Iso-truss structure

Abstract

An iso-truss structure ( 10 ) includes at least two helical components ( 30, 32 ) and at least one reverse helical component ( 34 ) attached thereto with opposing angular orientations. Each helical and reverse helical component preferably includes at least four elongate, straight segments ( 22 ) rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about a common axis ( 14 ) forming a first square cross section. The structure may further include at least two rotated helical components ( 80, 92 ) and at least one rotated reverse helical component ( 98 ) which are rotated with respect to the helical and reverse helical components forming a second square cross section, rotated with respect to the first. The structure may be straight, curved, flexible, or form angles.

1 . A structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         2 . A structural member in accordance with  claim 1 , wherein all of the helical components have continuous strands of fiber; and wherein the helical components are attached to one another at intersecting locations by over-lapping the fibers of the helical components.  
     
     
         3 . A structural member in accordance with  claim 1 , wherein the helical components define a hollow interior substantially void of material.  
     
     
         4 . A structural member in accordance with  claim 1 , wherein the helical components define openings there between.  
     
     
         5 . A structural member in accordance with  claim 1 , wherein helical components define an imaginary tubular member of square cross section.  
     
     
         6 . A structural member in accordance with  claim 1 , further comprising: 
 a) at least two, spaced apart, rotated helical components, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, each having: 
 1) a common rotated longitudinal axis,  
 2) a common angular orientation about the rotated longitudinal axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the rotated axis; and  
   b) at least one rotated reverse helical component, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, having: 
 1) a common rotated longitudinal axis with the at least two rotated helical components,  
 2) an opposing angular orientation with respect to the two rotated helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         7 . A structural member in accordance with  claim 6 , wherein the longitudinal axis and the rotated longitudinal axis are concentric, and the segments of the helical components form an imaginary tubular member having a cross section of an eight-pointed star.  
     
     
         8 . A structural member in accordance with  claim 6 , wherein the longitudinal axis and the rotated longitudinal axis are concentric, and the segments form an imaginary tubular member having a cross section of two squares having a common longitudinal axis, but with one square rotated with respect to the other.  
     
     
         9 . A structural member in accordance with  claim 1 , further comprising: 
 an end plate, attached at an end of the helical components, to attach the helical components to another object.    
     
     
         10 . A structural member in accordance with  claim 9 , wherein the helical components have continuous strands of fiber; and wherein the end plate is attached by winding the continuous strands of fiber around the end plate.  
     
     
         11 . A structural member in accordance with  claim 9 , wherein the end plate includes a perimeter, a plurality of indentations formed about the perimeter to receive strands of fiber, and a plurality of holes to attach the end plate to another object.  
     
     
         12 . A structural member in accordance with  claim 1 , 
 wherein the helical components and segments form a repeating pattern of triangles and tetrahedrons; and further comprising:    a connector, attached to the helical components and segments, to attach other objects to the helical components and segments, the connector being elongated and having a substantially triangular, cross sectional shape, the connector extending through at least two of the triangles formed by the helical components and segments.    
     
     
         13 . A structural member in accordance with  claim 1 , wherein the axes are vertically oriented, a lower end is attached to a support surface, and an upper end is located above the lower end; and further including another object attached to the upper end selected from the group consisting of: a sign placard with indicia; a horizontal utility member configured to hold utility lines; a light source.  
     
     
         14 . A structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis;  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis;  
   c) at least two, spaced apart, rotated helical components, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, each having: 
 1) a common rotated longitudinal axis,  
 2) a common angular orientation about the rotated longitudinal axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the rotated axis; and  
   d) at least one rotated reverse helical component, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, having: 
 1) a common rotated longitudinal axis with the at least two rotated helical components,  
 2) an opposing angular orientation with respect to the two rotated helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         15 . A structural member in accordance with  claim 14 , wherein the longitudinal axis and the rotated longitudinal axis are concentric, and the segments of the helical components form an imaginary tubular member having a cross section of an eight-pointed star.  
     
     
         16 . A structural member in accordance with  claim 14 , wherein the longitudinal axis and the rotated longitudinal axis are concentric, and the segments form an imaginary tubular member having a cross section of two squares having a common longitudinal axis, but with one square rotated with respect to the other.  
     
     
         17 . A structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration;  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
   c) the at least one reverse helical component forming an angle with respect to the at least two helical components greater than 60 degrees.    
     
