Composite Lattice Frames for Lightweight Opto-Mechanical Support

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Solution Overview

Problem

Current fiber-reinforced polymer-matrix composite opto-mechanical support structures face limitations in stiffness and strength in non-fiber orientations, leading to increased thickness, weight, complexity, and cost, along with manufacturing challenges and risks in shell/ribs connections.

Innovation Solution

An interconnected lattice frame structure composed of unidirectionally fiber-reinforced composite rods with varying cross-sectional profiles and interstices, formed using Automated Fiber Placement (AFP) techniques, allowing for improved structural integrity and reduced weight, with the option to form continuous or dis-continuous loops and incorporate different materials and layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If fiber-reinforced polymer-matrix composite structures are used to substitute metal, then weight is reduced and corrosion resistance is improved, but stiffness and strength in non-fiber orientations deteriorate

Engineering Contradiction:

ImproveweightVSAvoidstiffness and strength in non-fiber orientations

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The structure is divided into a lattice framework composed of discrete composite rods arranged in specific geometric patterns. This segmentation allows each rod to be optimized for its specific load direction while the overall lattice structure provides multi-directional stiffness through the arrangement of rods rather than relying on material properties alone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses fiber-reinforced polymer-matrix composite materials with unidirectional fiber reinforcement. The composite rods are configured in lattice structures where the fiber orientation in each rod aligns with the primary load path, and the lattice geometry itself provides the necessary stiffness in non-fiber orientations through structural arrangement rather than material composition.

Inventive Principle:

Principle #40Composite materials

2Strength

If thickness is increased to compensate for low stiffness and strength in non-fiber orientations, then structural integrity is improved, but weight and fabrication complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Instead of increasing the thickness of solid composite shells, the structure is segmented into a lattice of slender rods. This allows the structure to achieve equivalent or superior structural integrity through the distributed arrangement of load-bearing elements, maintaining thin profiles and low weight while providing necessary stiffness through the lattice geometry.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from two-dimensional shell structures to three-dimensional lattice structures. This dimensional change allows the structure to achieve structural integrity through spatial arrangement and geometric configuration rather than relying on increased thickness, enabling thin-walled, lightweight designs with high structural performance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If current composite shell-based designs are used, then manufacturing is simplified, but stiffness and strength in non-fiber orientations are reduced requiring thickness increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstiffness in non-fiber orientations

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the fundamental geometric parameters of the structure from solid shells to lattice configurations. This parameter change transforms the structural behavior, allowing the use of thin-walled composite rods in lattice arrangements to achieve the same structural performance as thick solid shells, thereby maintaining manufacturing simplicity while improving stiffness-to-weight ratio.

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If manual labor is increased for fabrication of composite structures, then manufacturing precision is improved, but productivity decreases and cost increases

Engineering Contradiction:

Improvefabrication precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical assembly operations with automated robotic systems for fabricating composite rods and assembling lattice structures. This substitution maintains high manufacturing precision through controlled automated processes while dramatically improving productivity by eliminating manual labor bottlenecks and reducing assembly time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12181098B2Composite frames for opto-mechanical support structures

Publication Date: 2024.12.31 GOODRICH CORP

AI summary

A frame for an opto-mechanical support structure includes an interconnected lattice of frame composite rods defined about an interior space with interstices 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.