beam structure
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.
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.