Columnar structural component and method of forming

Abstract

A columnar structural component and method of forming a columnar structural element from a sandwich panel includes forming a number of sets of recesses in the sandwich panel and bending the sandwich panel at each set of recesses to form a columnar structural element. The columnar structural component includes a number of support members at least partially disposed within an area bounded formed with the sandwich panel is bent in the areas of the sets of recesses.

1 . A method for forming a columnar structural element from a sandwich panel having first outer layer and a second outer layer separated from one another by a core, the second outer layer having a surface facing in a direction opposite the core, comprising:
 forming a number of sets of recesses in the sandwich panel;   bending the sandwich panel at each set of recesses to form a columnar structural element such that the second outer layer forms at least a first inner corner at a first set of recesses and a second inner corner at a second set of recesses; and   applying bonding material across the first inner corner such that the bonding material contacts the surface of the second layer facing in a direction opposite the core on opposing sides of the first set of recesses.   
     
     
         2 . The method of  claim 1 , wherein the forming of the sets of recesses includes forming a number of substantially continuous channels between a first end of the sandwich panel and a second end of the sandwich panel. 
     
     
         3 . The method of  claim 1 , wherein the forming a number of sets of recesses comprises forming a first set of recesses and a second set of recesses, and wherein the bending includes bending the sandwich panel at the first set of recesses to form a first round corner, and bending the sandwich panel at the second set of recesses to form a second round corner. 
     
     
         4 . The method of  claim 3 , wherein the forming a number of sets of recesses further comprises forming a third set of recesses and a fourth set of recesses, and wherein the bending includes bending the sandwich panel at the third set of recesses to form a third round corner, and bending the sandwich panel at the fourth set of recesses to form a fourth round corner. 
     
     
         5 . The method of  claim 1 , wherein the bending of the sandwich panel at least partially bounds an area. 
     
     
         6 . The method of  claim 5 , further comprising connecting at least one support member to the sandwich panel, wherein the support member is at least partially contained by the bounded area. 
     
     
         7 . The method of  claim 6 , wherein connecting at least one support member to the sandwich panel includes applying bonding material. 
     
     
         8 . The method of  claim 1 , wherein bending the sandwich panel forms a corner at each set of recesses, and wherein the method further comprises applying bonding material to at least one of the corners. 
     
     
         9 . The method of  claim 8 , wherein the applying bonding material includes applying bonding material at a first inner corner formed in an area of a first set of recesses and applying bonding material at a second inner corner formed at an area of a second set of recesses. 
     
     
         10 . The method of  claim 1 , further comprising securing the sandwich panel in the bent position for a period of time to allow the bonding material to cure. 
     
     
         11 . The method of  claim 10 , wherein the forming a number of sets of recesses includes forming recesses having a triangular cross-section. 
     
     
         12 . The method of  claim 1 , wherein adjacent surfaces of the recesses are angled such that the bending results in a 90-degree angle between a plane of the panel to one side of a set of recesses and a plane of the other side of the set of recesses. 
     
     
         13 . The method of  claim 1 , further comprising connecting a first edge of the sandwich panel to a second edge of the sandwich panel. 
     
     
         14 . A structural component comprising:
 a sandwich panel having first outer layer and a second outer layer separated from one another by a core, the second outer layer having a surface facing in a direction opposite the core, and wherein the sandwich panel is bent to bound at least part of an area such that the second outer layer forms at least a first inner corner at a first set of recesses and a second inner corner at a second set of recesses;   a support member disposed inside the bounded area and connected to the sandwich panel to form a columnar structural component, the sandwich panel and the support member cooperative to form a columnar structural component having at least a first inner corner and a second inner corner formed by the second outer layer; and   bonding material applied across the first inner corner such that the bonding material contacts the surface of the second layer facing in a direction opposite the core on opposing sides of the first set of recesses.   
     
     
         15 . The structural component of  claim 14 , wherein the sandwich panel includes a number of sets of recesses, wherein each set of recesses includes a number of substantially continuous channels between a first end of the sandwich panel and a second end of the sandwich panel. 
     
     
         16 . The structural component of  claim 14 , wherein the sandwich panel includes a round corner in the area of each of the sets of recesses. 
     
     
         17 . The structural component of  claim 16 , wherein each round corner includes a corresponding inner corner and bonding material applied to at least a portion of each inner corner. 
     
     
         18 . The structural component of  claim 15 , wherein the sandwich panel includes four sets of recesses corresponding to a first, second, third and fourth round corner of the sandwich panel. 
     
     
         19 . The structural component of  claim 15 , wherein the sandwich panel further comprises a first edge and a second edge, and wherein the sandwich panel is bent such that the first edge and the second edge are connected to each other. 
     
     
         20 . A method for forming a column from a sandwich panel having first outer layer and a second outer layer separated from one another by a core, the second outer layer having a surface facing in a direction opposite the core, comprising:
 bending the sandwich panel at the area of a first set of recesses and a second set of recesses to partially bound an area with the sandwich panel such that the second outer layer forms at least a first inner corner at the first set of recesses and a second inner corner at the second set of recesses;   applying bonding material across the first inner corner such that the bonding material contacts the surface of the second outer layer facing in a direction opposite the core on opposing sides of the first set of recesses;   connecting a support member to the sandwich panel, the support member at least partially within the bounded area; and   bending the sandwich panel at a third set of recesses and the fourth set of recesses to enclose the support member in the bounded area.   
     
     
         21 . (canceled)