U.S. patent application number 12/063998 was filed with the patent office on 2009-08-06 for apparatus, system, and method for filamentary composite lattice structure manufacturing.
Invention is credited to James T. Ayers III, David L. Blunck, Jennifer Boyce, Keith Davis, Tyler Evans, Boyd Kimber Gunnell, Steve Hansen, David W. Jensen, Gregory James Larson, Eve Pate, Sarita Rogers.
Application Number | 20090193961 12/063998 |
Document ID | / |
Family ID | 37758319 |
Filed Date | 2009-08-06 |
United States Patent
Application |
20090193961 |
Kind Code |
A1 |
Jensen; David W. ; et
al. |
August 6, 2009 |
Apparatus, System, and Method for Filamentary Composite Lattice
Structure Manufacturing
Abstract
An apparatus, system, and method are disclosed for the
manufacture of composite lattice structures comprising a weaving
mechanism 104 configured to position fibers in a lattice structure,
the weaving mechanism 104 comprising one or more bobbins 304, each
one or more bobbin 304 configured to carry fiber and a plurality of
horn gears 302 configured to move the one or more bobbins 304
across the face of the weaving mechanism 104 to control the
position of the fiber carried by the one or more bobbins 304 in the
lattice structure, and a shape retention structure 108 configured
to hold the fibers in lattice structure. Beneficially, such an
apparatus, system, and method would automate the process of
manufacturing composite lattice structures and reduce the costs
associated with the existing methods for manufacturing such
structures.
Inventors: |
Jensen; David W.; (Mapleton,
UT) ; Davis; Keith; (Albany, OR) ; Gunnell;
Boyd Kimber; (Somerville, MA) ; Larson; Gregory
James; (Vail, AZ) ; Blunck; David L.; (Canby,
OR) ; Evans; Tyler; (Salt Lake City, UT) ;
Hansen; Steve; (Draper, UT) ; Rogers; Sarita;
(Boise, ID) ; Boyce; Jennifer; (Renton, WA)
; Pate; Eve; (Provo, UT) ; Ayers III; James
T.; (Doraville, GA) |
Correspondence
Address: |
Kunzler & McKenzie
8 EAST BROADWAY, SUITE 600
SALT LAKE CITY
UT
84111
US
|
Family ID: |
37758319 |
Appl. No.: |
12/063998 |
Filed: |
August 16, 2006 |
PCT Filed: |
August 16, 2006 |
PCT NO: |
PCT/US06/31903 |
371 Date: |
August 19, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60708558 |
Aug 16, 2005 |
|
|
|
Current U.S.
Class: |
87/8 ; 87/33 |
Current CPC
Class: |
D04C 3/38 20130101; B29C
70/222 20130101; D02H 1/00 20130101; D03D 47/34 20130101; B29C
53/564 20130101; B29C 53/8066 20130101; D03D 37/00 20130101 |
Class at
Publication: |
87/8 ; 87/33 |
International
Class: |
D04C 1/00 20060101
D04C001/00; D04C 3/00 20060101 D04C003/00 |
Claims
1. An apparatus to manufacture filamentary composite lattice
structures, the apparatus comprising: a weaving mechanism
configured to position fibers in a lattice structure, the weaving
mechanism comprising: one or more bobbins, each one or more bobbin
configured to carry fiber; and a plurality of horn gears configured
to move the one or more bobbins across the face of the weaving
mechanism to control the position of the fiber carried by the one
or more bobbins in the lattice structure; and a shape retention
structure configured to hold the fibers in lattice structure until
the lattice structure is cured to a rigid state.
2. The apparatus of claim 1, further comprising a curing device
configured to cure resin on the fibers held in the shape retention
structure.
3. The apparatus of claim 1, further comprising a resin
impregnation device configured to apply a resin to the fibers in
the filamentary composite lattice structure.
4. The apparatus of claim 1, further comprising a pulling device
configured to apply an axial force to the filamentary composite
lattice structure.
5. The apparatus of claim 1 wherein one or more of the plurality of
horn gears are driven by a spur gear on an adjacent one or more of
the plurality of horn gears such that a motor attached to one of
the plurality of horn gears drives the plurality of horn gears.
6. The apparatus of claim 1 wherein one or more of the plurality of
horn gears are driven by an individual motor.
7. The apparatus of claim 1 wherein the weaving mechanism further
comprises one or more switches configured to transfer the bobbin
from one of the plurality of horn gears to an adjacent one of the
plurality of horn gears.
8. The apparatus of claim 1 wherein one or more of the plurality of
horn gears further comprise an aperture configured to allow a fiber
to pass through the aperture.
9. The apparatus of claim 1 wherein one or more of the plurality of
horn gears further comprises a gear assembly configured to be
individually removed from the weaving mechanism.
10. The apparatus of claim 1, further comprising a transition
device configured to transfer fibers from the weaving mechanism to
the shape retention structure.
