Devices for implementing node-to-node connections

Abstract

The present application relates to apparatus for implementing node-to-node connections. Techniques for joining nodes and subcomponents are presented herein. A first additively manufactured node or subcomponent has a slot. A second additively manufactured node or subcomponent has a tenon configured to extend into and mate with the slot to form a tongue-and-groove connection between the first and second nodes or subcomponents. In some aspects, the tongue-and-groove connection can extend generally around the periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface can be coupled to a second subcomponent having a fluid pipe interface via a tongue-and-groove connection, thereby allowing fluid to flow between the subcomponents of the resulting integrated component.

Description

[0001] This application is a divisional application of the invention application with the application date of July 6, 2018, application number 201810736097.0, and name “System and method for implementing node-to-node connection in mechanized components”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Patent Application No. 15 / 644,719, entitled “SYSTEMS AND METHODS FOR IMPLEMENTING NODE TO NODE CONNECTIONS IN MECHANIZED ASSEMBLIES,” filed on July 7, 2017, which is expressly incorporated herein by reference in its entirety. Technical Field

[0004] The present disclosure relates generally to techniques for joining subassemblies, and more particularly to joining nodes and other subassemblies using additively manufactured parts and techniques. Background Art

[0005] Three-dimensional (3D) printing, also known as additive manufacturing (AM), has recently provided new opportunities to more efficiently build automobiles and other transportation structures, such as aircraft, boats, motorcycles, buses, trains, etc. Applying AM processes to the industries that produce these products has been shown to produce structurally more efficient transportation structures. For example, cars produced using 3D printed parts can be made stronger, lighter, and therefore more fuel-efficient. In addition, AM allows manufacturers to 3D print parts that are more complex and equipped with more advanced features and capabilities than parts manufactured via conventional machining and casting techniques.

[0006] Despite these recent advances, many obstacles remain relative to the practical implementation of AM technologies in transport structures and other mechanized components. For example, regardless of whether AM is used to produce the various components of such devices, manufacturers typically rely on labor-intensive and expensive techniques such as welding, riveting, etc. to join components (such as nodes used in transport structures) together. The shortcomings associated with welding and similar techniques also apply to parts that are currently too large to be 3D printed in a single AM ​​step, such as vehicle gearboxes. A given 3D printer is typically limited to providing objects of limited size, often determined by the available surface area of ​​the 3D printer's build plate and the allowable volume that the printer can accommodate. In these cases, manufacturers often relegate to using conventional, expensive and time-consuming machining techniques to build the component. Alternatively, manufacturers can 3D print multiple sub-components and combine them to form a complete functional component. Summary of the Invention

[0007] Several aspects of techniques for joining nodes and subcomponents using adhesives are more fully described below with reference to three-dimensional (3D) printing techniques.

[0008] One aspect of the apparatus includes an additively manufactured first node having a slot, and an additively manufactured second node having a tenon extending into the slot to form a tongue-and-groove connection between the first and second nodes.

[0009] Another aspect of the apparatus includes an additively manufactured first subcomponent comprising a tongue structure disposed along a first peripheral region thereof and an additively manufactured second subcomponent comprising a groove structure disposed along a second peripheral region thereof, wherein the tongue structure is configured to cooperate with the groove structure along the first peripheral region and the second peripheral region.

[0010] Another aspect of the apparatus includes an additively manufactured first subcomponent comprising a first outer wall, and an additively manufactured second subcomponent comprising a second outer wall, wherein the first subcomponent and the second subcomponent mate via a tongue-and-groove connection circumferentially disposed around respective edges of the first and second outer walls.

[0011] One aspect of a method for manufacturing a component for a transport structure includes additively manufacturing a first subcomponent including a tongue structure disposed along a first peripheral region; additively manufacturing a second subcomponent including a groove structure disposed along a second peripheral region; and mating the tongue structure with the groove structure along the first peripheral region and the second peripheral region.

[0012] Another aspect of the method includes additively manufacturing a first subcomponent comprising a first outer wall; additively manufacturing a second subcomponent comprising a second outer wall; and mating the first and second subcomponents via a tongue-and-groove connection circumferentially disposed around respective edges of the first and second outer walls.