     
         18 . A structural member in accordance with  claim 17 , wherein the at least one reverse helical component forms an angle with respect to the at least two helical components greater than approximately 75 degrees.  
     
     
         19 . A structural member in accordance with  claim 17 , wherein each helical component includes at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
     
     
         20 . A flexible structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration;  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least three elongate, straight segments connected end to end in a helical configuration; and  
   c) the helical members being laterally flexible, and are bendable between: 
 1) a first, straight position in which the axes are substantially straight; and  
 2) a second, arcuate position in which the axes are substantially arcuate.  
   
     
     
         21 . A structural member in accordance with  claim 20 , wherein the helical members store energy in the second, arcuate position.  
     
     
         22 . A structural member in accordance with  claim 20 , wherein the helical members are rotationally rigid about the longitudinal axes.  
     
     
         23 . An arcuate structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common arcuate axis,  
 2) a common angular orientation about the axis, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common arcuate axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration.  
   
     
     
         24 . A structural member in accordance with  claim 23 , wherein the arcuate axes are circular.  
     
     
         25 . A structural member in accordance with  claim 23 , wherein each helical component includes at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
     
     
         26 . A structural member in accordance with  claim 23 , wherein the arcuate axes include a first curvature, and a different second curvature.  
     
     
         27 . A tapering structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
   c) the segments of each helical component sequentially reducing in length along the axes such that the structural member tapers.    
     
     
         28 . A structural member in accordance with  claim 27 , wherein each helical component includes at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
     
     
         29 . A preform member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 at least three segments connected end to end in a helical configuration; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 at least three segments connected end to end in a helical configuration; and  
   c) the helical components including fiber and being flexible and collapsible until impregnated with a resin matrix.    
     
     
         30 . A preform member in accordance with  claim 29 , wherein the helical components include a plurality of strands of fiber bound together.  
     
     
         31 . A bicycle frame, comprising: 
 a) a handlebar location configured to attach to a handlebar and front fork;    b) a seat location configured to attach to a seat;    c) a peddle location configured to be attached to a peddle assembly;    d) a rear wheel location configured to be attached to a rear wheel;    e) a plurality of members, each extending to and between at least one of the handlebar, seat, peddle, and rear wheel locations; and    f) at least one of the members including: 
 1) at least two, spaced apart, helical components each having: 
 i) a common longitudinal axis, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
 
 2) at least one reverse helical component, attached to the at least two helical components, having: 
 i) a common longitudinal axis with the at least two helical components, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis in an opposing angular orientation.  
 
   
     
     
         32 . A bicycle frame in accordance with  claim 31 , wherein each helical component includes at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
     
     
         33 . A method for forming a structural member, comprising the steps of: 
 a) providing a mandrel;    b) wrapping a fiber around the mandrel in order to create at least two helical components, each component having at least four elongated, straight segments, the at least two helical components having a common longitudinal axis, a common angular orientation about the axis, and forming a single, substantially complete rotation about the axis;    c) wrapping a fiber around the mandrel in order to create at least one reverse helical component having at least four elongate, straight segments having a common longitudinal axis with the at least two helical components, but in an opposing angular orientation, and forming a single, substantially complete rotation about the axis;    d) adding a matrix to the fiber; and    e) curing the matrix.    
     
     
         34 . A method in accordance with  claim 33 , wherein the step of providing a mandrel further includes: 
 providing a mandrel having an elongated core, and a plurality of heads disposed longitudinally and radially about the core, each head configured to receive and hold fiber for at least two, opposing helical components, and including four angled indentations, two angled indentations for each helical component.    
     
     
         35 . A method in accordance with  claim 33 , further comprising the step of: 
 wrapping a fiber along a length of the mandrel in order to create at least one longitudinal component parallel with the longitudinal axes; and wherein the step of providing a mandrel further includes:    providing a mandrel having an elongated core, and a plurality of heads disposed longitudinally and radially about the core, each head configured to receive and hold fiber for at least two, opposing helical components and at least one longitudinal component, and including at least six indentations, including two angled indentations for each helical component and two indentations for the longitudinal component.    
     
     
         36 . A method in accordance with  claim 33 , wherein the step of providing a mandrel further includes providing a collapsible mandrel having: 
 a) an elongated, hollow tube including a plurality of holes,    b) an elongated core, removably disposed within the tube,    c) a plurality of inserts, removably disposed between the core and the tube, having a plurality of holes,    d) a plurality of pins, removably disposed in the holes of the tube and inserts, and    e) a plurality of heads disposed on the pins; and further including the steps of:    a) removing the core from the tube after curing;    b) removing the inserts from the core;    c) displacing the pins through the holes into the tube;    d) removing the tube; and    e) removing the heads.    
     
