Device for joining nodes and tube structures

Abstract

The present application provides an apparatus for joining a node and a tube structure. The apparatus may include an additively manufactured first node and a second node, a tube, and an interconnect connecting the tube to the first node and the second node. The apparatus may include: a node having an end portion having an inner concentric portion and an outer concentric portion forming an annular gap therebetween; and a tube having an end portion extending into the gap.

Description

[0001] This application is a divisional application of a Chinese patent application with a filing date of August 8, 2018, a national application number of 201810897202.9, and a name of “System and method for joining nodes and pipe structures”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Patent Application No. 15 / 671,894, filed on August 8, 2017, entitled “SYSTEM AND METHOD FOR JOINING JOINTS AND TUBE STRUCTURES,” which is expressly incorporated herein by reference in its entirety. Technical Field

[0004] The present disclosure relates generally to connections between structures and, more particularly, to connections between nodes and tubes. Background Art

[0005] Space frame and monocoque constructions are used in automotive, structural, marine and many other applications. An example of a space frame construction may be a welded tube frame chassis construction, which is often used in low volume and high performance vehicle designs due to the advantages of low tooling costs, design flexibility and the ability to produce efficient structures. These structures require the tubes of the chassis to be connected at various angles and may require the same connection points to accommodate a variety of tube geometries. Conventional methods of manufacturing the joining members used to connect such tube frame chassis may incur high equipment and manufacturing costs. In addition, the monocoque design may result in design inflexibility when using planar elements or may result in high tooling costs when incorporating formed panels. Summary of the invention

[0006] Several aspects of node-tube connections are described more fully below.

[0007] In various aspects, an apparatus may include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes.

[0008] In various aspects, an apparatus may include a node having an end portion having an inner concentric portion and an outer concentric portion forming an annular gap therebetween, and a tube having an end portion extending into the gap.

[0009] Other aspects will become apparent to those skilled in the art through the following detailed description, wherein only several embodiments are shown and described by way of illustration. As will be appreciated by those skilled in the art, the concepts herein are capable of other and different embodiments, and several details are capable of being modified in various other aspects, all without departing from the present disclosure. Therefore, the drawings and detailed description are to be regarded as illustrative rather than restrictive in nature. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Various aspects will now be presented in detail by way of example and not by way of limitation in the accompanying drawings in which:

[0011] Figure 1 An exemplary vehicle chassis, a Blade supercar chassis, is shown in which aspects of the present disclosure may be implemented.

[0012] Figure 2A -E shows exemplary nodes, tubes, interconnects, and seals that form a joint.

[0013] Figure 3A -D shows exemplary nodes, tubes, and interconnects that form a joint.

[0014] Figure 4A -D shows exemplary nodes, tubes, interconnects, and seals that form a joint including a double shear connection.

[0015] Figure 5A -C shows other exemplary nodes, tubes, and interconnects that form a joint.

[0016] Fig. 6A -D shows an exemplary node including a connection portion connected to a tube to form a joint. DETAILED DESCRIPTION

[0017] The detailed description set forth below in conjunction with the accompanying drawings is intended to provide a description of various exemplary embodiments of the concepts disclosed herein, and is not intended to represent the only embodiments in which the present disclosure may be implemented. The term "exemplary" used in the present disclosure means "used as an example, instance, or illustration," and should not be interpreted as being more preferred or advantageous than other embodiments proposed in the present disclosure. The detailed description includes specific details for the purpose of providing a comprehensive and complete disclosure that fully conveys the scope of the concept to those skilled in the art. However, the present disclosure may be implemented without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, to avoid blurring the various concepts proposed throughout the present disclosure.

[0018] A node is an additively manufactured (AM) structure that includes features (e.g., sockets, receivers, etc.) for receiving another structure (e.g., a tube, panel, etc.). The present disclosure focuses on attachment designs for connecting various parts of node-based assemblies. Some of the interconnect designs of the invention are primarily responsible for the higher levels of dimensional tolerance acceptance that may be encountered when assembling complex structures. Some designs are also constructed to reduce weight, minimize the post-processing involved, and maximize ease of assembly. These conceived repetitive parts use sockets to adjust tolerances and co-print parts to take advantage of the uniqueness of 3D printing and simplify the assembly process. For each method, brazing pastes, thermoplastics, thermosets, etc. can be used instead of adhesives.