[0013] It should be understood that other aspects of adhesively bonding nodes and subassemblies will become readily apparent to those skilled in the art from the following detailed description, wherein several embodiments are shown and described by way of example only. As will be appreciated by those skilled in the art, bonding of additively manufactured nodes and subassemblies can also be achieved using other embodiments without departing from the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Various aspects of apparatus and methods for adhesively joining nodes and subcomponents will now be presented in a detailed description by way of example and not by way of limitation in the accompanying drawings in which:

[0015] Figure 1 Shown is a perspective view illustrating an additively manufactured node-node joint.

[0016] Figure 2 Shows the instructions Figure 1 Cross-sectional view of a node-to-node joint.

[0017] Figure 3 Shown is a top view illustrating a gearbox relative to a build plate of a large-scale selective laser melting (SLM) machine.

[0018] Figure 4 Shown are top views illustrating a gearbox shown relative to build plate 402 , with build plate 402 in different orientations.

[0019] Figure 5 Shows the instructions Figure 3 Perspective view of a gearbox.

[0020] Figure 6 A cross-sectional view illustrating an additively manufactured tongue and groove joint is shown.

[0021] Figure 7 An interface plan view illustrating a fluid tube interface including a cross section of a tube for conveying fluid between subcomponents is shown.

[0022] Figure 8 Shown is a perspective view illustrating a plurality of additively manufactured subcomponents configured to be joined together as a component via a plurality of tongue and groove connections.

[0023] Figure 9 Shown is a perspective view illustrating a plurality of subcomponents having walls adjacent the subcomponents to convey fluid through a fluid conduit interface of the assembled component.

[0024] Figure 10 A side view illustrating a gearbox with metal nodes is shown.

[0025] Figure 11 A cross-sectional view illustrating a hexagonal gearbox constructed using nodes and shear panels is shown.

[0026] Figure 12A A perspective view illustrating a hexagonal gearbox is shown.

[0027] Figure 12B Shown with Figure 12A Exploded perspective view of two exemplary panels of a nodal fit used in a gearbox.

[0028] Figure 13 A flow chart illustrating an exemplary method for additively manufacturing components in a transport structure is shown.

[0029] Figure 14 A flow chart illustrating an exemplary method for additively manufacturing a fluid tube interface in a component is shown. DETAILED DESCRIPTION

[0030] The detailed description set forth below in conjunction with the accompanying drawings is intended to provide a description of exemplary embodiments of joining additively manufactured nodes and subcomponents, and is not intended to represent the only embodiments in which the invention may be implemented. The term "exemplary," as used throughout this disclosure, means "serving as an example, instance, or illustration," and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may also be practiced without these specific details. In some cases, well-known structures and components may be shown in block diagram form, or omitted entirely, to avoid obscuring the various concepts presented throughout this disclosure.

[0031] The use of additive manufacturing in joining two or more parts provides significant flexibility and cost-saving benefits, allowing manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries at a lower cost to consumers. The joining techniques described hereinabove relate to processes for joining AM parts and / or commercial off-the-shelf (COTS) parts. AM parts are printed three-dimensional (3D) parts that are printed by adding material layer by layer based on a pre-programmed design. The parts described hereinabove may be parts used to assemble transport structures (such as automobiles). However, it will be understood by those skilled in the art that the manufactured parts may be used to assemble other complex mechanical products, such as vehicles, trucks, trains, motorcycles, boats, aircraft, etc., as well as other mechanized assemblies, without departing from the scope of the invention.

[0032] In one aspect of the present disclosure, a joining technique for additively manufactured nodes is disclosed. A node is an example of an AM component. A node can be any 3D printed component that includes a socket or other mechanism for receiving a component such as a tube and / or panel (e.g., features for receiving these components). The node can have internal features configured to receive a specific type of component. Alternatively or in combination, the node can be shaped to receive a specific type of component. In some embodiments of the present disclosure, the node can have internal features for positioning the component in the socket of the node. However, as will be understood by one of ordinary skill in the art, the node can utilize any feature, including various geometries, to receive any type of component without departing from the scope of the present disclosure. For example, certain nodes can include simple recesses, grooves, or notches for receiving other structures, which can be further joined via adhesives, fasteners, or other mechanisms.

