A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.
B29C 70/36 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
E04C 5/07 - Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
B29C 51/10 - Forming by pressure difference, e.g. vacuum
A cross-corrugated support structure includes a sheet having a first and a second set of corrugations. The first set of corrugations is defined by a series of alternating ridges and grooves that extend the length of the sheet in a first direction. The second set of corrugations is also defined by a series of ridges and grooves that extend the length of the sheet in a second direction that intersects with the first direction. The intersection of the first and second set of corrugations creates cross-corrugations throughout the sheet. To provide compressive and tensile strengths suitable for large-scale construction applications, the sheet may be made of a carbonaceous material such as carbon fiber or graphite treated to rigidly retain a shape including the first and second set of corrugations within the sheet. The sheet may be reinforced by securing support members or additional corrugated sheets to the sheet.
E04C 5/07 - Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
B29C 70/36 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.
B29C 70/36 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
E04C 5/07 - Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
B29C 51/10 - Forming by pressure difference, e.g. vacuum
A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.
B29C 70/36 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
A cross-corrugated support structure is provided. The support structure has a sheet having a first and second set of corrugations. The first set of corrugations is defined by a series of alternating ridges and grooves that extend the length of the sheet in a first direction. The second set of corrugations is also defined by a series of ridges and grooves that extend the length of the sheet in a second direction that intersects with the first direction. The intersection of the first and second set of corrugations creates cross- corrugations throughout the sheet. To provide compressive and tensile strengths suitable for large-scale construction applications, the sheet may comprise a carbonaceous material such as carbon fiber or graphite treated to rigidly retain the first and second set of corrugations therein. The sheet is reinforced by securing support members or additional corrugated sheets thereto.
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
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