11. A system to manufacture filamentary composite lattice
structures, the system comprising: a weaving mechanism configured
to position fibers in a lattice structure, the weaving mechanism
comprising: one or more bobbins, each one or more bobbin configured
to carry fiber; and a plurality of horn gears configured to move
the one or more bobbins across the face of the weaving mechanism to
control the position of the fiber carried by the one or more
bobbins in the lattice structure; a shape retention structure
configured to hold the fibers in a lattice structure using one or
more attachment mechanisms; and a control module configured to
control the weaving mechanism and direct the positioning of the
fibers in the lattice structure.
12. The system of claim 11 wherein the one or more attachment
mechanisms comprise one or more hooks configured to hold the
lattice structure in a desired configuration.
13. The system of claim 11 wherein the one or more attachment
mechanisms comprise one or more servo mechanisms configured to hold
the lattice structure in a desired configuration.
14. The system of claim 11 wherein the relative position of the one
or more attachment mechanisms is variable such that a bay length in
a filamentary composite lattice structure manufactured by the
system is adjustable.
15. The system of claim 11 wherein the relative position of the one
or more attachment mechanisms is variable such that a diameter of a
filamentary composite lattice structure manufactured by the system
is adjustable.
16. The system of claim 11 wherein the one or more attachment
mechanisms move relative to the weaving mechanism as the system
manufactures a filamentary composite lattice structure such that
the filamentary composite lattice structure is continuously
manufactured.
17. The system of claim 11 wherein the shape retention structure is
curved such that the filamentary composite lattice produced by the
system is curved.
18. A method for manufacturing a filamentary composite lattice
structure, the method comprising: positioning fibers to form a
lattice structure with a weaving mechanism configured to position
fibers in a lattice structure, the weaving mechanism comprising:
one or more bobbins, each one or more bobbin configured to carry
fiber; and a plurality of horn gears configured to move the one or
more bobbins across the face of the weaving mechanism to control
the position of the fiber carried by the one or more bobbins in the
lattice structure; and constraining the geometry of the assembled
lattice structure in the shape definition component.
19. The method of claim 17, wherein the method further comprises
curing resin in the assembled lattice structure.
20. The method of claim 17, further comprising tensioning the
fibers with a pulling device.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/708,558 entitled "Apparatus, System, and
Method for Filament Wound Lattice Structure Manufacturing" and
filed on Aug. 16, 2005 for David W. Jensen, et al., and PCT
Application Number PCT/US2006/031903 entitled "Apparatus, System,
and Method for Filament Wound Lattice Structure Manufacturing" for
David W. Jensen, et al., which is incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the manufacture of filamentary
composite lattice structures and more particularly relates to the
automated manufacture of filamentary composite lattice structures
using a weaving component, a shape definition component, and a
curing component.
[0004] 2. Description of the Related Art
[0005] The pursuit of structurally efficient structures in the
civil, mechanical, and aerospace arenas is an ongoing quest. An
efficient truss structure is one that has a high strength to weight
ratio and/or a high stiffness to weight ratio. An efficient truss
structure can also be described as one that is relatively
inexpensive, easy to fabricate and assemble, and does not waste
material.
[0006] Advanced composite structures have been used in many types
of applications to create structurally efficient structures. Some
of these composite structures have been used to create structural
members having enhanced load bearing capacity per unit mass and
capable of withstanding multiple loadings. An example of these
composite structures is a filament composite structure with
multiple, straight members attached in a lattice structure, such as
the IsoTruss.
[0007] These filamentary composite lattice structures can provide
excellent weight to performance ratios in multi-planar bending,
buckling, axial loading, and combined loading and torsion
applications, and are therefore very valuable. The manufacture of
these structures using existing methods, however, is
labor-intensive, time consuming, and costly.
[0008] From the foregoing discussion, it should be apparent that a
need exists for an apparatus, system, and method for manufacturing
a filamentary composite lattice structure. Beneficially, such an
apparatus, system, and method would automate the process of
manufacturing filamentary composite lattice structures and reduce
the costs associated with the existing methods for manufacturing
such structures.
SUMMARY OF THE INVENTION
[0009] The present invention has been developed in response to the
present state of the art, and in particular, in response to the
problems and needs in the art that have not yet been fully solved
by currently available methods for manufacturing filamentary
composite lattice structures. Accordingly, the present invention
has been developed to provide an apparatus, system, and method for
manufacturing filamentary composite lattice structures that
overcome many or all of the above-discussed shortcomings in the
art.
[0010] The apparatus to manufacture filamentary composite lattice
structures is provided with a plurality of modules configured to
functionally execute the necessary steps of weaving a filamentary
composite lattice structure, defining the shape of the filamentary
composite lattice structure, and transitioning the filamentary
composite lattice structure from a weaving mechanism to a shape
retention structure. These modules in the described embodiments
include a weaving mechanism configured to position fibers in a
lattice structure, a shape retention structure configured to hold
the fibers in lattice structure, and a transition device configured
to transfer fibers from the weaving mechanism to the shape
retention structure.
[0011] In one embodiment, the apparatus further comprises a curing
device configured to cure resin on the fibers held in the shape
retention structure. In another embodiment, the apparatus further
comprises a resin impregnation device configured to apply a resin
to the fibers in the filamentary composite lattice structure. In a
further embodiment, the apparatus includes a pulling device
configured to apply an axial force to the filamentary composite
lattice structure.