[0033] Nodes as described herein may further include structures for joining tubes, panels, and other components for use in transport structures or other mechanical assemblies. For example, a node may include a joint that can serve as an intersection for two or more panels, connecting tubes, or other structures. To this end, the node may be constructed with a hole or recessed portion that is configured to receive such other structure so that the structure is securely assembled at the node. Nodes can join connecting tubes to form a space frame vehicle chassis. Nodes can also be used to join interior or exterior panels and other structures. In many cases, it may be necessary to join various nodes together to achieve their intended purpose, i.e., to allow the above-mentioned structure to be constructed. A number of different such joining techniques are described below.

[0034] In one embodiment, a tongue and groove arrangement is used to connect two or more nodes. Figure 1 A perspective view of an additively manufactured node-node joint 100 is shown. More specifically, node-node joint segments 100a and 100b are shown joined together at gap 108. Node-node joint 100 also includes standoff tabs 102a-c arranged around the perimeter of node-node joint 100. In an exemplary embodiment, gap 108 is a 0.25 mm gap (or gap of another size) configured to allow for appropriate spacing of nodes constructed from dissimilar metals or other materials. This spacing ensures that the two subcomponents being joined do not physically contact each other, thereby preventing galvanic corrosion. This spacing isolates the nodes / subcomponents. In addition to providing a seal, the sealant can also serve as a spacer. In other embodiments where corrosion is not an issue, node-node joint segments 100a and 100b can be flush with each other, such that no gap exists. Each of node-node joint segments 100a and 100b can include sidewalls 110 within the interior of node-node joint 100.

[0035] The node-to-node joint 100 further includes an inlet port 104 for allowing adhesive to enter the node-node joint 100 and a vacuum port 106 for drawing a vacuum to facilitate the flow of adhesive within the node-node joint 100. In the illustrated embodiment, the respective inlet and vacuum ports 104, 106 are constructed into the node 100b and are designed to provide adhesive flow to assist in joining the nodes 100a and 100b, as described below.

[0036] Figure 2 A cross-sectional view of the node-node joint 200 taken along plane AAAA is shown. In this view, Figure 2 The side wall 110 and Figure 1 corresponds to the side wall 110, and Figure 2 The foot protrusion 102b and Figure 1The support leg protrusion 102b corresponds to the support leg protrusion 102b. Figure 2 Shown on the sidewall 110 of the node 100 is a gap 108. The tongue 202 of the node-node joint 200 is part of the node 100A, comprises the first material represented by the diagonal lines of the node 100A, and is disposed along a generally peripheral region 210 of the node 100A. In one embodiment, the tongue 202 extends all the way around the peripheral region 210 and is, in effect, a single protrusion disposed around the peripheral region 210. The tongue 202 protrudes outwardly along the peripheral region 210 relative to the node 100B and around the node 100A, and the lateral extension of the tongue 202 can be seen as being out of the view in this view. The groove 204 of the node-node joint 200 is part of the node 100b and is disposed along a generally peripheral region 212 of the node 100b. The groove 204 can, but need not, be comprised of the material of the node 100b, represented by the diagonal lines in the node 100b that extend in a direction opposite to the diagonals of the node 100a. In one embodiment, the groove 204 extends all the way around the peripheral region 212 and is actually a single notch in the node 100b that extends all the way around the peripheral region 212. The groove 202 is recessed inwardly along the peripheral region 212 relative to the node 100a and extends laterally around the node 100b and can also be seen as coming out of the figure in this view. The tongue 202 and groove 204 can be arranged on the respective nodes 100a and 100b so that when the two nodes are properly placed in contact, the tongue 202 can be aligned with the groove 204 and can be fitted into the groove 204 around the peripheral regions 210, 212.

