Method and system for forming composite geometric support structures
First Claim
1. A method for forming a composite lattice support structure having a plurality of cross supports intersecting one another to form a plurality of multi-layered nodes, said method comprising:
- obtaining a rigid mold having a working surface with a network of channels intersecting at strategic locations, said channels cooperatively establishing a substantially continuous interconnected lattice corresponding to a three dimensional geometric configuration to be imparted to a composite lattice support structure;
depositing a fiber material, in the presence of a resin, within said channels to provide a fiber material lay-up systematically arranged to contribute to the makeup of a plurality of composite cross supports that intersect to form a plurality of nodes;
applying a dynamic pressure transfer layer about said rigid mold and said fiber material lay-up, said pressure transfer layer being resilient and adapted to displace about said working surface and concentrate an applied pressure about said channels and onto said fiber material lay-up to compact said fiber material within said channels;
forming a vacuum enclosure about said fiber material lay-up and said rigid mold to facilitate drawing of a vacuum;
subjecting said fiber material lay-up to a curing cycle to consolidate said fiber material to form said lattice support structure having said cross supports and said nodes; and
releasing said lattice support structure from said rigid mold;
wherein said pressure transfer layer comprises a liquid material curable under ambient conditions adapted to be applied to and seal said rigid mold and to comprise and function as said vacuum enclosure.
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Accused Products
Abstract
A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect. Subjecting these to a curing system functions to consolidate the cross supports and multi-layered nodes to produce the composite lattice support structure.
241 Citations
25 Claims
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1. A method for forming a composite lattice support structure having a plurality of cross supports intersecting one another to form a plurality of multi-layered nodes, said method comprising:
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obtaining a rigid mold having a working surface with a network of channels intersecting at strategic locations, said channels cooperatively establishing a substantially continuous interconnected lattice corresponding to a three dimensional geometric configuration to be imparted to a composite lattice support structure; depositing a fiber material, in the presence of a resin, within said channels to provide a fiber material lay-up systematically arranged to contribute to the makeup of a plurality of composite cross supports that intersect to form a plurality of nodes; applying a dynamic pressure transfer layer about said rigid mold and said fiber material lay-up, said pressure transfer layer being resilient and adapted to displace about said working surface and concentrate an applied pressure about said channels and onto said fiber material lay-up to compact said fiber material within said channels; forming a vacuum enclosure about said fiber material lay-up and said rigid mold to facilitate drawing of a vacuum; subjecting said fiber material lay-up to a curing cycle to consolidate said fiber material to form said lattice support structure having said cross supports and said nodes; and releasing said lattice support structure from said rigid mold; wherein said pressure transfer layer comprises a liquid material curable under ambient conditions adapted to be applied to and seal said rigid mold and to comprise and function as said vacuum enclosure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A system for forming a composite lattice support structure, said system comprising:
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a rigid mold having a working surface with a network of channels intersecting at strategic locations, said channels cooperatively establishing a substantially continuous interconnected lattice corresponding to a three dimensional geometric configuration to be imparted to a composite lattice support structure; a fiber material deposited, in the presence of a resin, within said channels to provide a fiber material lay-up systematically arranged to contribute to the makeup of a plurality of composite cross supports that intersect to form a plurality of nodes; a dynamic pressure transfer layer situated about said rigid mold and said fiber material lay-up, said pressure transfer layer being resilient and adapted to displace about said working surface and concentrate an applied pressure about said channels and onto said fiber material lay-up to compact said fiber material within said channels; a vacuum enclosure situated about said fiber material lay-up and said rigid mold to facilitate drawing of a vacuum; and a curing system adapted to consolidate said fiber material to form said lattice support structure having said cross supports and said nodes, wherein said pressure transfer layer comprises a liquid material curable under ambient conditions adapted to be applied to and seal said rigid mold and to comprise and function as said vacuum enclosure.
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Specification