[0012] The weaving mechanism of the apparatus, in one embodiment,
comprises a plurality of horn gears configured to move a bobbin
carrying fiber across the face of the weaving mechanism. In a
further embodiment, one or more of the plurality of horn gears are
driven by a spur gear on an adjacent one or more of the plurality
of horn gears such that a motor attached to one of the plurality of
horn gears drives the plurality of horn gears. In another
embodiment, one or more of the plurality of horn gears are driven
by an individual motor.
[0013] The weaving mechanism of the apparatus, in one embodiment,
further comprises one or more switches configured to transfer the
bobbin from one of the plurality of horn gears to an adjacent one
of the plurality of horn gears. In another embodiment, one or more
of the plurality of horn gears further comprise an aperture
configured to allow a fiber to pass through the aperture. In yet
another embodiment, one or more of the plurality of horn gears
further comprises a gear assembly configured to be individually
removed from the weaving mechanism.
[0014] A system of the present invention is also presented to
manufacture filamentary composite lattice structures. The system
may be embodied a weaving mechanism, a shape retention structure,
and a control module. In particular, the system, in one embodiment,
includes a weaving mechanism configured to position fibers in a
lattice structure, a shape retention structure configured to hold
the fibers in a lattice structure using one or more attachment
mechanisms, and a control module configured to control the weaving
mechanism and direct the positioning of the fibers in the lattice
structure.
[0015] The one or more attachment mechanisms in the system, in one
embodiment, may further include one or more hooks configured to
hold the lattice structure in a desired configuration. In another
embodiment, the one or more attachment mechanisms include one or
more servo mechanisms configured to hold the lattice structure in a
desired configuration.
[0016] In one embodiment, the relative position of the one or more
attachment mechanisms is variable such that a bay length in a
filamentary composite lattice structure manufactured by the system
is adjustable. In another embodiment, the relative position of the
one or more attachment mechanisms is variable such that a diameter
of a filamentary composite lattice structure manufactured by the
system is adjustable.
[0017] The system, in one embodiment, includes the one or more
attachment mechanisms that move relative to the weaving mechanism
as the system manufactures a filamentary composite lattice
structure such that the filamentary composite lattice structure is
continuously manufactured. In another embodiment, the shape
retention structure is curved such that the filamentary composite
lattice produced by the system is curved.
[0018] A method of the present invention is also presented for
manufacturing a filamentary composite lattice structure. The method
in the disclosed embodiments substantially includes the steps
necessary to carry out the functions presented above with respect
to the operation of the described apparatus and system. In one
embodiment, the method includes positioning fibers to form a
lattice structure with a weaving mechanism, transitioning fibers in
assembled lattice structure to a shape retention structure, and
constraining the geometry of the assembled lattice structure in the
shape definition component.
[0019] In a further embodiment, the method includes curing resin in
the assembled lattice structure. The method may include, in another
embodiment, tensioning the fibers with a pulling device.
[0020] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized with the present
invention should be or are in any single embodiment of the
invention. Rather, language referring to the features and
advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment of the present
invention. Thus, discussion of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0021] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize that the invention may be practiced without one or
more of the specific features or advantages of a particular
embodiment. In other instances, additional features and advantages
may be recognized in certain embodiments that may not be present in
all embodiments of the invention.
[0022] These features and advantages of the present invention will
become more fully apparent from the following description and
appended claims, or may be learned by the practice of the invention
as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order that the advantages of the invention will be
readily understood, a more particular description of the invention
briefly described above will be rendered by reference to specific
embodiments that are illustrated in the appended drawings.
[0024] Understanding that these drawings depict only typical
embodiments of the invention and are not therefore to be considered
to be limiting of its scope, the invention will be described and
explained with additional specificity and detail through the use of
the accompanying drawings, in which:
[0025] FIG. 1 is a schematic block diagram illustrating one
embodiment of a system for manufacturing a filamentary composite
lattice structure in accordance with the present invention;
[0026] FIG. 2 is a side view illustrating one embodiment of an
apparatus to manufacture a filamentary composite lattice structure
in accordance with the present invention;
[0027] FIG. 3 is a front view illustrating one embodiment of a
weaving mechanism apparatus in accordance with the present
invention;
[0028] FIG. 4 is a front view illustrating one embodiment of a
weaving mechanism apparatus in accordance with the present
invention;
[0029] FIG. 5 is a cut away side view illustrating one embodiment
of a gear assembly apparatus in accordance with the present
invention;
[0030] FIG. 6 is a side view illustrating one embodiment of a
bobbin carrier apparatus in accordance with the present
invention;
[0031] FIG. 7 is a side view illustrating one embodiment of a shape
retention structure apparatus in accordance with the present
invention;
[0032] FIG. 8 is a side view illustrating one embodiment of a
transition device apparatus in accordance with the present
invention; and
[0033] FIG. 9 is a schematic flow chart diagram illustrating one
embodiment of a filamentary composite lattice structure
manufacturing method in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Many of the functional units described in this specification
have been labeled as modules, in order to more particularly
emphasize their implementation independence. For example, a module
may be implemented as an assembly of one or more mechanical
components, a hardware circuit comprising custom VLSI circuits or
gate arrays, off-the-shelf semiconductors such as logic chips,
transistors, or other discrete components. A module may also be
implemented in programmable hardware devices such as field
programmable gate arrays, programmable array logic, programmable
logic devices or the like.