[0037] In one exemplary embodiment, the groove 204 includes a centering feature 208, which is a narrow area that widens the opening of the groove 202 and helps allow the tongue 202 to properly mate with the groove 204 to thereby center the node-to-node joint 200. In another exemplary embodiment, an overflow sealant reservoir 226 is provided on each side of the tongue 202, each reservoir 226 having a sealant groove 220 that can be used to apply a suitable sealant, for example, to control the flow of an adhesive to be applied.

[0038] As compared to Figure 1 and Figure 2As shown, adhesive and vacuum ports 104, 106 are provided accordingly. In one embodiment, sealant is first applied at the sealant groove 220 of the node 100a. The leg tabs 102a-c can then be used as alignment points to align the two nodes 100a and 100b and securely hold them in place. A vacuum can be applied at the vacuum port 106 to ensure that the node is sealed. Once a complete seal is achieved, adhesive can be applied through the inlet port 104. In one embodiment, the internal structure of the vacuum port 106 is similar to the internal structure of the inlet port 104. The adhesive-vacuum action causes the adhesive to penetrate into the space between the tongue 202 and the groove 204 and flow around the peripheral areas 210, 212 in this space until the adhesive properly fills the tongue and groove connection around the peripheral areas.

[0039] In one embodiment, the foot tabs 120a-c can also be used to help prevent sealant pushback during the adhesive flow and curing process. Once the adhesive has substantially completely filled the gap between the tongue 202 and groove 204 sections, the adhesive can be allowed to cure. The vacuum pressure during the adhesive flow process can be monitored and can indicate complete adhesive fill. After curing is complete, in one embodiment, the foot tabs can be broken off.

[0040] Using this technique, the nodes can be effectively and durably joined. In one embodiment, AM is used to form the structure necessary to implement the joining of the nodes, so that additional processes other than applying adhesives and / or sealants (such as welding or using various external fastening mechanisms) are unnecessary.

[0041] In another aspect of the present disclosure, techniques are disclosed for joining subcomponents of larger additively manufactured components, such as engines, transmissions, gearboxes, and the like. In the following discussion, the present disclosure will be described in the context of an additively manufactured gearbox within a transmission of a transport structure. However, it should be understood that the teachings of the present disclosure are not limited thereto, and that any number and type of additively manufactured components may be assembled using the principles described herein.

[0042] Gearboxes and Other Components. Exemplary embodiments will now be presented in the context of gearboxes and related components used in mechanized assemblies. Rotating shaft power transmissions typically include a shaft supported by lubricant-cooled bearings. The bearing forces in such a configuration can be modest, resulting primarily from gravity and unbalanced forces. With multi-speed transmissions, gears can be used to impose a speed differential to match the input shaft speed to the output. Multi-shaft transmissions are common and may have gears on each shaft separated by a "center distance" to allow the gear teeth to mesh on the outer diameters of the gears. As a result of this meshing, multi-shaft transmissions using involute gear profiles can generate forces that propagate through the shafts due to the pressure angles at the contact points between the gears. The propagated forces are typically reacted through the bearings and thence through a housing known as a gearbox.

[0043] Gear meshes typically use lubricants to extend gear life to a useful level. The lubricant can also transport frictional heat away for cooling. For example, in automotive racing applications, the gearbox may also react to loads from the suspension, aerodynamic loads on the vehicle, and other sources. Therefore, in such cases, the gearbox may have complex loads, may be fluid-tight, and in applications with high power levels, may operate at significantly elevated temperatures. Metal gearbox construction is generally suitable for powertrain applications, using light alloys of aluminum, magnesium, and titanium as the most common materials.

