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A pultruded composite tension rod of hexagonal cross section is provided, as are larger composite rods made up of assemblies of smaller, nested-together parallel hexagonal tension rods that are re-pultruded together. A manufacturing process involving assembling and re-pultruding the smaller rods is

A pultruded composite tension rod of hexagonal cross section is provided, as are larger composite rods made up of assemblies of smaller, nested-together parallel hexagonal tension rods that are re-pultruded together. A manufacturing process involving assembling and re-pultruding the smaller rods is also disclosed.

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1. A tension rod combined in the rigging system of a sailing vessel and forming at least one rigging line in said rigging system, said rod comprising a pultrudate of composite material, said material comprising fiber-reinforced resin, said pultrudate having a hexagonal cross-section, said pultrudate

1. A tension rod combined in the rigging system of a sailing vessel and forming at least one rigging line in said rigging system, said rod comprising a pultrudate of composite material, said material comprising fiber-reinforced resin, said pultrudate having a hexagonal cross-section, said pultrudate having a terminal fitting on at least one end.2. A tension rod comprising a first-stage pultrudate of composite material, said material comprising fiber-reinforced resin, said rod being one of an assembly of like rods bonded together by heat-curable resin in parallel relationship with each other and forming at least the principal part of a second-stage pultrudate, said second-stage pultrudate having an overall cross-section whose principal component is a tessellation of hexagonal sections each corresponding to its own associated one of said like rods, said tessellation being centered on the center of the overall cross-section of said second stage pultrudate, and said tessellation having a rotational symmetry of 60 degrees.3. An article as in claim 2, said rod being one of an assembly of at least 7 like rods, including a core rod and 6 surrounding rods, nested together in parallel relationship and pulled through a second-stage pultrusion die to form a larger rod having a cross-sectional area at least 7 times that of each of the assembled rods.4. A tension rod comprising a first-stage pultrudate of composite material, said material comprising fiber-reinforced resin, said rod being one of an assembly of like rods nested together in parallel relationship and forming at least the principal part of a second-stage pultrudate, said second-stage pultrudate having an overall cross-section whose principal component is a tessellation of hexagonal sections each corresponding to its own associated one of said like rods, said tessellation being centered on the center of the overall cross-section of said second stage pultrudate, and said tessellation having a rotational symmetry of 60 degrees, said assembly being an assembly of at least 7 like rods, including a core rod and 6 surrounding rods, nested together in parallel relationship and pulled through a second-stage pultrusion die to form a larger rod, said larger rod having a hexagonal cross-sectional area nine times that of each of the assembled rods, {fraction (2/9)} of said latter cross-sectional area being filled by resin and fiber pultruded with and in addition to the resin and fiber in said assembly of like rods.5. An article as in claim 2, said article having a fiber density close to that of each of the nested rods.6. A method of making composite tension rods comprising the steps of nesting together in parallel relationship a given number of hexagonal composite rods of fiber-reinforced resin each formed as a first-stage pultrudate and pulling said nested rods together through a heated pultrusion die to bond them together using heat-curable resin and form a second-stage pultrudate comprising a larger rod having a cross-sectional area at least as many times greater than the cross-sectional area of each of the nested rods as said given number and having a cross-section that includes a tessellation of the cross-fsections of the nested rods.7. A method as in claim 6, said step of nesting together comprising nesting together at least seven hexagonal composite rods of fiber-reinforced resin, said step of pulling said nested rods together through a heated pultrusion die resulting in the formation of a larger rod having a cross-sectional area at least seven times greater than the cross-sectional area of each of the nested rods.8. A method of making composite tension rods comprising the steps of nesting together in parallel relationship a given number of hexagonal composite rods of fiber-reinforced resin and pulling said nested rods together through a heated pultrusion die to form a larger rod having a cross-sectional area at least as many times greater than the cross-sectional area of each of the nested rods as said given number and having a cross-section that includes a tessellation of the cross-sections of the nested rods, said step of pulling said nested-together rods through a heated pultrusion die including the steps of accompanying said nested-together rods with additional fiber and resin as they are pulled into the die, and passing the nested-together rods and the additional fiber and resin through a die opening that is greater in area than the combined cross-sectional areas of said nested-together rods.9. A method of making composite tension rods comprising the steps of nesting together in parallel relationship a given number of hexagonal composite rods of fiber-reinforced resin and pulling said nested rods together through a heated pultrusion die to form a larger rod having a cross-sectional area at least as many times greater than the cross-sectional area of each of the nested rods as said given number and having a cross-section that includes a tessellation of the cross-sections of the nested rods, said step of pulling said nested-together rods through a heated pultrusion die including the steps of accompanying said nested-together rods with additional fiber and resin as they are pulled into the die, and passing the nested-together rods and the additional fiber and resin through a die opening that is greater in area than the combined cross-sectional areas of said nested-together rods, said die opening being hexagonal, and said aforesaid steps forming hexagonal rod.10. A method of making composite tension rods comprising the steps of nesting together in parallel relationship a given number of hexagonal composite rods of fiber-reinforced resin and pulling said nested rods together through a heated pultrusion die to form a larger rod having a cross-sectional area at least as many times greater than the cross-sectional area of each of the nested rods as said given number and having a cross-section that includes a tessellation of the cross-sections of the nested rods, said step of pulling said nested-together rods through a heated pultrusion die including the steps of accompanying said nested-together rods with additional fiber and resin as they are pulled into the die, and passing the nested-together rods and the additional fiber and resin through a die opening that is greater in area than the combined cross-sectional areas of said nested-together rods, said die opening being hexagonal, said aforesaid steps forming hexagonal rod, said method further including the steps of nesting together said last-named hexagonal rod with other hexagonal rod of like size and shape, and including said nested-together rods as feedstock in performing a higher-stage pultrusion to form a still larger rod having a cross-section that includes a tessellation of the cross-sections of the nested rods used as feedstock.11. A method of making composite tension rods as in claim 6, said method of claim 6 being integrated into a method of making and supplying two different sizes of composite tension rods, said latter method comprising the steps of: (1) forming hexagonal composite rods of relatively small size as first-stage pultrudate, and (2) using (a) some of said first-stage pultrudate for supplying purchasers of rods of said relatively small size and (b) other of said first-stage pultrudate as feedstock in the practice of said method of claim 6 to form composite rods of relatively large size as second-stage pultrudate, said second-stage pultrudate being usable for supplying purchasers of rods of said relatively large size.12. A method as in claim 6, said step of nesting together comprising nesting together at least seven hexagonal composite rods of fiber-reinforced resin, said step of pulling said nested rods together through a heated pultrusion die resulting in the formation of a larger rod having a cross-sectional area in excess of seven times greater than the cross-sectional area of each of the nested rods.