[0019] Figure 1 An exemplary sports car chassis, namely the Blade supercar chassis 100 manufactured by Divergent Technologies, is shown, which includes nodes and tubes as part of the structure. Automobile chassis, such as the Blade supercar chassis 100, are examples of structures in which aspects of the present disclosure may be implemented. Although the examples described herein are primarily directed to vehicle structures (such as chassis, buffers, etc.), it should be understood that aspects of the present disclosure may be applied to other structures including node-tube connections.

[0020] Blade super sports car chassis 100 includes carbon fiber tubes 101 connected by one or more nodes 103. Each node 103 may include, for example, a mid-body and one or more ports extending from the mid-body. In various embodiments, multi-port nodes may be configured to connect tubes (such as carbon fiber tubes 101) to form a two-dimensional or three-dimensional structure. For example, the structure may be a frame. In one example, a structure with tubes having axes in substantially the same plane may be referred to as a planar frame, while a structure with tubes having axes in different planes may be referred to as a space frame. A space frame may define a volume. In some examples, a three-dimensional space frame structure may be a vehicle chassis. A vehicle chassis may have a length, width, and height that define a space, such as a passenger compartment of a vehicle.

[0021] The vehicle chassis can form the framework of the vehicle. The vehicle chassis can provide a structure for placing the body panel (such as door panel, top panel, bottom panel or any other panel forming the vehicle closure) of the vehicle. In addition, the chassis can be a structural support for wheels, powertrain, engine block, electrical components, heating and cooling system, seat, storage space, etc. The vehicle can be a passenger car, truck, etc. The example of the vehicle can include but is not limited to sedan, truck, bus, truck, minivan, wagon, recreational vehicle, trailer, tractor, cart, automobile, train or motorcycle, ship, spacecraft or aircraft (for example, winged aircraft, rotorcraft, glider, lighter-than-air aerial vehicle). The vehicle can be a land-based vehicle, an aerial vehicle, a water-based vehicle or a space-based vehicle. Any description of any type of vehicle or vehicle chassis herein can be applicable to any other type of vehicle or vehicle chassis.

[0022] The vehicle chassis can provide a form factor that matches the form factor of the vehicle type. Depending on the type of vehicle, the vehicle chassis can have different configurations. The vehicle chassis can have different levels of complexity. In some cases, a three-dimensional space frame can be provided, which can provide an external frame for the vehicle. The external frame can be configured to receive body panels to form a three-dimensional closure. In some cases, internal supports or components can be provided. The internal supports or components can be connected to the space frame by one or more engaging members connected to the space frame. Different layouts of multi-port nodes and connecting pipes can be provided to accommodate different vehicle chassis configurations. In some cases, a group of nodes can be arranged to form a single unique chassis design. In some cases, at least one subset of the group of nodes can be used to form a multi-chassis design. In some cases, at least one subset of nodes in a group of nodes can be assembled into a first chassis design, and then disassembled and reused to form a second chassis design. The first chassis design and the second chassis design can be the same or they can be different.

[0023] In this example, the carbon fiber tube 101 is a carbon fiber material. In various embodiments, other composite materials may be used. Examples of composite materials include high modulus carbon fiber composites, high strength carbon fiber composites, plain carbon fiber composites, satin woven carbon composites, low modulus carbon fiber composites, low strength carbon fiber composites, etc. In some embodiments, the tube may be formed of other materials such as plastics, polymers, metals, metal alloys, etc. The tube may be formed of a rigid material. The tube may be formed of one or more metals and / or non-metallic materials.

[0024] The connecting pipe can have different cross-sectional shapes. For example, the connecting pipe can have a generally circular shape, a square shape, an oval shape, a hexagonal shape, or an irregular shape. The connecting pipe cross section can be a closed cross section. The connecting pipe cross section can be an open cross section, such as a C channel, an I-beam, an angle, etc.

[0025] The tube may be a hollow tube. The hollow portion may be provided along the entire length of the tube. For example, the connecting tube may have an inner surface and an outer surface. The inner diameter of the tube may correspond to the inner surface of the connecting tube. The outer diameter of the tube may correspond to the outer diameter of the connecting tube. The connecting tube may have two ends. The two ends may be opposite to each other. In some embodiments, the connecting tube may have three, four, five, six or more ends.

[0026] The various aspects of the node-to-tube connectors presented in this disclosure may be applicable to vehicle chassis frames, such as Figure 1 Nodes in the chassis 100 frame can be designed to accommodate tube angles dictated by the chassis design. Nodes can be manufactured in desired geometries to allow for rapid and low-cost assembly of the chassis. In some embodiments, 3D printing techniques can be used to manufacture nodes. 3D printing can allow nodes to be formed into a variety of geometries that can accommodate different frame configurations. 3D printing can allow nodes to be formed based on a computer-generated design file that includes node dimensions.