[0044] Many different AM technologies can be well suited for constructing gearboxes and other force- or power-intensive components in transport structures or other mechanized assemblies. Such 3D printing technologies can include, for example, selective laser melting (SLM), selective laser sintering (SLS), direct metal laser sintering (DMLS), electron beam melting (EBM), and other AM processes involving the melting or fusion of metal powders. As in other 3D printing technologies, SLM, SLS, and other powder bed fusion ("PBF") systems build up the build sheet layer by layer. Each layer or "sheet" is formed by depositing a layer of powder and exposing portions of the powder to an energy beam. The energy beam is applied to melt areas of the powder layer that coincide with cross-sections of the build sheet in the layer. The melted powder cools and fuses to form a sheet of the build sheet. The process can be repeated to form the next sheet of the build sheet, and so on. Each layer is deposited on top of the previous layer. The resulting structure is a build sheet assembled from scratch, sheet by sheet. SLS and various other PBF technologies can be well suited for the construction of gearboxes and other transport structure components. However, it should be understood that other AM techniques such as fused deposition modeling (FDM) can also be used in this application.

[0045] Conventional gearbox construction uses castings, which can be thin-walled to reduce mass. However, large transmissions have constraints associated with machining casting molds. Due to the dimensional stability of conventional machining and other factors, these constraints can drive the minimum wall thickness higher than required for the intended load case. Furthermore, using conventional casting techniques, the minimum wall thickness can be significantly greater than necessary to ensure fluid tightness, especially given that the pressure differential across the case can be relatively low in many applications.

[0046] In contrast, as discussed above, these and other conventional AM technologies, including selective laser melting 3D printers (and the like), currently have limited maximum dimensions and, therefore, can only provide structures up to a maximum size. Figure 3 A gearbox 300 is shown relative to a build plate 302 associated with an exemplary large-format selective laser melting machine. As is apparent from the illustration, the build plate 302 is substantially smaller than the gearbox 300. Consequently, conventional selective laser melting printers and other AM techniques may require that various components, such as the gearbox 300, be constructed as multiple sub-components. This is generally in contrast to conventional manufacturing techniques, in which the body of the gearbox may be cast as a single component. One aspect of the present disclosure is therefore directed to solutions for integrating multiple AM ​​components into a single component having properties and characteristics sufficient to accommodate the intended purpose of the component. Addressing the attendant challenges of assembling the sub-components into the integrated AM component may be particularly important if, for example, conveying a fluid within the component is a necessary or desired feature of the component to be constructed.

[0047] Figure 4 4 shows a gearbox 400 shown relative to a build plate 402, wherein the build plate 402 is positioned in different orientations. In this example, a conventional PBF printer (e.g., a selective laser melting 3D printer) may have the capability to provide the gearbox 400 using two sub-components printed at orthogonal relative angles relative to each other, depending on the size of the gearbox 400. Thus, as Figure 4 As demonstrated, in some embodiments it may be desirable to minimize the number of subcomponents by exploiting the geometry of the component to be designed.

[0048] As discussed above, using AM to provide a component as multiple sub-components presents unique challenges. These challenges may be particularly evident in the case of transport structural components such as gearboxes, where the delivery of fluid lubricants or coolants may be necessary. Fluid delivery pipes in such gearboxes can often be constructed with lower mass when integrated with the gearbox wall. This advantageously provides a lighter gearbox and can add additional volume within the gearbox to accommodate internal structures. However, where fluid delivery is desired or necessary in an integrated AM component such as a gearbox, the combination of sub-components forming the component or gearbox should be assembled together in a manner that reliably seals the fluid delivery between the sub-components to avoid fluid leakage and resulting component failure.

[0049] Thus, in another aspect of the present disclosure, components of a transport structure are additively manufactured as multiple subcomponents that are at least partially joined together using one or more tongue-and-groove connections to form a uniform and reliably integrated component. For example, using the principles described herein, a load-bearing gearbox can be constructed using multiple AM ​​subcomponents and seamlessly integrated to form a single gearbox. Thin-walled structures such as gearboxes can be joined together from their constituent AM subcomponents.

[0050] Figure 5 Shown Figure 3 502. The gearbox 500 is shown in FIG. 504. In this exemplary embodiment, the gearbox 500 has been additively manufactured as two subcomponents separated by a line 502. Each subcomponent 504A and 504B includes a wall 505. The subcomponents 504A and 504B of the gearbox 500 have been seamlessly joined together at the walls 505 extending around the perimeter of the line 502 to form a single component 500, as described in further detail below. It should be noted that unlike conventional techniques, where larger gearboxes may be cast with unnecessarily thick walls, which add undesirable mass and volume, and which result in reduced performance of the associated transport structure, Figure 5 The walls 505 of the gearbox 500 in FIG. 5 can be 3D printed to the precise specifications required to withstand the associated pressures without adding unnecessary material.

