Tailorable fiber-reinforced support structure for use in precision manufacturing

Abstract

A fiber-reinforced support structure for use in precision manufacturing includes a composite housing having a core sandwiched between first and second groups of carbon-fiber reinforced layers. A plurality of cavities in the housing are provided for removably receiving inserts utilized to support components during precision manufacturing. Each of the cavities is lined with a carbon-fiber reinforced layer, and a protective ultraviolet-cured coating is provided on the exterior of the housing to prevent contamination in the manufacturing environment.

What is claimed is:  
     
         1 . A fiber-reinforced support structure for use in precision manufacturing, comprising: 
 a core having upper and lower surfaces;    a plurality of fiber-reinforced layers disposed on each of said upper and lower surfaces; and    at least one cavity extending partially through the thickness of said core and through the fiber-reinforced layers on one of said upper and lower surfaces for receiving an insert to support a component used in precision manufacturing.    
     
     
         2 . The support structure of  claim 1 , wherein said core comprises a honeycomb structure.  
     
     
         3 . The support structure of  claim 1 , wherein said core comprises an aramid fiber honeycomb structure.  
     
     
         4 . The support structure of  claim 1 , wherein at least one of said fiber-reinforced layers comprises a carbon fiber-reinforced epoxy layer.  
     
     
         5 . The support structure of  claim 1 , wherein at least one of said fiber-reinforced layers comprises a graphite fiber-reinforced epoxy layer.  
     
     
         6 . The support structure of  claim 1 , wherein said at least one cavity includes an internal lining comprising a graphite fiber-reinforced epoxy layer.  
     
     
         7 . The support structure of  claim 1 , wherein: 
 said core comprises side surfaces; and    said side surfaces are provided with at least one of said fiber-reinforced layers.    
     
     
         8 . The support structure of  claim 1 , further comprising a protective covering of an ultraviolet-cured epoxy provided on the exterior of the support structure.  
     
     
         9 . The support structure of  claim 5 , wherein said graphite fiber-reinforced epoxy layer comprises a unidirectionally aligned fiber layer.  
     
     
         10 . The support structure of  claim 9 , wherein a plurality of said unidirectionally aligned fiber layers are superimposed so as to be oriented at an angle of 0°-90° from each other.  
     
     
         11 . The support structure of  claim 10 , wherein six of said unidirectionally aligned fiber layers are disposed on each of said upper and lower surfaces on said core.  
     
     
         12 . A fiber-reinforced support structure for use in precision manufacturing, comprising: 
 a composite housing including a core sandwiched between first and second groups of carbon fiber-reinforced layers;    a plurality of cavities in said housing for removably receiving inserts utilized to support components used in precision manufacturing;    each of said cavities being lined with a carbon fiber-reinforced layer; and    a protective ultraviolet-cured coating provided on the exterior of said housing.    
     
     
         13 . The support structure of  claim 12 , wherein: 
 one of said first and second groups of carbon fiber-reinforced layers comprises unidirectionally aligned graphite-fiber layers; and    said graphite-fiber layers are oriented at an angle of 0°-90° with respect to each other.    
     
     
         14 . The support structure of  claim 13 , wherein said one of said first and second groups comprises six graphite-fiber layers.  
     
     
         15 . The support structure of  claim 13 , wherein said core comprises an aramid fiber honeycomb structure.  
     
     
         16 . The support structure of  claim 13 , wherein said graphite-fiber layers are oriented at an angle of about 45° with respect to each other.