[0035] Modules may also be implemented in software for execution by
various types of processors. An identified module of executable
code may, for instance, comprise one or more physical or logical
blocks of computer instructions which may, for instance, be
organized as an object, procedure, or function. Nevertheless, the
executables of an identified module need not be physically located
together, but may comprise disparate instructions stored in
different locations which, when joined logically together, comprise
the module and achieve the stated purpose for the module.
[0036] Indeed, a module of executable code may be a single
instruction, or many instructions, and may even be distributed over
several different code segments, among different programs, and
across several memory devices. Similarly, operational data may be
identified and illustrated herein within modules, and may be
embodied in any suitable form and organized within any suitable
type of data structure. The operational data may be collected as a
single data set, or may be distributed over different locations
including over different storage devices, and may exist, at least
partially, merely as electronic signals on a system or network.
[0037] Reference throughout this specification to "one embodiment,"
"an embodiment," or similar language means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
present invention. Thus, appearances of the phrases "in one
embodiment," "in an embodiment," and similar language throughout
this specification may, but do not necessarily, all refer to the
same embodiment.
[0038] Reference to a signal bearing medium may take any form
capable of generating a signal, causing a signal to be generated,
or causing execution of a program of machine-readable instructions
on a digital processing apparatus. A signal bearing medium may be
embodied by a transmission line, a compact disk, digital-video
disk, a magnetic tape, a Bernoulli drive, a magnetic disk, a punch
card, flash memory, integrated circuits, or other digital
processing apparatus memory device.
[0039] Furthermore, the described features, structures, or
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. In the following description,
numerous specific details are provided, such as examples of
programming, software modules, user selections, network
transactions, database queries, database structures, hardware
modules, hardware circuits, hardware chips, etc., to provide a
thorough understanding of embodiments of the invention. One skilled
in the relevant art will recognize, however, that the invention may
be practiced without one or more of the specific details, or with
other methods, components, materials, and so forth. In other
instances, well-known structures, materials, or operations are not
shown or described in detail to avoid obscuring aspects of the
invention.
[0040] Some basic features of the manufacture of a complex
composite structure are described in U.S. Pat. Publication No.
US2004/0247866A1, published Dec. 9, 2004, which is herein
incorporated by reference into this document.
[0041] FIG. 1 illustrates a system 100 for manufacturing a lattice
structure. The system 100, in one embodiment, may comprise a
lattice structure manufacturing device 102, a weaving mechanism
104, a transition device 106, a shape retention structure 108, a
resin impregnation device 110, a curing device 112, a pulling
device 114, and a control module 116. The system 100 manufactures a
lattice structure from fibers.
[0042] The lattice structure manufacturing device 102, in one
embodiment comprises a weaving mechanism 104, a transition device
106, a shape retention structure 108, a resin impregnation device
110, a curing device 112, and a pulling device 114. The weaving
mechanism 104 directs the relative position of a plurality of
fibers that make up the lattice structure. In one embodiment, the
weaving mechanism 104 may weave a plurality of fibers. In another
embodiment, the weaving mechanism 104 may braid a plurality of
fibers. In yet another embodiment, the weaving mechanism 104 may
wrap one or more fibers around one or more fibers.
[0043] As will be appreciated by one skilled in the art, a variety
of configurations of the weaving mechanism 104 should be considered
to fall within the scope of the invention. For example, in one
embodiment, the weaving mechanism 104 may interweave fibers at the
joints of a lattice structure that may be stronger and more durable
than non-interwoven joints. In another embodiment, the weaving
mechanism 104 may wrap fibers around the straight elements of the
lattice structure to aid in consolidation of fibers. In yet another
embodiment, the weaving mechanism 104 may be capable of arranging
fibers into multiple lattice configurations, such as IsoTrusses,
rectangular lattice structure trusses, flat lattice structure
panels, and the like.
[0044] In one embodiment, the transition device 106 guides fibers
from the weaving mechanism 104 onto the shape retention structure
108. The transition device 106 may comprise hooks, clasps, guides,
or the like. The transition device 106 acts to ensure proper
transition of the fibers into a correct geometry.
[0045] The shape retention structure 108, in one embodiment,
receives fibers from the transition device 106 and holds the fibers
in the proper shape for the lattice structure. The shape retention
structure 108 constrains the geometry of the lattice structure and
maintains the geometry during curing of the structure. The shape
retention structure 108 may be configured to operate continuously
as a lattice structure is formed, releasing portions of the
structure that have been cured, and accepting additional uncured
portions of the lattice structure from the transition device 106.
In one embodiment, the shape retention structure 108 may comprise
hooks, clasps, grips, or the like that are held in a frame and
attach to the lattice structure.
