Composite Lattice Frame for Lightweight Opto-Mechanical Stiffness
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Solution Overview
Problem
Existing opto-mechanical support structures based on metallic shell designs face limitations in stiffness, strength, and manufacturing complexity, particularly in non-fiber orientations, leading to increased thickness, weight, and cost, with composite structures mimicking metallic designs requiring manual labor and risk of damage.
Innovation Solution
A frame for opto-mechanical support structures is designed using an interconnected lattice of unidirectionally fiber-reinforced composite rods with varying cross-sectional profiles and interstices, formed via Automated Fiber Placement (AFP) technique, allowing for improved stiffness and strength while reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite structures mimic existing metallic shell-based designs, then corrosion resistance and durability are improved, but stiffness and strength in non-fiber orientations deteriorate
Solution Approach 1:
The patent divides the continuous shell structure into a lattice framework composed of discrete composite rods arranged in triangular patterns. This segmentation allows each rod to be optimally oriented with fibers aligned along its length, maximizing strength-to-weight ratio while the triangulated geometry provides structural stability in all directions, resolving the contradiction between composite material advantages and non-fiber orientation performance
Solution Approach 2:
The patent transitions from a two-dimensional shell design to a three-dimensional lattice structure. By adding the vertical dimension and creating a spatial framework, the structure achieves enhanced stiffness and strength in multiple orientations without increasing weight, as the 3D geometry provides structural integrity that compensates for the anisotropic nature of composite materials
2Strength
If thickness is increased to compensate for low stiffness and strength in non-fiber orientations, then structural integrity is improved, but weight increases
Solution Approach 1:
The patent employs fiber-reinforced composite materials with unidirectional fiber orientation in each rod element. By aligning fibers with the principal stress directions in each rod and using high-strength-to-weight ratio composite materials, the structure achieves superior structural integrity without increasing thickness or weight, as the composite material properties are optimized for the specific load paths in the lattice structure
3Adaptability or versatility
If manual labor is used for fabrication of composite structures, then design flexibility is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces manual mechanical fabrication with automated fiber placement (AFP) technology. The AFP system uses computer-controlled robotic arms to precisely lay down composite fibers according to pre-programmed paths, eliminating manual labor while maintaining design flexibility. The automated system can efficiently fabricate complex lattice geometries and curved surfaces that would be difficult to manufacture traditionally, reducing both labor intensity and manufacturing complexity
Solution Approach 2:
The patent utilizes the ability of AFP technology to dynamically change fiber placement parameters (orientation, spacing, layering) during manufacturing. This allows the same automated system to produce different lattice configurations and rod cross-sections by modifying digital parameters rather than physical tooling, maintaining design flexibility while automating the manufacturing process
Data Source
Figure 1
Figure 2a
Figure 2b~2e
AI summary
A frame (100) for an opto-mechanical support structure includes an interconnected lattice (102) of frame composite rods (104) defined about an interior space (106) with interstices (108) defined between the frame composite rods. A method of making an opto-mechanical frame includes forming a frame of interconnected lattice of frame composite rods using one or more Automated Fiber Placement (AFP) around a mandrel. The method includes removing the mandrel from an interior space of the frame after forming the frame.