Importance

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Abstract

A method and apparatus is disclosed for forming integrated truss structures wherein the molding apparatus includes a plurality of alternating male mold members (17) and female mold members (29) arranged in two opposed layers or mold halves. The male mold members each have a plurality of open grooves (19, 19') formed therein which are disposed orthogonally therein and slope away from a top or plateau surface (21) thereof. Each of the female mold members (29) has a centrally located, generally circular recessed cavity (31) with a plurality of open grooves (33, 33') which are orthogonally disposed with regard to one another and which slop away from the plane of the recessed cavity (31). When the two layers each including male (17) and female (29) members are positioned opposite one another, the open grooves (19, 33) in opposed male and female members become aligned to define strut beam chambers (51) and plateau surface (21) of the male member is aligned with the recessed cavity (31) of the female member to define a junction chamber (53). Thus, a plurality of strut beam chambers (51) slope away from each junction chamber (53). When the mold halves are brought together they define between them alternate symmetrical upper and lower junction chambers interconnected by a plurality of strut chambers. Channels are formed preferably in the female members, for injecting a moldable material such as plastic into the struct beam chambers and the junction chambers. After injection occurs, the molds are separated to thereby form an integrally molded truss structure. The resulting integrated truss structures can be incorporated with exterior or interiorly mounted members to make composite truss panel structures having a wide variety of uses. The present invention also concerns techniques for securing such members to or within truss structures and the composite structures produced thereby.

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First Claim