[0046] One skilled in the art will recognize that a variety of
configurations of shape retention structure 108 should be
considered to be within the scope of the invention. For example, in
one embodiment, the shape retention structure 108 may comprise a
mandrel. In another embodiment, the shape retention structure 108
may include an integral transition device 106. In another
embodiment, the shape retention structure 108 may comprise robotic
arms that constrain the geometry of the lattice structure. In yet
another embodiment, the shape retention structure 108 may comprise
a frame that has a variable geometry such that the lattice
structure can be curved.
[0047] The resin impregnation device 110 applies resin to the
fibers in the lattice structure. The resin is later cured and acts
as a matrix to hold the fibers in position. In one embodiment, the
resin impregnation device 110 sprays resin onto fibers held in the
shape retention structure 108.
[0048] In another embodiment, the resin impregnation device 110
applies resin to fibers in the weaving mechanism 104. In yet
another embodiment, the resin impregnation device applies resin to
fibers in the transition device 106. In another embodiment, the
fibers are pre-impregnated with resin (pre-preg) and the resin
impregnation device 110 is not included.
[0049] The curing device 112, in one embodiment, cures the resin in
the lattice structure held by the shape retention structure 108.
The curing device 112 may continuously cure the resin in the
lattice structure as the lattice structure is assembled. In one
embodiment, the curing device 112 may comprise a heat curing
apparatus.
[0050] As will be appreciated by one skilled in the art, a variety
of types and configurations of curing device 112 may be implemented
without departing from the scope and spirit of the present
invention. For example, in one embodiment, the curing device 112
may use a microwave curing apparatus. In another embodiment, the
curing device 112 may use an ultraviolet light (UV) curing
apparatus. In yet another embodiment, the curing device 112 may
completely cure the resin in the lattice structure. In another
embodiment, the curing device 112 may cure the outer layer of the
lattice structure to maintain the geometry of the structure.
[0051] The pulling device 114, in one embodiment, applies an axial
force to the lattice structure. The axial force may be translated
through the lattice structure to the fibers in the weaving
mechanism 104. The axial force generated by the pulling device 114
pulls the lattice structure from the lattice structure
manufacturing device 102 as the structure is progressively
assembled, and maintains the correct tension in the fibers as the
lattice structure is assembled. In one embodiment, the pulling
device 114 comprises a motorized winch with a cable attached to the
lattice structure.
[0052] One skilled in the art will appreciate that a variety of
types and configurations of pulling device 112 may be implemented
without departing from the scope and spirit of the invention. For
example, in one embodiment, the pulling device 112 comprises a
weight attached to a cable attached to the lattice structure. In
another embodiment, the pulling device 112 comprises tension
applied by the shape retention structure 108 applied to the lattice
structure.
[0053] The control module 116, in one embodiment, provides control
over the various components of the lattice structure manufacturing
device 102. The control module 116 may comprise a computing device
configured within software code to control the movement and actions
of the weaving mechanism 104, the transition device 106, the shape
retention structure 108, the resin impregnation device 110, the
curing device 112, and/or the pulling device 114. In one
embodiment, the control module 116 may be configured to allow a
user to select or design the geometry of a lattice structure,
adjust the components of the lattice structure manufacturing device
102 to create that structure, and control the action of the
components of the lattice structure manufacturing device 102 as the
desired structure is created.
[0054] FIG. 2 illustrates one embodiment of a side view of an
apparatus 200 to manufacture a filamentary composite lattice
structure. The apparatus 200 may comprise a weaving mechanism 104,
a transition device 106, a shape retention structure 108, a curing
device 112, and a pulling device 114. Also illustrated are a
plurality of fibers 202 and a lattice structure 204. The apparatus
200 manufactures a lattice structure from fibers. The weaving
mechanism 104, the transition device 106, the shape retention
structure 108, the curing device 112, and the pulling device 114
are similar in function to like numbered elements discussed above
in relation to FIG. 1.
[0055] The plurality of fibers 202, in one embodiment, comprises
fibers that are formed by the apparatus 200 into a lattice
structure. The fibers 202 may be any fiber used to make composite
structures, such as carbon, aramid, fiberglass, or the like. In one
embodiment, the fibers 202 are impregnated with resin before
entering the apparatus 200. In another embodiment, the fibers 202
are not impregnated with resin before entering the apparatus
200.
[0056] The lattice structure 204 is formed from the plurality of
fibers 202 by the apparatus 200. In one embodiment, the lattice
structure 204 may be an IsoTruss structure. In another embodiment,
the lattice structure 204 may be a lattice structure truss with a
rectangular cross-section. In yet another embodiment, the lattice
structure 204 may be a flat lattice structure panel. In another
embodiment, the lattice structure 204 may be a curved lattice
structure. In another embodiment, the lattice structure 204 may be
a tapered lattice structure.
[0057] FIG. 3 illustrates a front view of one embodiment of a
weaving mechanism 300. The weaving mechanism 300 comprises a
plurality of horn gears 302, and one or more bobbin carriers 304.
The weaving mechanism 300 transports the one or more bobbin
carriers 304 on a path across the face of the weaving mechanism 300
to position fibers in a lattice structure.
