Structure including a plurality of cells of cured resinous material, method of forming the structure and apparatus for forming the structure

Abstract

A structure that includes a plurality of cells of a cured resinous material. Each cell is joined to at least one other cell.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of International Application No. PCT / US01 / 11170, filed Apr. 5, 2001 which claims the benefit of prior filed co-pending U.S. Application No. 60 / 196,027, filed on Apr. 7, 2000.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a structure that may be formed of a plurality of resinous cells, a method and an apparatus for forming such a structure. The structure may be formed in place where it is to be utilized. [0004] 2. Description of Related Art [0005] In many situations, it may be desirable to form a structure in place where it is to be utilized. Sometimes, a structure is preformed and then assembled in place. One proposed application of such structures is in outer space. For example, it has been proposed to form spacecraft or portions of spacecraft from prefabricated inflatable structures. Prefabricated inflatable structures have also been proposed for...

AI Technical Summary

Benefits of technology

The solution provides lightweight, high-strength structures with reduced payload weight and minimal gas usage, preventing contamination and maintaining structural integrity over time, suitable for space and terrestrial applications.

Problems solved by technology

As a result, lost inflatant mass would decrease with increasing antenna size.

Any gas that does leak or diffuse through the structure over time will be a possible contaminant to sensors and solar cell arrays.

This is true even for a structure that only depends on the gas for deployment, not to maintain structural rigidity.

A mechanical approach has been successful in a number of cases, but it is limited to smaller structures due to the inefficiencies inherent in joints, fasteners and sliding surfaces.

A number of deployment failures have occurred that were traced to environmental effects, such as thermal expansion and contraction or to tribological effects.

However, the energy requirements for heating can be very taxing on a spacecraft's power system.

The residual stresses developed in a composite structure as it is heated during curing and cooled to ambient, and possibly very low, temperatures add complication to the design.

Another detrimental factor of such techniques is outgassing of the resin as it is processed.

Again, this presents a contamination issue.

The primary drawback to this technology has been the inability to develop a process that allows the resin to be cured with UV while the composite material is being compacted.

A composite structure cured with no compacting load will have a substantially reduced performance due to low fiber volume fraction.

Unfortunately, all of the commercial foaming technology produces a gas that can become a contaminant as it diffuses through the polymer.

A two component foaming technology is very difficult to control in terms of cell size and cell size distribution throughout a structure's cross-section.

These structures have limited application, as the spacecraft must be spinning.

The tubular boom is, however, limited by its buckling strength at the root.

This technology is limited by the amount of strain that can be placed on the longerons in the storage container.

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