[0051] In one embodiment, a tongue and groove connection is used to join the subcomponents. The tongue and groove connection may include using an adhesive to react loads between the components via shear. Figure 6 A cross section of an additively manufactured tongue and groove joint 600 is shown extending along respective edges of a gearbox wall 605, wherein one wall is associated with a first subassembly and one wall is associated with a second subassembly. Figure 6 It is shown that at the intersection 502 ( Figure 5) where the edge extends into and out of the illustration. The joint 600 includes a wall edge 607 that can correspond to and be associated with the first subassembly 601B and the second subassembly 601A. The joint 600 further includes a tenon 602 and a slot 604. In one embodiment, the tenon 602 extends along the gearbox 500 ( Figure 5 ) is provided along a first peripheral region 635 of the first sub-assembly 601B of the gearbox 500, and the groove 604 is provided along a second peripheral region 633 of the second sub-assembly 601A of the gearbox 500. As is apparent from the illustration, the tongue 602 and the groove 604 are tapered in this embodiment to facilitate assembly (i.e., to facilitate insertion of the tongue into the groove), and corresponding edges 607 of the wall 605 are in contact or abutment.

[0052] The gap 606 between the tongue 602 and the groove 604 can be filled with adhesive. For example, while vacuum is drawn through the vacuum port 608 disposed on the second side of the subassembly 601A, adhesive can be injected through the external fill port 610 disposed on the first side of the subassembly 601A using vacuum infusion to spread the adhesive through the gap 606.

[0053] Subcomponent 601A-B may further include sealing grooves 612A and 612B, which in one embodiment may be built into the edge 607 of subcomponent 601B. In an exemplary embodiment, sealing grooves 612A-B are filled with elastomeric sealants 614A-B, which may be cured prior to adhesive infusion to control and limit the flow of adhesive. This curing may also allow a strong vacuum to be established during adhesive infusion via deformation of the sealant around protruding seal compression features 616A-B and seal expansion gaps 618A-B, the latter feature being provided on the edge 607 of subcomponent 601A. The gap 606 between tongue 602 and groove 604 may be a nominal thickness. In one embodiment, gap 606 is approximately 500 microns, although a variety of other thicknesses are possible. Gap 606 may be appropriately maintained using a centering feature 620 provided at the widest point of groove 604.

[0054] Furthermore, in an exemplary embodiment, the joint portion located at edge 607 outside of the sealing grooves 612A-B (i.e., to the right of the sealing groove 612B and to the left of the sealing groove 612A) can be designed with a gap (not shown) between the joined subcomponents 601A-B to prevent erosion and galvanic corrosion between the dissimilar metals. The joint clamping features 622A, 623A and 622B, 623B can assist in maintaining this gap. The clamping features 622A, 623A and 622B, 623B can have material raised from the interface surface to provide a gap when the clamping feature 622A contacts the clamping feature 623A on one side of the wall 605 and when the clamping feature 622B contacts 623B on the other side of the wall 605.

[0055] In one embodiment, the gap extends across the entire subassembly interface (edge ​​607). However, the gap can be filled with adhesive or sealant in the area inside the sealing grooves 612A-B, but the gap can be unfilled in the area outside the sealing grooves 612A-B. The seal expansion gaps 618A-B on the subassembly 601A can allow the sealant from the sealing grooves 612A-B to expand when necessary to provide a strong seal. In another embodiment, the vacuum port 608, the fill port 610, and the clamping features 622-23A and 622-23B can be cut to allow the attachment features 613A and 613B to be broken off and removed after the joint is fully bonded.

[0056] In another aspect of the present disclosure, a component includes a fluid conduit extending generally along or adjacent one of the walls of the component. In one embodiment, the fluid conduit is coupled to the gearbox 500 ( Figure 5 ) wall integration, to achieve the above advantages. In other embodiments, the fluid tube is separated from but close to the wall of the component. In still other embodiments, the fluid tube is within the subcomponent at some desired location.