[0058] As will be appreciated by one skilled in the art, variations
of the weaving mechanism 300 that comprise any number of horn gears
302 and are arranged in any shape should be considered to be within
the scope and spirit of the invention. FIG. 1 illustrates a weaving
mechanism 300 containing 16 horn gears 302 arranged in a square
panel. In another embodiment, the weaving mechanism 300 may contain
hundreds of horn gears 302. In another embodiment, the horn gears
302 may be arranged in a circle across the face of the weaving
mechanism 300.
[0059] The plurality of horn gears 302, in one embodiment, each
comprises one or more notches 306, an aperture 308, and an axis of
rotation 310. Each horn gear 302 rotates around its axis of
rotation 310 and may carry a bobbin carrier 304 in a notch 306. A
horn gear 302 may transfer a bobbin carrier 304 to an adjacent horn
gear 302. Transfer of a bobbin carrier 304 may occur in response to
both horn gears 302 having aligned notches 306 and the direction of
a switch (not shown). Through these transfers, a bobbin carrier 304
may follow a path across the surface of the weaving mechanism
300.
[0060] The plurality of horn gears 302 may be gear driven such that
each horn gear 302 rotates at the same rate as each adjacent horn
gear 302, but in the opposite direction. In another embodiment, the
rotation of each horn gear 302 is independently controlled. The
plurality of horn gears 302 may be driven by one or more
motors.
[0061] The plurality of horn gears 302 may each include an aperture
308 at the axis of rotation 310. One or more fibers may pass
through the aperture 308 and be incorporated into the lattice
structure. In one embodiment, the fibers that pass through an
aperture 308 form the longitudinal members of the lattice
structure. The fibers that pass through an at aperture 308 may be
drawn through the aperture 308 by the progression of the lattice
structure.
[0062] The one or more bobbin carriers 304, in one embodiment, may
each carry a bobbin of fiber as they traverse the weaving mechanism
300. Fiber may be drawn from the bobbins and arranged into a
lattice structure by the motion of the bobbin carriers 304 and the
progression of the lattice structure. As the bobbin carriers 304
move across the weaving mechanism 300, fibers may be braided,
woven, and/or wrapped around one another.
[0063] FIG. 4 illustrates a front view of one embodiment of a
weaving mechanism 400. The weaving mechanism 400 comprises a
plurality of horn gears 302, one or more bobbin carriers 304, and
one or more switches 402. The weaving mechanism 400 transports the
one or more bobbin carriers 304 on a path across the face of the
weaving mechanism 400 to position fibers in a lattice
structure.
[0064] In one embodiment, the plurality of horn gears 302 and the
one or more bobbin carriers 304 are preferably configured in a
manner similar to like numbered components described above in
relation to FIG. 3. The one or more switches 402 direct the
transfer of the bobbin carriers 304 between horn gears 302. In one
embodiment, the switches 402 are located at the interface between
horn gears 302.
[0065] In one embodiment, the one or more switches 402 comprise a
variable-geometry guide that switches between a transfer state and
a continue state. A bobbin carrier 304 traversing a switch 402 in
the transfer state is transferred to the adjacent horn gear 302. A
bobbin carrier 304 traversing a switch 402 in the continue state
continues to travel on its current horn gear 302.
[0066] The one or more switches 402 may be switched between a
transfer state and a continue state by a solenoid. In another
embodiment, the one or more switches 402 may be switched by a
motor. In another embodiment, the one or more switches 402 may be
switched pneumatically.
[0067] FIG. 5 illustrates a side view cross section of one
embodiment of a gear assembly 500. The gear assembly 500 comprises
a horn gear 302, a weaving mechanism surface 502, an axle 504, and
a drive gear 506. The gear assembly 500 controls the rotation of
the horn gear 302 in a weaving mechanism.
[0068] In one embodiment, the horn gear 302 includes an aperture
308 and an axis of rotation 310. The horn gear 302, aperture 308
and axis of rotation 310 are preferably configured in a manner
similar to like numbered components described above in relation to
FIG. 3. The horn gear 302 rotates around the axis of rotation 310
and may carry one or more bobbin carriers 304 across the weaving
mechanism 300.
[0069] The weaving mechanism surface 502, in one embodiment,
provides a surface for the bobbin carrier to slide. In one
embodiment, the weaving mechanism surface 502 is sectioned such
that each gear assembly 500 may be removed from the weaving
mechanism for maintenance and repair. The gear assembly 500 may
slide toward the horn gear 302 for removal. In another embodiment,
the gear assembly 500 may slide toward the drive gear 506 for
removal. In yet another embodiment, the segmented weaving mechanism
surface 502 may be removably attached to adjacent weaving mechanism
surfaces 502 by a fastener.
[0070] The axle 504, in one embodiment, may be attached to the horn
gear 302 and share a common axis of rotation 310 with the horn gear
302. The axle 504 translates motion from the drive gear 506 to the
horn gear 302. In another embodiment, the axle 504 is hollow and
provides an aperture 308. Fiber used to form a lattice structure
may pass through the aperture 308. The axle 504 may be made from
any material strong and stiff enough to transfer force from the
drive gear 506 to the horn gear 302, such as steel, aluminum,
alloys, plastic, composites, or the like.
