Wire-Woven Octet Truss Structure for Lightweight High-Strength Applications
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional cellular light structures, such as metal foams and truss-type materials, face challenges in achieving optimal mechanical and electrical properties due to high manufacturing costs, material inefficiencies, and inferior structural integrity, particularly when attempting to replicate ideal Octet or Kagome truss structures.
Innovation Solution
A three-dimensional wire-woven cellular light structure is created by intercrossing six groups of continuous wires at 60 degrees or 120 degrees angles in a three-dimensional space, forming a truss-type structure similar to the ideal Octet or Kagome truss, with the option to bond intersection points using adhesives or welding, and filling the empty space with resin or metal to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal foam is used to create cellular light structures, then the structure achieves light weight, but the mechanical properties such as strength and rigidity are inferior
Solution Approach 1:
The structure is segmented into a truss-type framework composed of multiple continuous wires arranged in octahedral and tetrahedral patterns, rather than using a homogeneous metal foam. This segmentation allows for optimized load distribution while maintaining light weight.
Solution Approach 2:
The invention uses composite construction by combining multiple continuous wires into a truss framework, creating a composite light structure that achieves both light weight and high mechanical strength through the synergistic arrangement of individual wire elements.
2Strength
If traditional manufacturing methods are used for truss structures, then the structural integrity is maintained, but the manufacturing cost is high and material waste is significant
Solution Approach 1:
Multiple continuous wires are merged and interwoven to form the complete truss structure in a single weaving process, eliminating the need for separate manufacturing and assembly steps. This merging reduces both manufacturing cost and material waste while maintaining structural integrity.
Solution Approach 2:
The weaving process uses continuous wires that are woven throughout the entire structure without interruption or discontinuity. This continuous action ensures structural integrity while improving manufacturing efficiency and reducing costs compared to traditional segmented assembly methods.
3Strength
If six groups of continuous wires are intercrossed to form ideal Octet or Kagome truss structures, then the mechanical properties are improved, but the manufacturing complexity increases
Solution Approach 1:
The weaving mechanism is designed with universal functionality to handle six groups of continuous wires simultaneously, performing multiple functions of intercrossing, tensioning, and positioning within a single integrated system. This multi-functionality reduces manufacturing complexity despite the intricate truss structure.
Solution Approach 2:
The manufacturing process transitions from two-dimensional wire arrangement to three-dimensional intercrossing of six wire groups, creating ideal Octet or Kagome truss structures. This dimensional transformation enables complex mechanical properties while the weaving mechanism manages the complexity through systematic spatial organization.
4Area of stationary object
If wire nets are laminated and bonded to create multi-layered structures, then the structural coverage is improved, but the bonding cost and number of bonding points increase
Solution Approach 1:
The bonding process is extracted and eliminated entirely by using a single-step weaving method that creates multi-layered structures through the interlacing of continuous wires. This removes the need for separate bonding operations, reducing bonding cost and the number of bonding points while maintaining comprehensive structural coverage.
Data Source
AI summary
Disclosed herein is a three-dimensional cellular light structure formed of continuous wire groups. In the cellular light structure, six orientational-wire groups are intercrossed each other at 60 degrees or 120 degrees of angles in a three-dimensional space to thereby construct the structure similar to the ideal Octet or Kagome truss and having a good mechanical property such as strength, rigidity or the like. A method of mass-producing the structure in a cost-effective manner is also disclosed. The three-dimensional cellular light structure has a similar form to the ideal Octet or Kagome truss. When required, the intersection points of the wires are bonded by means of welding, brazing, soldering, or a liquid- or spray-form adhesive to provide a structural material having a light weight and a good mechanical strength and rigidity. It can be made into a fiber-reinforced type composite material by filling part of or entire internal empty space of the structure.