[0027] The nodes may be made of metallic materials (e.g., aluminum, titanium, stainless steel, brass, copper, chrome steel, iron, etc.), composite materials (e.g., carbon fiber, etc.), polymer materials (e.g., plastic, etc.), combinations of these and / or other materials, etc. The nodes may be formed of powdered materials. The nodes may be formed of one or more metal and / or non-metallic materials. The 3D printer may melt and / or sinter at least a portion of the powdered material to form the nodes. The nodes may be formed of a substantially rigid material.

[0028] Figure 2A -E, Figure 3A -D. Figure 4A -D. Figure 5A -C and Fig. 6A -D shows an exemplary node-tube joint (also called a connector). Figure 2A -E, Figure 3A -D. Figure 4A -D and Figure 5A -C shows a technique where the first node and the second node can be joined to the tube with an interconnect connecting the tube to the first node and the second node. Figures 6A-6DA technique is shown in which a node can be joined to a tube. In various embodiments, the joining can form a smooth, flat surface with an attractive appearance, and it reduces the need for post-processing such as grinding, finishing, etc. In this way, for example, nodes and tubes can be joined in a manner that reduces manufacturing time and cost. In various embodiments, one or more spacing structures can be arranged between the components of the joint (e.g., between a node and a tube, between two nodes, between a tube and an interconnect, etc.) to prevent these components from contacting each other. In this way, for example, nodes and tubes made of different materials can be joined in a manner that helps reduce or prevent different materials from reacting with each other. For example, nodes and tubes made of different metals can be joined in a manner that helps reduce or prevent galvanic corrosion. For example, this can expand the available options for materials used in different components of the joint, which can allow more suitable materials to be selected for each component. In turn, expanding material options can allow for better performance, durability, weight reduction, cost, etc. of the joint.

[0029] Figure 2A -E shows the formation of the joint 200 ( Figure 2D and Figure 2E ) of an exemplary node, tube, and interconnect. This example configuration includes a spacing structure formed between the components of the joint. In this example, the spacing structure includes the arrangement of a sealant that forms a sealed space between the components, and an adhesive that is injected into the sealed space. Through the sealed space, the sealant can prevent the adhesive from leaking from the sealed space, which can allow the joint to be formed more effectively and can provide a cleaner joint. In addition, the sealant can keep the components separated at a desired distance when the adhesive is cured. The sealant can also help protect the adhesive from environmental influences such as air, water, etc., which can reduce damage or degradation of the adhesive caused by environmental factors. Depending on the composition and design of the sealant, once the adhesive is cured, the sealant can provide other benefits to the spacing structure, such as increasing rigidity, flexibility, durability, etc. to the structure. The distance generated by the spacing structure between the components can be designed to prevent or reduce reactions such as galvanic corrosion between the components.

[0030] Figure 2A 200 prior to assembly and engagement. In particular, the first node 201, the tube 203, and the second node 205 may be engaged by an interconnecting member 206. The first node 201, the second node 205, and the interconnecting member 206 may each include a notch 208 for positioning a seal 207. Prior to assembly, as shown in FIG. Figure 2AAs shown in , one of the seals 207 can be positioned in the recess 208 on the shaft 211 of the interconnect 206. In various embodiments, the seal 207 can be a rubber seal (such as a rubber ring) that can be pressed to form a seal between adjacent components once the joint is assembled. In various embodiments, the seal can be made of other materials such as plastic, metal, etc.

[0031] The interconnect 206 may include a base 209 and a shaft 211. The shaft 211 may include an outer surface 212. When the components of the joint 200 are assembled, the first node 201, the tube 203, the second node 205, and the various surfaces of the interconnect 206 may be positioned close to each other inside the joint. These surfaces may be referred to as engagement surfaces. The base 209 may include an engagement surface 213 and an engagement surface 215. A channel 217 may extend through the interconnect 206, wherein one end of the channel includes an opening 219 in the base 209, and the other end of the channel includes an opening 221 in the shaft 211. In various embodiments, the channel 217 may include an opening at other locations on the interconnect 206, may include more than two openings, may include one or more openings at each engagement surface 213 and 215, may include openings arranged in a uniform distribution around the cross-sectional surface of the interconnect, and many other possible configurations. As described above, one of the seals 207 may be positioned in a recess 208, which may extend around the periphery of the shaft 211. In this regard, for example, the seal 207 may be positioned on the interconnect 206 before the interconnect is moved into position for assembly.