[0071] The drive gear 506, in one embodiment, may be attached to
the axle 504 and share a common axis of rotation with the axle 504
and the horn gear 302. The drive gear 506 may be a spur gear that
meshes with adjacent drive gears 506 in adjacent gear assemblies
500. The drive gear 506 may be driven by an adjacent drive gear
506. The drive gear 506 may drive an adjacent drive gear 506. The
drive gear 506 transfers rotational motion to the axle 504 to drive
the horn gear 302. The drive gear 506 may be made from any material
sufficiently strong, stiff, and durable enough to transfer
rotational motion, such as steel, aluminum, alloys, plastic,
composites, or the like.
[0072] As will be appreciated by one skilled in the art, a variety
of configurations of drive gear 506 may be employed without
departing from the scope or spirit of the invention. For example,
in one embodiment, the drive gear 506 may be independently driven
by a motor. In another embodiment, the drive gear 506 may be driven
by a belt.
[0073] FIG. 6 illustrates one embodiment of a side view of a bobbin
carrier 600. The bobbin carrier 600 comprises a bobbin 602, a horn
gear interface 604, and a track guide 606. The bobbin carrier 600
is transported by a horn gear 302 across a weaving mechanism
surface 502 and carries a bobbin of fiber as fiber is drawn from
the bobbin 602 to make a lattice structure.
[0074] In one embodiment, the bobbin 602 is wrapped with a single
strand of fiber that is drawn from the bobbin 402. The bobbin 602
may be removable from the bobbin carrier 600. In another
embodiment, the bobbin 602 is integral with the bobbin carrier 600.
In another embodiment, the bobbin 602 carries more than one strand
of fiber.
[0075] The horn gear interface 604, in one embodiment, has a shape
that matches the notches on a horn gear 302 in a weaving mechanism.
The horn gear interface 604 allows the bobbin carrier 300 to
securely rest in a rotating horn gear 302 as the bobbin carrier 300
moves. In one embodiment, the horn gear interface 604 may have a
circular cross section, allowing for any rotational orientation
within a notch of a horn gear 302. In another embodiment, the horn
gear interface 604 may have a shaped cross section, allowing
specific rotational orientations within a notch of a horn gear
302.
[0076] The track guide 606, in one embodiment, interfaces with a
track on the weaving mechanism surface 502 and guides the motion of
the bobbin carrier 600. The track guide 606 may interact with a
switch to control transfer of the bobbin carrier between horn
gears.
[0077] FIG. 7 illustrates one embodiment of a shape retention
structure 700. The shape retention structure 700 comprises a frame
702 and one or more attachment mechanisms 704. The shape retention
structure 700 constrains the geometry of a curing lattice structure
706.
[0078] In one embodiment, the frame 702 may provide a base for the
one or more attachment mechanisms 704. The frame 702 may remain
stationary as the lattice structure 706 is assembled and allow the
one or more attachment mechanisms 704 to travel with the lattice
structure 706. In an alternate embodiment, the frame 702 may travel
with the lattice structure 706 as it is assembled. In one
embodiment, the frame 702 may comprise one or more rails arranged
around the lattice structure 706.
[0079] As will be appreciated by one skilled in the art, a variety
of types and configurations of frame 702 may be implemented without
departing from the scope or spirit of the invention. For example,
in one embodiment, the frame 702 may comprise one or more rings
that encircle the lattice structure 706. In another embodiment, the
frame 702 may comprise one or more tracks arranged around the
lattice structure 706. In another embodiment, the frame 702 may
comprise a base on which actuators for controlling the one or more
attachment mechanisms 704 are mounted.
[0080] In one embodiment, the frame 702 is adjustable such that a
diameter 708 of the lattice structure 706 may be varied. In another
embodiment, the frame 702 is adjustable such that a bay length 710
of the lattice structure 706 may be varied. In another embodiment,
the diameter 708 and/or bay length 710 may be varied during the
process of assembling a lattice structure 706.
[0081] In another embodiment, the frame 702 may be adjustable such
that the lattice structure 706 may be held in a bent or curved
position. The frame 702 may, in another embodiment, be configured
to hold a lattice structure 706 in an iso-truss configuration. In
another embodiment, the frame 702 may be configured to hold a
lattice structure 706 in a flat panel configuration. In another
embodiment, the frame 702 may be configured to hold a lattice
structure 706 in a rectangular cross-section configuration.
[0082] The one or more attachment mechanisms 704 attach to the
lattice structure 706 and constrain the geometry of the lattice
structure 706. The lattice structure 706 is held in shape during
curing. In one embodiment, the one or more attachment mechanisms
704 are hooks connected to the frame 702.
[0083] As will be appreciated by one skilled in the art, a variety
of types and configurations of one or more attachment mechanisms
704 may be employed without departing from the scope and spirit of
the invention. For example, in one embodiment, the one or more
attachment mechanisms 704 may comprise a grip mechanism. In another
embodiment, the one or more attachment mechanisms 704 may comprise
a variable geometry mechanism that allows the constraint and
release of the lattice structure 706. In another embodiment, the
one or more attachment mechanisms 704 may comprise one or more
robotic arms with controllable servo mechanisms.
