Structural assembly and a method for its manufacture

Abstract

A structural assembly comprising profile members imparting axial strength to the assembly. The profile members extend along a length. Ribbon holds the profile members together along their length. The ribbon imparts lateral strength to the assembly by being braced to the profile members. A method for manufacturing the structural assembly comprises winding the ribbon about a support structure to form a bracing lattice, positioning the profile members in a predetermined position on the support structure; and bonding the profile members to the bracing lattice to form a structural assembly.

1 . A structural assembly comprising: 
 at least two profile members imparting axial strength to the assembly, each of the profile members extending along a length; and    at least one ribbon, the at least one ribbon holding the at least two profile members together along their length, the at least one ribbon imparting lateral strength to the assembly by being braced to the at least two profile members.    
   
   
       2 . The structural assembly according to  claim 1 , wherein the at least two profile members each have a longitudinal convexity, with the convexities of the at least two profile members facing away from one another, the at least one ribbon being braced upon the convexities.  
   
   
       3 . The structural assembly according to  claim 2 , wherein a width of the at least one ribbon is locally enlarged opposite the convexities.  
   
   
       4 . The structural assembly according to  claim 1 , wherein the at least two profile members each have a longitudinal concavity, with the concavities of the at least two profile members facing toward one another, the at least one ribbon being connected to an interior surface of the concavities of the at least two profile members.  
   
   
       5 . The structural assembly according to  claim 4 , wherein a width of the at least one ribbon is locally enlarged within the concavities.  
   
   
       6 . The structural assembly according to  claim 1 , wherein the at least one ribbon is wound in a spiral about the at least two profile members.  
   
   
       7 . The structural assembly according to  claim 1 , wherein the at least one ribbon is wound at a fixed longitudinal position along the length of the at least two profile members.  
   
   
       8 . The structural assembly according to  claim 1 , wherein the at least two profile members are each a pultrusion profile member made of a composite material.  
   
   
       9 . The structural assembly according to  claim 8 , wherein the composite material comprises an anti-UV additive.  
   
   
       10 . The structural assembly according to  claim 1 , wherein the at least one ribbon comprises reinforcing fibers.  
   
   
       11 . A method of manufacturing a structural assembly comprising: 
 providing at least two profile members and at least one ribbon;    winding the at least one ribbon about a support structure to form a bracing lattice;    positioning the at least two profile members in a predetermined position on the support structure; and    bonding the profile members to the bracing lattice to form a structural assembly.    
   
   
       12 . The method according to  claim 11 , wherein the step of positioning the at least two profile members on the support structure is performed prior to the step of winding the ribbon to the support structure whereby the bracing lattice is formed over the at least two profile members.  
   
   
       13 . The method according to  claim 11 , wherein the step of positioning the at least two profile members on the support structure is performed after the step of winding the ribbon to the support structure whereby the at least two profile members are positioned above the bracing lattice.  
   
   
       14 . The method according to  claim 13 , further comprising a step of winding another one of the at least one ribbon on the at least two profile members on the support structure to form another layer of the bracing lattice.  
   
   
       15 . The method according to  claim 11 , wherein the step of winding is performed by winding the at least one ribbon at fixed longitudinal positions on the profile members.  
   
   
       16 . The method according to  claim 11 , wherein the step of winding is performed by winding the at least one ribbon in a spiral on the profile members.  
   
   
       17 . A mandrel for producing a structural assembly, the mandrel comprising: 
 at least one faceplate having a face oriented outwardly;    corner members positioned at opposite ends of the at least one faceplate, the corner members each being adapted to support a profile member;    actuator members supporting the at least one faceplate and the corner members between an extended position in which a ribbon is wound about the mandrel so as to form a bracing lattice interrelating the profile members, and a collapsed position in which the mandrel is separated from the structural assembly resulting from a bonding of the bracing lattice and the profile members; and    channels defined in the face of the at least one faceplate to accommodate the ribbon wound on the mandrel.    
   
   
       18 . The mandrel according to  claim 17 , wherein the channels are arranged to form spirals of ribbon for the structural assembly being formed about the mandrel.  
   
   
       19 . The mandrel according to  claim 17 , wherein the channels are arranged to form annular members of ribbon at fixed intervals along the length of the mandrel.  
   
   
       20 . The mandrel according to  claim 17 , comprising three of the faceplate and three of the corner members.