The present disclosure is drawn to a lattice support structures and methods of making such structures, including tooling and articles used therein. In one embodiment, a method for forming a composite lattice support structure can comprise: obtaining a semi-rigid mold having semi-rigid channels, at least some of the semi-rigid channels intersecting at strategic locations; laying up a fiber material, in the presence of a resin, within the semi-rigid channels forming a lay- up within the semi-rigid channels, such that the lay-up extends above the surface of the mold; consolidating the lay-up to form composite cross supports having a pre-determined lateral cross-sectional area controlled by a cross-sectional area of the channels, and that intersect to form nodes, thereby forming the composite lattice support structure; and subjecting the composite lattice support structure to a particulate, wherein the composite lattice support structure is at least partially submerged in the particulate and systematically rotated to cause the particulate to contact the various surfaces of the cross supports and nodes thereby reducing at least of portion of material on the surfaces.
Three-dimensional carbon fiber based composite support structures and methods for the manufacture and use thereof are disclosed and described. In one aspect, such a support structure may include a lattice of intersecting support members made of a carbon fiber composite material and a cover of the same carbon fiber composite material as the lattice, fused to at least one side of the lattice and covering at least a portion thereof.
B32B 3/12 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
3.
METHOD AND SYSTEM FOR FORMING COMPOSITE LATTICE SUPPORT STRUCTURES
A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration is disclosed. The lattice support structure can be created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect. Subjecting these to a curing system functions to consolidate the cross supports and multi-layered nodes to produce the composite lattice support structure.
B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
B29C 70/10 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements
B29C 70/30 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core
4.
METHOD & SYSTEM FOR FORMING COMPOSITE LATTICE SUPPORT STRUCTURES
A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect. Subjecting these to a curing system functions to consolidate the cross supports and multi-layered nodes to produce the composite lattice support structure.
B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
5.
COLLAPSIBLE MANDREL TOOLS AND ASSOCIATED METHODS FOR FABRICATION OF WOUND COMPOSITE ARTICLES
Mandrels of various configuration, and action, including collapsible mandrels, to be used in forming composite articles with preselected three dimensional shapes and construction are disclosed and described. In one aspect, such a mandrel may have a plurality of discrete segments coupled about a longitudinal axis and collectively forming an enclosure with a substantially continuous exterior working surface. The working surface can have a network of intersecting grooves formed therein, and such grooves can cooperatively establish a substantially continuous interconnected lattice corresponding to the three dimensional geometric configuration to be imparted to a composite article formed. The mandrel may optionally include a removable core assembly to aid in collapse of the mandrel.
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