[0032] The engagement surface 223 of the first node 201 and the engagement surface 213 of the interconnect 206 may be complementary surfaces. In other words, the engagement surfaces 213 and 223 may be complementary to each other so that the surfaces fit together. For example, the engagement surface 213 may include a portion of a hemispherical surface, and the engagement surface 223 may include a complementary portion of an inverse hemispherical surface.

[0033] The tube 203 may include an inner surface 227, a joint surface 229, and a joint surface 231. The joint surface 229 may be shaped to fit the joint surface 225 of the first node 201. In this example, the joint surface 229 is a tapered surface. In various embodiments, the joint surface 229 may include a flat cross-sectional surface at the end (i.e., when the tube is cut perpendicular to the length axis). In various embodiments, the tube 203 may be a straight cylinder without a taper, and the joint surface 229 may include a portion of the outer surface of the tube 203 without a taper. In various embodiments, the joint surface 229 may be smooth, threaded, etc. The joint surface 225 of the first node 201 may be a complementary shape of the joint surface 229.

[0034] For example, the inner surface 227 of the tube 203 can be a straight cylindrical surface. In various embodiments, the inner surface 227 can include a tapered cylindrical surface, a threaded surface, etc. The inner surface 227 can be shaped to fit with the interconnect 206, and in particular, can be shaped to fit with the outer surface 212 of the shaft 211 of the interconnect.

[0035] Similarly, the second node 205 may include an engagement surface 233 shaped to mate with the engagement surface 231 of the tube 203 and may include an engagement surface 235 shaped to mate with the engagement surface 215 of the interconnect 206 .

[0036] Engagement surface 223 may include one of notches 208, and engagement surface 225 may include the other of notches 208. Likewise, engagement surface 233 may include one of notches 208, and engagement surface 235 may include the other of notches 208.

[0037] Figure 2B It is shown how the first node 201 and the second node 205 can be positioned so that the seal 207 can be inserted into the recess 208. In particular, one of the seals 207 can be inserted into the recess 208 in the joining surfaces 225 and 233, and the other of the seals 207 can be inserted into the recess in the joining surfaces 223 and 235. For example, these seals 207 can also be rubber seals (such as rubber rings). In this embodiment, the seal 207 inserted into the recess 208 in the first node 201 and the second node 205 is thicker than the seal inserted into the recess around the shaft 211 of the interconnect 206. The thicker seal can form a desired distance between components made of different materials. In this example, the first node 201 and the second node 205 can be made of a first metal, and the tube 203 and the interconnect 206 can be made of a second metal. As will be described below with reference to Figure 2D Described in more detail, thicker seals may provide a greater distance between a first metal component (ie, a node) and a second metal component (ie, a tube and an interconnect).

[0038] Figure 2C All components of the joint 200 are shown assembled together prior to joining. In particular, Figure 2C It shows how the various engaging surfaces of the components complement each other and fit together.

[0039] Figure 2DVarious parts of the joint 200 that is assembled and joined are shown. In particular, adhesive 237 can be injected into channel 217. Adhesive 237 can be filled in the space between the joint surfaces 213 and 223, 225 and 229, 231 and 233, 235 and 215, and in the space between the inner surface 227 of the pipe 203 and the outer surface 212 of the interconnecting member 206. In this example, the seal 207 can include the adhesive 237 to the space between the joint surfaces. In this way, for example, the first node 201, the pipe 203 and the second node 205 can be joined together with the interconnecting member 206. In addition, the seal 207 can allow the adhesive 237 to be injected more forcefully without worrying that the excess adhesive leaks from the joint, which can allow faster assembly. Similarly, the seal 207 can allow the use of an adhesive with less viscosity, which can allow the use of a wider range of adhesives.

[0040] like Figure 2D As shown, seal 207 and adhesive 237 can form a spacing structure 239 that can separate the various components of joint 200. In particular, a thicker seal separates a first metal component (i.e., a node) from a second metal component (i.e., a tube and an interconnect) by a greater distance, while a thinner seal around the interconnect shaft separates the tube from the interconnect by a smaller distance. In this way, for example, components made of different metals can be separated by a greater distance to reduce or prevent galvanic corrosion, while components made of the same (or similar) metals can be spaced more closely together, which can allow for a more rigid structure.

