초록 ▼

A method and apparatus for fabricating a complex, three-dimensional structure (12), such as a truss, from composite fiber/resin includes pulling a plurality of continuous fibers (50) from a feed source (62) along a processing path (58) about a longitudinal axis (14). At least some of the fibers are

A method and apparatus for fabricating a complex, three-dimensional structure (12), such as a truss, from composite fiber/resin includes pulling a plurality of continuous fibers (50) from a feed source (62) along a processing path (58) about a longitudinal axis (14). At least some of the fibers are wound around the longitudinal axis in opposite directions (70,72) by rotational elements to form helical and reverse helical components (30, 34) that intersect at nodes (26,28). Select nodes are engaged by engagement members (84) and are maintained radially outwardly from the longitudinal axis by a support frame (80) to create sequential discrete segments (22) in the helical and reverse helical components. The select nodes can be engaged and maintained from outside the helical and reverse helical components. Resin can be applied to the fibers by resin applicator (90) and cured. A three-dimensional structure (200) can be formed with one or more continuous fibers forming two or more different components (204, 206) of the structure and transitioning at transition nodes ( 207). A three-dimensional structure can be formed with the components including a sleeve (162) of braided fibers surrounding a core ( 163) of elongated fibers to reduce gaps.

대표청구항 ▼

What is claimed is: 1. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) pulling a plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; b) winding at least some of the fibers around