[0057] A fluid tube (which may carry lubricant, coolant, or another suitable fluid) may span the joint defined by the edges 607 of subassemblies 601A and 601B. If a fluid tube is required to span this combined joint, the joint may be sealed around both the fluid tube and the gearbox wall 605.

[0058] Figure 7 FIG. 7 is an interface plan view of a fluid tube interface 700 including a cross section of a fluid tube 704 for conveying fluid between subassemblies. Figure 7A cross-section of the joint is shown, wherein the fluid can travel in a direction entering or exiting the illustration relative to the viewer. The plan view shows the fluid tube interface 700 near the wall 710 of the first subcomponent, which can be configured to securely engage with a similarly structured fluid tube interface of a second subcomponent. The fluid tube interface 702 can further include a generally flat section 706 designed to be positioned approximately flush with a similar section on the other subcomponent. In other embodiments, the section 706 can be contoured or can have another shape. The fluid tube interface 700 can also include an outer wall 708 disposed around its periphery and adjacent to the subcomponent wall 710. In addition, the fluid tube interface 700 can include a tongue and groove joint 702. In an exemplary embodiment, the tongue and groove joint 702 includes a tongue protrusion extending orthogonally relative to the plane of the illustration and is configured to mate with a similar groove section associated with the fluid tube interface of the other subcomponent. Alternatively, the tongue and groove joint 702 may include a groove that is recessed into the plane of the illustration and is designed to receive a similar tongue section associated with a fluid pipe interface of another component. In some embodiments, the tongue and groove joint 702 need not completely surround the fluid pipe interface of the other component. Figure 7 The fluid tube is shown extending along a periphery, but may be configured to extend partially along or adjacent to such a periphery.

[0059] Figure 8 is a perspective view illustrating a plurality of AM subassemblies 802, 806, and 808, which are configured to be joined together as a component via multiple tongue-and-groove connections. For clarity, a generally cylindrical set of subassemblies is shown; however, a wide variety of shapes, sizes, and configurations of subassemblies are possible, depending on the nature of the component and the overall configuration. Furthermore, for clarity, internal structures that may be housed within the subassemblies or components have been omitted from the illustration.

[0060] In this exemplary embodiment, each of sub-components 802 and 806 constitutes some portion of a cylindrical structure. Sub-component 802 may include an outer wall 815 having an edge 809, which in this example includes a tenon protrusion 804. Similarly, sub-component 806 may be configured to have a groove connection 855 to receive and mate with the tenon protrusion 804. Typically, depending on the configuration, the tongue and groove connection 804 may include a tongue or a groove and may be configured to mate with a corresponding edge (partially hidden from view) of sub-component 806, as previously described. Similarly, the tenon protrusion 827 (or, in other cases, a groove connection) may be provided on the other edge 810 of sub-component 802 and may be configured to mate with a corresponding groove connection 858 of sub-component 806.

[0061] also, Figure 8A cylindrical sub-assembly 808 is shown, which in this embodiment is designed to be flush mounted against the combination of sub-assemblies 802 and 806. Sub-assembly 808 may include an outer wall having an edge 811, wherein another tongue-and-groove connection 812 may be provided on edge 811 around a peripheral area of ​​sub-assembly 808. Tongue-and-groove connection 812 may thereby mate with a corresponding combined tongue-and-groove connection (not visible in the view) provided by the distal ends of sub-assemblies 802 and 806.

[0062] It should be noted that, depending on the configuration, the tongue and groove connections of the various subassemblies can be generally orthogonal or otherwise at different angles relative to each other. For example, in this embodiment, tongue and groove connection 804 is generally orthogonal to tongue and groove connection 812. In other embodiments, tongue and groove connection 812 need not traverse the entire perimeter of subassembly 808, and similarly, tongue projections 804 and 827 need not traverse the entire length of respective edges 809 and 810 of subassembly 806.