[0041] The spacing structure can be constructed to meet the design requirements of the joint. For example, the spacing structure can form various spacing distances between the parts of the joint. In various embodiments, the spacing structure can form a larger spacing distance between the parts to reduce or prevent the reaction between the parts. For example, a larger spacing distance can help reduce or prevent galvanic corrosion, particularly in the joint of adjacent parts with very different electrode potentials. The spacing structure can be made of a variety of materials, such as rubber, adhesive, plastic, metal, etc. The material composition of the spacing structure can be designed to provide special benefits, such as providing the flexibility of movement between the joint parts, providing rigidity to reduce or prevent movement between the joint parts, making the joint water-resistant or waterproof, making the joint resistant to other materials such as oil, grease, dirt, etc. In various embodiments, for example, the structural design and material composition of the spacing structure can allow the joint to fail smoothly, which can allow the joint to be used as a part of the buffer zone by allowing a portion of the collision energy to dissipate in the controlled local failure of the joint.

[0042] Figure 2E A perspective view of the joint 200 is shown. Figure 2E As shown, the bonding technique may allow the exposed surface of the base 209 (eg Figure 2A -D is shown at the bottom of the base) and is flush with the bottom surface of the first node 201 and the second node 205, and at the same time, due to the spacing structure 239, the surfaces of the base, the first node, and the second node are allowed to be separated by the gap 241 (in addition, Figure 2D In this manner, for example, the joining technique can form a smooth, planar surface that has an attractive appearance and reduces the need for post-processing such as grinding, finishing, etc., and thus, nodes and tubes can be joined in a manner that reduces manufacturing time and cost.

[0043] The first node 201 and the second node 205 and one or both of the tube 203 and the interconnect 206 may be manufactured by additive manufacturing. For example, the first node 201, the second node 205, and the interconnect 206 may be additively manufactured. In some embodiments, the first node 201, the second node 205, and the interconnect 206 may be additively manufactured in the same print run. In various embodiments, the interconnect 206 and the complementary surfaces of the first node 201 and the second node 205 may be utilized to additively manufacture these structures closely connected with the complementary surfaces adjacent to each other by spaced manufacturing. In this way, for example, these structures may allow for a more efficient additive manufacturing process because they can be packed more tightly together, thereby increasing the output of each print run.

[0044] Figure 3A -D shows the formation of the joint 300 ( Figure 3C and Figure 3D ) of exemplary nodes, tubes, and interconnects. Figure 3A Various components of the joint 300 are shown prior to assembly and engagement. In particular, the first node 301, the tube 303, and the second node 305 can be joined by the interconnect 307. The interconnect 307 can include a base 309 and a shaft 311. The shaft 311 can include an outer surface 312. The base 309 can include an engagement surface 313 and an engagement surface 315. A channel 317 can extend through the interconnect 307, wherein one end of the channel includes an opening 319 in the base 309, and the other end of the channel includes an opening 321 in the shaft 311. In various embodiments, the channel 317 can include an opening at other locations on the interconnect 307, can include more than two openings, can include one or more openings at each of the engagement surfaces 313 and 315, can include openings evenly distributed around the cross-section of the interconnect, and many other possible configurations.

[0045] The first node 301 may include a bonding surface 323 and a bonding surface 325. The bonding surface 323 of the first node 301 and the bonding surface 313 of the interconnect 307 may be complementary surfaces. In other words, the bonding surfaces 313 and 323 may be complementary to each other so that the surfaces fit together. For example, the bonding surface 313 may include a portion of a hemispherical surface, and the bonding surface 323 may include a complementary portion of an inverse hemispherical surface.

[0046] The tube 303 may include an inner surface 327, a joint surface 329, and a joint surface 331. The joint surface 329 may be shaped to fit the joint surface 325 of the first node 301. In this example, the joint surface 329 is a tapered surface. In various embodiments, the joint surface 329 may include a flat cross-sectional surface at the end (i.e., as if the tube was cut perpendicular to the length axis). In various embodiments, the tube 303 may be a straight cylinder without a taper, and the joint surface 329 may include a portion of the outer surface of the tube 303 without a taper. In various embodiments, the joint surface 329 may be smooth, threaded, etc. The joint surface 325 of the first node 301 may be a complementary shape of the joint surface 327.

[0047] For example, the inner surface 327 of the tube 303 can be a straight cylindrical surface. In various embodiments, the inner surface 327 can include a tapered cylindrical surface, a threaded surface, etc. The inner surface 327 can be shaped to fit with the interconnect 307, and in particular, can be shaped to fit with the outer surface 312 of the shaft 311 of the interconnect.

[0048] Similarly, the second node 305 may include an engagement surface 333 shaped to mate with the engagement surface 331 of the tube 303 and may include an engagement surface 335 shaped to mate with the engagement surface 315 of the interconnect 307 .

[0049] Figure 3B The various components of the joint 300 are shown assembled together prior to joining. In particular, Figure 3B It shows how the various engaging surfaces of the components complement each other and fit together.