What is claimed is: 1. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) pulling a plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; b) winding at least some of the fibers around the longitudinal axis in opposite directions to form helical and reverse helical components that intersect at nodes; c) engaging the fibers in the processing path substantially only at locations localized at select nodes without substantially engaging the helical and reverse helical components; d) maintaining the select nodes radially outwardly from the longitudinal axis to create sequential discrete segments in the helical and reverse helical components forming a skeleton structure; e) simultaneously pulling the skeleton structure along the processing path while forming the skeleton structure; f) applying a resin to the fibers; and g) curing the resin. 2. A method in accordance with claim 1, wherein the step of engaging the select nodes further includes engaging the select nodes from outside the helical and reverse helical components; and wherein the step of maintaining the select nodes further includes maintaining the select nodes radially outwardly by a force originating from outside the helical and reverse helical components. 3. A method in accordance with claim 1, wherein the step of maintaining further includes the step of displacing the select nodes radially outwardly from the longitudinal axis. 4. A method in accordance with claim 1, wherein the step of maintaining further includes maintaining the fibers in a desired configuration without using an internal mandrel disposed inside an interior space defined by the helical and reverse helical components. 5. A method in accordance with claim 1, further comprising the step of: arranging a plurality of continuous fibers into a skeleton structure having a desired configuration, including at least: 1) continuous straight strands oriented along the processing path and spaced apart from the longitudinal axis; 2) helical strands with sequential discrete segments wrapping around the longitudinal axis in one direction; and 3) reverse helical strands with sequential discrete segments wrapping around the longitudinal axis in another opposite direction, with the helical and reverse helical strands intersecting at nodes. 6. A method in accordance with claim 1, further comprising the step of: a) guiding the plurality of continuous fibers along the processing path and around the longitudinal axis in opposite directions to form: 1) at least two, spaced apart, helical components each having a common angular orientation about the longitudinal axis, and 2) at least one reverse helical component, attached to the at least two helical components having an opposing angular orientation with respect to the two helical components; and wherein engaging and maintaining the nodes forms at least three elongate, discrete segments sequentially connected end to end in a helical configuration forming a single, substantially complete rotation about the longitudinal axis. 7. A method in accordance with claim 1, further comprising the step of: a) guiding other of the plurality of continuous fibers along the processing path and the longitudinal axis substantially parallel with the longitudinal axis to form longitudinal components; and b) intersecting the helical, reverse helical, and longitudinal components at internal nodes. 8. A method in accordance with claim 1, further comprising the step of: a) guiding other of the plurality of continuous fibers along the processing path and the longitudinal axis substantially parallel with the longitudinal axis to form longitudinal components; and b) intersecting the helical, reverse helical, and longitudinal components at external nodes. 9. A method in accordance with claim 1, further comprising the step of: a) arranging a plurality of continuous fibers to form a plurality of elongated strands in a predetermined orientation including at least two different strands with different orientations that intersect one another at at least one of the nodes; b) overlapping the plurality of fibers at the node; and c) consolidating the plurality of fibers in each strand together. 10. A method in accordance with claim 9, wherein the step of overlapping the plurality of fibers at the nodes includes forming gaps between the plurality of fibers; and wherein the step of consolidating the plurality of fibers includes compacting the fibers together and reducing the gaps. 11. A method in accordance with claim 9, wherein the step of consolidating the fibers in each strand together includes twisting at least one of the strands. 12. A method in accordance with claim 9, wherein the step of consolidating the fibers in each strand together includes: wrapping other fibers around at least one of the strands to form a core of substantially unidirectional fibers wrapped with a layer of outer fibers. 13. A method in accordance with claim 9, wherein the step of consolidating the fibers in each strand together includes braiding at least one of the strands. 14. A method in accordance with claim 9, wherein the step of consolidating the fibers in each strand together includes: braiding other fibers around at least one of the strands to form a core of substantially unidirectional fibers wrapped with a layer of outer braided fibers. 15. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) pulling a plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; b) winding at least some of the fibers around the longitudinal axis in opposite directions to form helical and reverse helical components that intersect at nodes; c) engaging the fibers in the processing path substantially only at locations localized at select nodes from outside the helical and reverse helical components and without substantially engaging the helical and reverse helical components; d) maintaining the select nodes radially outwardly from the longitudinal axis by a force originating from outside the helical and reverse helical components to create sequential discrete segments in the helical and reverse helical components; e) applying a resin to the fibers; and f) curing the resin. 16. A method in accordance with claim 15, wherein the step of maintaining further includes the step of displacing the select nodes radially outwardly from the longitudinal axis. 17. A method in accordance with claim 15, wherein the step of maintaining further includes maintaining the fibers in a desired configuration without using an internal mandrel disposed inside an interior space defined by the helical and reverse helical components. 18. A method in accordance with claim 15, further comprising the step of: arranging a plurality of continuous fibers into a skeleton structure having a desired configuration, including at least: 1) continuous straight strands oriented along the processing path and spaced apart from the longitudinal axis; 2) helical strands with sequential discrete segments wrapping around the longitudinal axis in one direction; and 3) reverse helical strands with sequential discrete segments wrapping around the longitudinal axis in another opposite direction, with the helical and reverse helical strands intersecting at nodes. 19. A method in accordance with claim 15, further comprising the step of: a) guiding the plurality of continuous fibers along the processing path and around the longitudinal axis in opposite directions to form: 1) at least two, spaced apart, helical components each having a common angular orientation about the longitudinal axis, and 2) at least one reverse helical component, attached to the at least two helical components having an opposing angular orientation with respect to the two helical components; and wherein engaging and maintaining the nodes forms at least three elongate, discrete segments sequentially connected end to end in a helical configuration forming a single, substantially complete rotation about the longitudinal axis. 20. A method in accordance with claim 15, further comprising the step of arranging a plurality of continuous fibers into a skeleton structure having a desired configuration. 21. A method in accordance with claim 20, further comprising the step of simultaneously pulling the skeleton structure along the processing path while arranging the continuous fibers. 22. A method in accordance with claim 15, further comprising the step of: a) guiding other of the plurality of continuous fibers along the processing path and the longitudinal axis substantially parallel with the longitudinal axis to form longitudinal components; and b) intersecting the helical, reverse helical, and longitudinal components at internal nodes. 23. A method in accordance with claim 15, further comprising the step of: a) guiding other of the plurality of continuous fibers along the processing path and the longitudinal axis substantially parallel with the longitudinal axis to form longitudinal components; and b) intersecting the helical, reverse helical, and longitudinal components at external nodes. 24. A method in accordance with claim 15, further comprising the step of: a) arranging a plurality of continuous fibers to form a plurality of elongated strands in a predetermined orientation including at least two different strands with different orientations that intersect one another at at least one of the nodes; b) overlapping the plurality of fibers at the node; and c) consolidating the plurality of fibers in each strand together. 25. A method in accordance with claim 24, wherein the step of overlapping the plurality of fibers at the nodes includes forming gaps between the plurality of fibers; and wherein the step of consolidating the plurality of fibers includes compacting the fibers together and reducing the gaps. 26. A method in accordance with claim 24, wherein the step of consolidating the fibers in each strand together includes twisting at least one of the strands. 27. A method in accordance with claim 24, wherein the step of consolidating the fibers in each strand together includes: wrapping other fibers around at least one of the strands to form a core of substantially unidirectional fibers wrapped with a layer of outer fibers. 28. A method in accordance with claim 24, wherein the step of consolidating the fibers in each strand together includes braiding at least one of the strands. 29. A method in accordance with claim 24, wherein the step of consolidating the fibers in each strand together includes: braiding other fibers around at least one of the strands to form a core of substantially unidirectional fibers wrapped with a layer of outer braided fibers. 30. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) pulling a plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; b) winding at least some of the fibers around the longitudinal axis in opposite directions to form helical and reverse helical components that intersect at nodes; c) engaging the fibers in the processing path substantially only at locations localized at select nodes without substantially engaging the helical and reverse helical components; d) maintaining the select nodes radially outwardly from the longitudinal axis to create sequential discrete segments in the helical and reverse helical components; e) displacing the select nodes radially outwardly from the longitudinal axis; f) applying a resin to the fibers; and g) curing the resin. 31. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) pulling a plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; b) winding at least some of the fibers around the longitudinal axis in opposite directions to form helical and reverse helical components that intersect at nodes; c) engaging the fibers in the processing path substantially only at locations localized at select nodes without substantially engaging the helical and reverse helical components; d) maintaining the select nodes radially outwardly from the longitudinal axis to create sequential discrete segments in the helical and reverse helical components, and maintaining the fibers in a desired configuration without using an internal mandrel disposed inside an interior space defined by the helical and reverse helical components; e) applying a resin to the fibers; and f) curing the resin. 32. A method for fabricating a complex, three-dimensional structure from composite fiber/resin, comprising the steps of: a) arranging a plurality of continuous fibers into a skeleton structure having a desired configuration by: i) pulling the plurality of continuous fibers from a feed source along a processing path about a longitudinal axis; ii) winding at least some of the fibers around the longitudinal axis in opposite directions to form helical and reverse helical components that intersect at nodes; iii) engaging the fibers in the processing path substantially only at locations localized at select nodes without substantially engaging the helical and reverse helical components; and iv) maintaining the select nodes radially outwardly from the longitudinal axis to create sequential discrete segments in the helical and reverse helical components; b) simultaneously pulling the skeleton structure along the processing path while arranging the continuous fibers; c) applying a resin to the fibers; and d) curing the resin.