     
         37 . A utility pole, comprising: 
 a) an elongated member, vertically oriented, having a longitudinal axis and upper and lower ends, and being formed of: 
 1) at least two, spaced apart, helical components each having: 
 i) a common angular orientation about the longitudinal axis, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
 
 2) at least one reverse helical component, attached to the at least two helical components, having: 
 i) an opposing angular orientation with respect to the two helical components, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis;  
 
   b) an end plate, attached to the lower end of the elongated member, configured to attach the lower end of the elongated member to a support surface; and    c) an arm, attached to the elongated member near the upper end and extending generally horizontally, configured to hold a utility line.    
     
     
         38 . A utility pole in accordance with  claim 37 , wherein the elongated member further includes: 
 a) at least two, spaced apart, rotated helical components, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, each having: 
 1) a common rotated longitudinal axis,  
 2) a common angular orientation about the rotated longitudinal axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the rotated axis; and  
   b) at least one rotated reverse helical component, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, having: 
 1) a common rotated longitudinal axis with the at least two rotated helical components,  
 2) an opposing angular orientation with respect to the two rotated helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         39 . A utility pole in accordance with  claim 37 , wherein the segments of each helical component sequentially reduce in length along the axes such that the structural member tapers.  
     
     
         40 . A sign post, comprising: 
 a) an elongated member, vertically oriented, having a longitudinal axis and upper and lower ends, and being formed of: 
 1) at least two, spaced apart, helical components each having: 
 i) a common angular orientation about the longitudinal axis, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
 
 2) at least one reverse helical component, attached to the at least two helical components, having: 
 i) an opposing angular orientation with respect to the two helical components, and  
 ii) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis;  
 
   b) an end plate, attached to the lower end of the elongated member, configured to attach the lower end of the elongated member to a support surface; and    c) a sign, coupled to the elongated member, including indicia.    
     
     
         41 . A sign post in accordance with  claim 40 , wherein the elongated member further includes: 
 a) at least two, spaced apart, rotated helical components, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, each having: 
 1) a common rotated longitudinal axis,  
 2) a common angular orientation about the rotated longitudinal axis, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the rotated axis; and  
   b) at least one rotated reverse helical component, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, having: 
 1) a common rotated longitudinal axis with the at least two rotated helical components,  
 2) an opposing angular orientation with respect to the two rotated helical components, and  
 3) at least four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         42 . A sign post in accordance with  claim 40 , further comprising: 
 a) an arcuate member having a first end attached to the upper end of the elongated member, and also including: 
 1) at least two, spaced apart, helical components each having: 
 i) a common arcuate axis,  
 ii) a common angular orientation about the axis, and  
 iii) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
 
 2) at least one reverse helical component, attached to the at least two helical components, having: 
 i) a common arcuate axis with the at least two helical components,  
 ii) an opposing angular orientation with respect to the two helical components, and  
 iii) at least three elongate, straight segments rigidly connected end to end in a helical configuration; and  
 
   b) the sign is coupled to the arcuate member.    
     
     
         43 . A structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         44 . A structural member in accordance with  claim 43 , further comprising: 
 a) at least two, spaced apart, rotated helical components, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, each having: 
 1) a common rotated longitudinal axis,  
 2) a common angular orientation about the rotated longitudinal axis, and  
 3) four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the rotated axis; and  
   b) at least one rotated reverse helical component, attached to and rotated with respect to the at least two helical components and at least one reverse helical component, having: 
 1) a common rotated longitudinal axis with the at least two rotated helical components,  
 2) an opposing angular orientation with respect to the two rotated helical components, and  
 3) four elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.  
   
     
     
         45 . A structural member, comprising: 
 a) at least two, spaced apart, helical components each having: 
 1) a common longitudinal axis,  
 2) a common angular orientation about the axis, and  
 3) five elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis; and  
   b) at least one reverse helical component, attached to the at least two helical components, having: 
 1) a common longitudinal axis with the at least two helical components,  
 2) an opposing angular orientation with respect to the two helical components, and  
 3) five elongate, straight segments rigidly connected end to end in a helical configuration forming a single, substantially complete rotation about the axis.