Nested Unit Cell Structures With Decoupled Load Paths
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Solution Overview
Problem
Existing components often require larger sizes and higher weights to handle multiple types of loads, leading to inefficiencies and increased costs due to shared load paths, which can result in excessive weight and expense.
Innovation Solution
A nested unit cell structure with decoupled load paths is created using additive manufacturing, where a first section defines a first load path and a second section defines a separate load path with unit cells nested within the first section, allowing independent load carrying and optimized load-bearing characteristics for each type of load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If structures use the same load paths for different loads, then the structure can handle multiple types of loads, but the structure becomes excessively heavy and more expensive
Solution Approach 1:
The structure is divided into multiple independent load paths, each optimized for specific load types. The lattice structure comprises first lattice elements arranged in a first pattern for carrying first loads, and second lattice elements arranged in a second pattern for carrying second loads, allowing each segment to be optimized independently rather than using a single monolithic structure for all loads
Solution Approach 2:
The patent employs nested lattice structures where one lattice pattern is embedded within another. The first lattice elements are positioned within the spaces formed by the second lattice elements, creating a hierarchical nested arrangement that allows multiple load paths to coexist in a compact configuration, reducing overall structural weight while maintaining multiple load-bearing capabilities
2Reliability
If structures are built larger to handle multiple loads with sufficient safety factor, then the structure maintains adequate safety, but the component becomes excessively heavy
Solution Approach 1:
Different regions of the lattice structure have different element densities, orientations, and material properties optimized for the specific load types they encounter. The first lattice elements have properties optimized for first loads while the second lattice elements have properties optimized for second loads, allowing each local region to provide sufficient safety factor without requiring the entire structure to be oversized
Solution Approach 2:
The patent varies key structural parameters including lattice element size, spacing, orientation, and material composition across different regions of the structure. By changing these parameters locally to match the specific load requirements of each region, the structure achieves adequate safety factors for multiple load types without uniformly increasing size and weight throughout the entire component
3Device complexity
If a single structure handles multiple loads, then the component is simpler in configuration, but the load-bearing characteristics cannot be optimized for each load type
Solution Approach 1:
The unified lattice structure is segmented into functionally distinct zones with different lattice element patterns and orientations. Each segment is optimized for specific load types (e.g., compression, tension, shear), allowing load-bearing characteristics to be optimized for each load type while maintaining an integrated single-component configuration rather than requiring separate structural elements
Solution Approach 2:
The lattice structure is designed as a single multifunctional component that simultaneously handles multiple load types through its integrated nested lattice elements. The structure performs multiple functions (carrying different loads) within one unified configuration, avoiding the need for separate structural components while still achieving optimized load-bearing characteristics for each load type through the differentiated lattice patterns
Data Source
AI summary
A unit cell structure is provided. The unit cell structure includes a first section and a second section. The first section defines a first load path and includes a first plurality of first unit cells joined together. The second section defines a second load path separate from the first load path and includes a second plurality of second unit cells joined together, each second unit cell of the second plurality of second unit cells nested within and spaced apart from each first unit cell of the first plurality of first unit cells of the first section.