Composite Truss Manufacturing via Segmented Unit Cell Fusion
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Solution Overview
Problem
Current methods for manufacturing fiber-composite trusses are limited in producing structures with continuous, variably aligned fibers, non-constant cross sections, and high consolidation, which are essential for optimal mechanical performance and cost-effectiveness.
Innovation Solution
The method involves fabricating trusses by individually molding unit cells and fusing them together, using a progressive molding process to consolidate aligned-fiber cross members with continuous fiber longerons, or unioning continuous-fiber longerons to planar cross members via mechanically interlocking joints, allowing for continuous fiber orientation and non-constant cross-sectional geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If continuous compression molding (CCM) is used to manufacture composite beams, then unidirectional fiber alignment and constant cross-section are achieved, but the ability to produce variably aligned fibers and non-constant cross sections is lost
Solution Approach 1:
The truss structure is divided into multiple unit cells, each independently molded and then assembled. This segmentation allows each unit cell to have optimized fiber alignment for its specific structural role, while the overall assembly achieves non-constant cross-section and variable fiber orientations through the combination of different unit cells.
Solution Approach 2:
The invention combines different fiber-reinforced composite materials with varying fiber orientations, lengths, and arrangements within the same truss structure. Longer continuous fibers are used in longerons for axial loading, while shorter fibers are used in cross members for transverse loading, optimizing mechanical performance for each structural element.
2Adaptability or versatility
If filament winding is used to produce beams with non-constant cross section, then cross-section variability is achieved, but unidirectional fiber alignment and high consolidation are lost
Solution Approach 1:
Instead of attempting to produce the entire truss in one continuous process, the structure is segmented into discrete unit cells that can be independently molded with precise fiber alignment using compression molding, then assembled to achieve the overall non-constant cross-section geometry.
Solution Approach 2:
The longerons are pre-formed with continuous unidirectional fibers using compression molding to ensure high fiber alignment and consolidation, then these pre-formed elements are assembled into the final truss structure with varying cross-section, combining the benefits of both approaches.
3Manufacturing precision
If braiding machines are used to produce closed-shape beams with axially-aligned fibers, then fiber alignment is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The complex truss structure is divided into simpler unit cells that can be manufactured using standard compression molding equipment. This segmentation eliminates the need for complex braiding machines while maintaining fiber alignment through proper mold design and preform placement.
Solution Approach 2:
The invention uses simple, readily available compression molding equipment rather than expensive, specialized braiding machines. The molds are designed to directly form the unit cells with appropriate fiber orientations, eliminating the need for complex machinery while achieving the desired fiber alignment.
4Shape
If traditional truss manufacturing methods are used, then lattice geometry is achieved, but high consolidation and applied pressure during manufacturing are lost
Solution Approach 1:
The truss is divided into unit cells that are independently molded under high pressure using compression molding, ensuring high consolidation and applied pressure during manufacturing. The lattice geometry is achieved through the assembly of these densely consolidated unit cells with precise fit-up at the joints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of trusses with improved mechanical performance and reduced costs by maximizing the second moment of area and fiber alignment, resulting in higher structural integrity and efficiency.
Implementation Method 1
subjected to heat and pressure sufficient to form structurally sound, consolidated components
Implementation Method 2
subjected to heat and pressure sufficient to form structurally sound, consolidated components
Implementation Method 3
adjacent ones of which are fused or otherwise joined together, with the longerons of adjacent unit cells being thermally bonded to one another
Data Source
AI summary
Methods for fabricating fiber-composite truss structures comprise a) individually molding multiple unit cells of a given size, and subsequently fusing them together in a repeating pattern, b) cross members are consolidated with longerons while maintaining continuity of fiber in the longerons, and c) compression-molded truss components are unioned to continuous fiber beams by means of mechanically interlocking joints.