[0050] Figure 3C The various components of the joint 300 are shown assembled and joined. In particular, adhesive 337 can be injected into channel 317. Adhesive 337 can fill the spaces between the joint surfaces 313 and 323, 325 and 329, 331 and 333, 335 and 315, and the spaces between the inner surface 327 of the tube 303 and the outer surface 312 of the interconnect 307. In this way, for example, the first node 301, the tube 303, and the second node 305 can be joined together with the interconnect 307.

[0051] Figure 3D A perspective view of the joint 300 is shown. Figure 3D As shown, the joining technique can allow the exposed surface of the base 309 (as shown at the bottom of the base) to be flush with the bottom surfaces of the first node 301 and the second node 305. In this way, for example, the joining technique can form a smooth, flat surface that has an attractive appearance and reduces the need for post-processing such as grinding, finishing, etc., and thus, the node and the tube can be joined in a manner that reduces manufacturing time and cost.

[0052] The first node 301 and the second node 305 and one or both of the tube 303 and the interconnect 307 may be manufactured by additive manufacturing. For example, the first node 301, the second node 305, and the interconnect 307 may be additively manufactured. In some embodiments, the first node 301, the second node 305, and the interconnect 307 may be additively manufactured in the same print run. In various embodiments, the interconnect 307 and the complementary surfaces of the first node 301 and the second node 305 may be utilized to additively manufacture these structures closely connected with the complementary surfaces adjacent to each other by spaced manufacturing. In this way, for example, these structures may allow for a more efficient additive manufacturing process because they can be packed more tightly together, thereby increasing the output of each print run.

[0053] Figure 4A -D shows the formation of the joint 400 ( Figure 4C and Figure 4D ) of exemplary nodes, tubes, and interconnects. Figure 4A Various components of the joint 400 are shown before assembly and engagement. In particular, the first node 401, the tube 403, and the second node 405 can be engaged by the interconnect 407. The interconnect 407 may include a base 409 and an axis 411. In this regard, the interconnect 407, the first node 401, and the second node 405 have various engagement surfaces, which are not labeled for clarity. The interconnect 407 may also include a flange 413. The flange 413 may provide additional engagement surface area for connecting the tube 403 to the interconnect 407. In this regard, the flange 413 may form a double shear connector 419 between the tube 403 and the interconnect 407.

[0054] The first node 401, the second node 405, and the interconnect 407 may include a seal 415 positioned within the recess 416, before the assembly is positioned (e.g., the seal is positioned in the recess of the interconnect) or after the partial assembly (e.g., the seal is positioned in the recess on the first node and the second node). For example, the seal 415 can be a rubber seal (e.g., a rubber ring) that can be pressed to form a seal between adjacent components once the joint is assembled. In various embodiments, the seal (e.g., the seal 415) can be part of a spacing structure that prevents portions of various components from contacting each other. The channel 417 can extend through the interconnect 407. In various embodiments, the channel (e.g., the channel 417) can include openings located at multiple locations on the interconnect 407, can include more than two openings, can include openings evenly distributed around the cross-section of the interconnect, and many other possible configurations. In this example, the channel 417 can include two branches so that the adhesive 421 injected into the channel can appear at two different joint surface locations. This may allow adhesive 421 to reach spaces between joining surfaces separated, for example, by seal 415. After first node 401, tube 403, second node 405, and interconnect 407 are joined together, adhesive 421 may be injected into channel 417 to join the node and tube together with the interconnect.

[0055] like Figure 4C As shown, the first node 401, the tube 403, the second node 405, and the interconnect 407 may include a plurality of engagement surfaces that may be complementary to each other so that the surfaces fit together. It should be noted that other configurations of the engagement surfaces are possible, for example, the tube 403 may include a tapered surface that fits with a similarly tapered opening formed by the flange 413 in various embodiments. In various embodiments, the various engagement surfaces may be smooth, threaded, etc.

[0056] Figure 4B The various components of the joint 400 are shown assembled together prior to joining. In particular, Figure 4B It shows how the various engaging surfaces of the components complement each other and fit together.

[0057] Figure 4C The various components of the joint 400 are shown assembled and joined. In particular, the adhesive 421 can be injected into the channel 417 and can fill the space between the first node 401 and the interconnect 407, between the interconnect 407 and the tube 403, and between the second node 405 and the interconnect 407. In this way, for example, the first node 401, the tube 403, and the second node 405 can be joined together with the interconnect 407.