[0084] In another embodiment, the one or more attachment mechanisms
704 may be adjustable such that the diameter 708 of the lattice
structure 706 may be varied. In another embodiment, the one or more
attachment mechanisms 704 may be adjustable such that the bay
length 710 of the lattice structure 706 may be varied. In another
embodiment, the diameter 708 and/or bay length 710 may be varied
during the process of assembling a lattice structure 706.
[0085] In one embodiment, the shape retention structure 700 may act
as a pulling device. The shape retention structure 700 may provide
tension in the fibers for the manufacturing process. The shape
retention structure 700 may also draw fiber from bobbins and move
the lattice structure 706 away from the weaving mechanism as the
lattice structure 706 is assembled.
[0086] FIG. 8 illustrates one embodiment of a side view of a
transition device 800. The transition device 800 comprises one or
more transition wheels 802. The transition device 800 guides fibers
from the weaving mechanism 104 to onto the shape retention
structure 108.
[0087] The one or more transition wheels 802 may each include a hub
804 and one or more hooks 806. The hub 802, in one embodiment,
rotates and provides an attachment for the one or more hooks 806.
The one or more hooks 806, in one embodiment, engage fibers from
the weaving mechanism 104 as the hub 804 rotates. The one or more
hooks 806 may carry the fiber in a predetermined orientation to the
shape retention structure 108. In one embodiment, the one or more
hooks 806 may release the fibers in response to the engagement of
the shape retention structure 108 with the fibers.
[0088] As will be appreciated by one skilled in the art, a variety
of types and configurations of transition devices 800 may be
utilized without departing from the scope and spirit of the present
invention. For example, the transition device 800, in one
embodiment, may comprise one or more servo-driven actuators
configured to engage fibers and deliver them to the shape retention
structure 108. In another embodiment, the transition device 800 may
include a four-bar linkage configured to carry the fibers on a
pre-determined path from the weaving mechanism 104 to the shape
retention structure 108.
[0089] The schematic flow chart diagrams that follow are generally
set forth as logical flow chart diagrams. As such, the depicted
order and labeled steps are indicative of one embodiment of the
presented method. Other steps and methods may be conceived that are
equivalent in function, logic, or effect to one or more steps, or
portions thereof, of the illustrated method. Additionally, the
format and symbols employed are provided to explain the logical
steps of the method and are understood not to limit the scope of
the method. Although various arrow types and line types may be
employed in the flow chart diagrams, they are understood not to
limit the scope of the corresponding method. Indeed, some arrows or
other connectors may be used to indicate only the logical flow of
the method. For instance, an arrow may indicate a waiting or
monitoring period of unspecified duration between enumerated steps
of the depicted method. Additionally, the order in which a
particular method occurs may or may not strictly adhere to the
order of the corresponding steps shown.
[0090] FIG. 9 illustrates a method 900 for manufacturing a lattice
structure. Initially, fiber tows are arranged 902 in the
manufacturing apparatus. In selected embodiments, fibers may be
threaded through an aperture 308 in a horn gear 302, or be placed
on a bobbin 602 on a bobbin carrier 304. The desired arrangement of
the fibers may be determined by the lattice structure to be
created.
[0091] Next, the fibers are attached 904 to the pulling device. The
fibers may be tied to the pulling device. In another embodiment,
fibers are attached to the pulling device by fasteners.
[0092] Next, the fibers are tensioned 906 by the pulling device.
The tension applied by the pulling device holds the fibers in
position. The tension may also draw fibers through the apparatus.
In another embodiment, the tension draws the assembled lattice
structure through the apparatus.
[0093] Next, the fibers are positioned 908 by the weaving
mechanism. Fibers may be arranged side by side, wrapped around
other fibers, woven together, and/or braided together by the
weaving mechanism. The positioning of the fibers may be controlled
by the weaving mechanism to arrange the fibers in the desired
configuration to form a lattice structure.
[0094] Next, the assembled lattice structure is transitioned 910
onto a shape retention structure. The lattice structure may be
placed on guides and/or attachment mechanisms 704.
[0095] Next, the geometry of the lattice structure is constrained
912 by the shape retention structure. The shape retention structure
holds the lattice structure in the desired shape and configuration
while the structure is flexible. The shape retention structure may
also tension the fibers.
[0096] Next, the resin in the lattice structure is cured 914. The
flexible structure held in the shape retention structure is made
rigid by the curing process. The resin may be cured by a heat
process, a microwave process, an ultraviolet process, or the like.
In one embodiment, the resin may be fully cured in the shape
retention structure. In another embodiment, the resin may be
partially cured in the shape retention structure.
[0097] Next, the lattice structure is released 916 from the shape
retention structure. The structure may be released through the
action of one or more variable geometry attachment mechanisms 704.
In another embodiment, the structure may be released releasing
tension on one or more attachment mechanisms 704.
[0098] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *