Apparatus, System, and Method for Filamentary Composite Lattice Structure Manufacturing

Abstract

An apparatus, system, and method are disclosed for the manufacture of composite lattice structures comprising a weaving mechanism 104 configured to position fibers in a lattice structure, the weaving mechanism 104 comprising one or more bobbins 304 , each one or more bobbin 304 configured to carry fiber and a plurality of horn gears 302 configured to move the one or more bobbins 304 across the face of the weaving mechanism 104 to control the position of the fiber carried by the one or more bobbins 304 in the lattice structure, and a shape retention structure 108 configured to hold the fibers in lattice structure. Beneficially, such an apparatus, system, and method would automate the process of manufacturing composite lattice structures and reduce the costs associated with the existing methods for manufacturing such structures.

1 . An apparatus to manufacture filamentary composite lattice structures, the apparatus comprising:
 a weaving mechanism configured to position fibers in a lattice structure, the weaving mechanism comprising:
 one or more bobbins, each one or more bobbin configured to carry fiber; and 
 a plurality of horn gears configured to move the one or more bobbins across the face of the weaving mechanism to control the position of the fiber carried by the one or more bobbins in the lattice structure; and 
   a shape retention structure configured to hold the fibers in lattice structure until the lattice structure is cured to a rigid state.   
     
     
         2 . The apparatus of  claim 1 , further comprising a curing device configured to cure resin on the fibers held in the shape retention structure. 
     
     
         3 . The apparatus of  claim 1 , further comprising a resin impregnation device configured to apply a resin to the fibers in the filamentary composite lattice structure. 
     
     
         4 . The apparatus of  claim 1 , further comprising a pulling device configured to apply an axial force to the filamentary composite lattice structure. 
     
     
         5 . The apparatus of  claim 1  wherein one or more of the plurality of horn gears are driven by a spur gear on an adjacent one or more of the plurality of horn gears such that a motor attached to one of the plurality of horn gears drives the plurality of horn gears. 
     
     
         6 . The apparatus of  claim 1  wherein one or more of the plurality of horn gears are driven by an individual motor. 
     
     
         7 . The apparatus of  claim 1  wherein the weaving mechanism further comprises one or more switches configured to transfer the bobbin from one of the plurality of horn gears to an adjacent one of the plurality of horn gears. 
     
     
         8 . The apparatus of  claim 1  wherein one or more of the plurality of horn gears further comprise an aperture configured to allow a fiber to pass through the aperture. 
     
     
         9 . The apparatus of  claim 1  wherein one or more of the plurality of horn gears further comprises a gear assembly configured to be individually removed from the weaving mechanism. 
     
     
         10 . The apparatus of  claim 1 , further comprising a transition device configured to transfer fibers from the weaving mechanism to the shape retention structure. 
     
     
         11 . A system to manufacture filamentary composite lattice structures, the system comprising:
 a weaving mechanism configured to position fibers in a lattice structure, the weaving mechanism comprising:
 one or more bobbins, each one or more bobbin configured to carry fiber; and 
 a plurality of horn gears configured to move the one or more bobbins across the face of the weaving mechanism to control the position of the fiber carried by the one or more bobbins in the lattice structure; 
   a shape retention structure configured to hold the fibers in a lattice structure using one or more attachment mechanisms; and   a control module configured to control the weaving mechanism and direct the positioning of the fibers in the lattice structure.   
     
     
         12 . The system of  claim 11  wherein the one or more attachment mechanisms comprise one or more hooks configured to hold the lattice structure in a desired configuration. 
     
     
         13 . The system of  claim 11  wherein the one or more attachment mechanisms comprise one or more servo mechanisms configured to hold the lattice structure in a desired configuration. 
     
     
         14 . The system of  claim 11  wherein the relative position of the one or more attachment mechanisms is variable such that a bay length in a filamentary composite lattice structure manufactured by the system is adjustable. 
     
     
         15 . The system of  claim 11  wherein the relative position of the one or more attachment mechanisms is variable such that a diameter of a filamentary composite lattice structure manufactured by the system is adjustable. 
     
     
         16 . The system of  claim 11  wherein the one or more attachment mechanisms move relative to the weaving mechanism as the system manufactures a filamentary composite lattice structure such that the filamentary composite lattice structure is continuously manufactured. 
     
     
         17 . The system of  claim 11  wherein the shape retention structure is curved such that the filamentary composite lattice produced by the system is curved. 
     
     
         18 . A method for manufacturing a filamentary composite lattice structure, the method comprising:
 positioning fibers to form a lattice structure with a weaving mechanism configured to position fibers in a lattice structure, the weaving mechanism comprising:
 one or more bobbins, each one or more bobbin configured to carry fiber; and 
 a plurality of horn gears configured to move the one or more bobbins across the face of the weaving mechanism to control the position of the fiber carried by the one or more bobbins in the lattice structure; and 
   constraining the geometry of the assembled lattice structure in the shape definition component.   
     
     
         19 . The method of  claim 17 , wherein the method further comprises curing resin in the assembled lattice structure. 
     
     
         20 . The method of  claim 17 , further comprising tensioning the fibers with a pulling device.