[0058] Figure 4D A perspective view of joint 400 is shown. Figure 4A -D joining techniques can allow the exposed surface of the base 409 (as shown at the bottom of the base) to be flush with the bottom surfaces of the first node 401 and the second node 405. In this way, for example, the joining technique can form a smooth, flat surface that has an attractive appearance and reduces the need for post-processing such as grinding, finishing, etc., and thus, the node and the tube can be joined in a manner that reduces manufacturing time and cost.

[0059] One or more of the first node 401, the tube 403, the second node 405, and the interconnect 407 may be manufactured by additive manufacturing. For example, the first node 401, the second node 405, and the interconnect 407 may be additively manufactured. In some embodiments, the first node 401, the second node 405, and the interconnect 407 may be additively manufactured in the same print run. In various embodiments, the interconnect 407 may be additively manufactured by spaced-apart manufacturing of these structures that are closely connected with complementary surfaces adjacent to each other using complementary surfaces of the first node 401 and the second node 405. In this way, for example, these structures may allow for a more efficient additive manufacturing process because they can be packed more tightly together, thereby increasing the output of each print run.

[0060] Figure 5A -C shows the formation of the joint 500 ( Figure 5B and Figure 5C Example nodes, tubes, and interconnects shown in FIG. Figure 5A 500 prior to assembly and engagement. In particular, the first node 501, the tube 503, and the second node 505 may be joined by an interconnect 507. The interconnect 507 may be an annular structure including a flange 509. In this regard, Figure 5A -B shows two parts (also referred to herein as elements) of the interconnect 507, and it should be understood that the two parts are part of the same structure of the interconnect. The two elements of the interconnect 507 form a slot 510 therebetween.

[0061] The first node 501 may include a bracket 511, and the second node 505 may include a bracket 513. The brackets 511 and 513 may be configured to support the flange 509. The brackets 511 and 513 may have, for example, an arc shape that matches the annular shape of the flange 509. The interconnect 507 may include a sealing component, such as a seal 515 that may be seated in the recess 517. For example, the sealing component may be included on the flange 509 and on the surface of the slot 510. In various embodiments, a seal, such as the seal 515, may be part of a spacing structure that prevents portions of various components from contacting each other.

[0062] Figure 5B The various components of the joint 500 are shown assembled and joined. In particular, the tube 503 can be inserted into the slot 510, wherein the adhesive 519 is applied in the space between the sealing components. In this regard, the seal 515 can contain the adhesive 519 to provide a more controlled bonding area. The seal 515 can be, for example, a rubber seal or another type of seal. Thus, as shown in FIG. Figure 5B As shown, interconnect 507 can be joined to first node 501, tube 503 can be joined to interconnect, and interconnect can be joined to second node 505. Brackets 511 and 513 can provide additional support to interconnect 507 by supporting flange 509, and the bracket and flange structure can provide a fail-safe connection between the interconnect and the first node and the second node in the event of failure of adhesive 519. In this regard, joint 500 can provide a graceful failure of the node-interconnect connection.

[0063] Figure 5C A perspective view of a joint 500 is shown. Figure 5C As shown, brackets 511 and 513 come together during assembly to completely cover the outer edge of interconnect 507 .

[0064] It should be noted that one or more of the first node 501, the tube 503, the second node 505, and the interconnect 507 can be manufactured by additive manufacturing. For example, the first node 501, the second node 505, and the interconnect 507 can be additively manufactured. In some embodiments, the first node 501, the second node 505, and the interconnect 507 can be additively manufactured in the same printing run. In various embodiments, the interconnect 507 can be additively manufactured by spaced-apart manufacturing of these structures that are closely connected with complementary surfaces adjacent to each other using complementary surfaces of the first node 501 and the second node 505. In this way, for example, these structures can allow for a more efficient additive manufacturing process because they can be packed more tightly together, thereby increasing the output of each printing run.

[0065] Fig. 6A -D shows a device comprising connecting to a tube to form a joint 600 ( Fig.6D An exemplary node of a connected portion of FIG. 1 ). Fig. 6AVarious components of the joint 600 before assembly and engagement are shown. In particular, the node 601 may include an inner portion 603 and an outer portion 605 at one end. The inner portion 603 and the outer portion 605 may form an annular gap 607 in the node 601. In various embodiments, the inner portion 603 may have a disc shape, and the outer portion 605 may have an annular shape concentric with the disc shape, so that the annular gap 607 includes an annular gap configured to fit a circular tube (such as tube 609). In various embodiments, the inner portion 603 and the outer portion 605 may have other shapes, such as square, rectangular, etc., to fit tubes with corresponding other shapes. In this example, the tube 609 is a carbon fiber tube, which includes a cured portion 610 and an uncured portion 611. The carbon fibers of the tube 609 are injected with resin in the cured portion 610, and the carbon fibers are not injected with resin in the uncured portion 611. In other words, the uncured portion has dry carbon fibers that are not bonded to each other, i.e., loose fibers.

[0066] Node 601 can be, for example, an additively manufactured metal structure, an additively manufactured plastic structure, a carbon fiber structure, etc. Seal 612 can be arranged on the inner surface of annular gap 607. Seal 612 can be, for example, a rubber seal or another type of seal. In various embodiments, a seal (such as seal 612) can be part of a spacing structure, which can, for example, prevent a portion of the tube from contacting the surface of the annular gap. Node 601 can also include a first port 613 and a second port 615. The first port 613 and the second port 615 can be channels, each of which connects a portion of the annular gap 607 to the outer surface of the node.

[0067] Figure 6B The various components of joint 600 are shown assembled together but not yet joined. In particular, tube 609 can be inserted into annular gap 607. The loose carbon fibers of uncured portion 611 of tube 609 can flare outward and expand as they move deeper into annular gap 607. Seal 612 can contact tube 609 to form a seal.

[0068] Figure 6C A method of joining node 601 to tube 609 is shown. Specifically, resin 617 can be injected into first port 613 while suction (e.g., vacuum 619) is applied to second port 615. Vacuum 619 draws resin 617 through annular gap 607 and impregnates the loose carbon fibers of uncured portion 611 of tube 609. Resin 617 is allowed to cure so as to form a carbon fiber bond between node 601 and tube 609.

[0069] like Figure 6B and Figure 6CAs shown, the diameter of the annular gap can increase with increasing distance from the node end (i.e., the depth of the annular gap), which allows the loose carbon fibers of the uncured portion 611 to expand outward when inserted into the annular gap, thereby forming an expanded portion of the tube 609 that is adapted to the annular gap.

[0070] Fig.6D The joint 600 is shown after the resin 617 has cured. When the resin 617 cures, the portion of the resin that impregnates the loose carbon fibers of the tube 609 forms a cured carbon fiber flange 621 that is an integral part of the tube. In addition, the cured carbon fiber flange is formed within the annular gap 607 and form fits to the annular gap 607, which can increase the structural integrity of the joint.

[0071] The previous description is provided to enable those skilled in the art to implement the various aspects described herein. The various modifications to these exemplary embodiments given throughout this disclosure will be apparent to those skilled in the art. Therefore, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but to conform to the full scope consistent with the language claims. All structural and functional equivalents of the elements of the exemplary embodiments described throughout this disclosure that are known to those of ordinary skill in the art or that are later known to those skilled in the art are intended to be covered by the claims. In addition, regardless of whether such disclosure is explicitly stated in the claims, the content disclosed herein is not intended to be dedicated to the public. No claim should be interpreted under the provisions of Section 112 (f) of Article 35 of the United States Constitution, or similar laws in applicable jurisdictions, unless the element is explicitly recorded using the phrase "device for...", or in the case of a method claim, the element is recorded using the phrase "step for...".

Claims

1. A device for joining a node and a tube structure, comprising: a node having an end portion having an inner concentric portion and an outer concentric portion forming an annular gap therebetween; as well as a tube having an end portion extending into the annular gap, Characterized in that the annular gap has a depth starting from the surface of the end portion of the node, and the diameter of the annular gap increases with increasing distance from the surface of the end portion within at least a portion of the depth, wherein a section of the end portion of the tube expands outwardly along the annular gap within at least a portion of the depth, and the tube is a carbon fiber tube, including a cured portion and an uncured portion.

2. The device for joining a node and a pipe structure according to claim 1, characterized in that The outwardly flared section of the end of the tube comprises dry carbon fibers.

3. The device for joining a node and a pipe structure according to claim 1, characterized in that The node includes a channel for resin injection extending from an outer surface of the node to the annular gap.

4. The device for joining a node and a pipe structure according to claim 3, characterized in that An outwardly flared section of the end portion of the tube includes resin and carbon fibers from the passageway.

5. The device for joining a node and a pipe structure according to claim 3, characterized in that The node further includes a second passage extending from an exterior of the node to the annular gap for applying a vacuum during resin injection.

6. The device for joining a node and a pipe structure according to claim 1, characterized in that Further including: A spacing structure is disposed between the node and the tube.

7. The device for joining a node and a pipe structure according to claim 6, characterized in that The spacing structure includes a seal.

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