[0063] Figure 9 A perspective view is shown illustrating a plurality of subassemblies having fluid conduit interfaces 922 adjacent to the walls of subassembly 902 for sealingly conveying fluid through the combined, integrated assembly. Subassembly 902 may include an edge 909 having a tongue-and-groove connection 904 and configured to mate with a corresponding tongue-and-groove connection of subassembly 906 to form an integrated combination of subassemblies 902 and 906. Further shown is a fluid conduit 914, which may be integrated with or disposed adjacent to the walls of subassembly 902 and may be configured to convey fluid within the integrated assembly. Subassembly 902 may further include a fluid conduit interface 922 comprising a fluid conduit segment 921. In one embodiment, fluid conduit interface 922 may be configured to fit substantially flush against a corresponding fluid conduit interface 941 of subassembly 908. In this manner, fluid conduit segment 921 can be seamlessly aligned with fluid conduit segment 914 of subassembly 908 to permit fluid flow through the resulting integrated assembly.

[0064] Subassembly 908, in this embodiment, is a generally cylindrical structure including a wall having an edge 911 along which a tongue-and-groove connection 912 may be provided for mating with subassemblies 902 and 906 along a peripheral region of the subassembly. As noted above, the fluid tube interface 941 of subassembly 908 may include a generally flat section 913 configured to be positioned generally flush with a corresponding section (not visible from view) on the fluid tube interface 922 of subassembly 902.

[0065] The fluid tube interface 941 of the subassembly 908 may further include another tongue-and-groove connection 915 configured to mate with a corresponding tongue-and-groove connection provided on the fluid tube interface 922 of the subassembly 902. The corresponding tongue-and-groove connection on the fluid tube interface 922 of the subassembly 902 may be generally similar in geometry to the fluid tube interface 941, except that the former may include the opposite mating structure (i.e., a groove if the tongue-and-groove connection 915 is a tongue, and vice versa).

[0066] Although not required, in one exemplary embodiment, section 913 is generally flat so that it can be pressed securely flush with a corresponding flat section of subcomponent 902; in other embodiments, section 913 may not be flat, or may include structure suitable for accommodating a seal around fluid tube 814. In other embodiments, section 913 may be contoured or textured, or may include another shape suitable for abutting with a complementary section on fluid tube interface 922 of subcomponent 902. The resulting component has a solid and flush joint of corresponding fluid tube interfaces 922, 941 that allows unimpeded flow of fluid within the component. In various embodiments, and depending on the AM component being manufactured, one or more holes (not shown) may be built into the subcomponent to allow tubes to protrude and / or fluid to be provided to or from an external source.

[0067] Generate as above Figure 7-9 The ability to have a continuous internal void for fluid passage, as shown in FIG, allows for the construction of other fluid transport mechanisms within the component. One such example includes the use of a fluid-to-fluid heat exchanger within a gearbox. However, depending on the nature and structure of the AM component, a variety of different embodiments and applications are possible.

[0068] In another aspect of the present disclosure, AM components for transport structures and other mechanized assemblies can be designed and assembled using multiple nodes connecting shear panels. In one embodiment, a gearbox for a transport structure is assembled using multiple AM ​​sub-components to integrate multiple shear panels into a component for use in a transport structure or other mechanized assemblies.

[0069] Figure 10A side view of a hexagonal gearbox 1000 with an AM node 1002A is shown, which, in one exemplary embodiment, can be additively manufactured using a suitable metal material. The AM node 1002A can be configured to include one or more interfaces for bearings, shafts, and other structures within the gearbox 1000 in a location where the gearbox 1000 can accommodate planar geometries. In this view, two shear panels 1004 of the hexagonal gearbox 1000 can be secured between respective AM nodes 1002A. The AM node 1002A can include an extended structure or recessed portion (not shown) for mating with the respective sides of the shear panels 1004, such as a tongue-and-groove connection, adhesive, or another suitable bonding mechanism. The AM node 1002A can be configured with a socket or recessed portion to position the shear panels 1004 during assembly. The AM node 1002A can also provide a sealing interface for the shear panels 1004. In one exemplary embodiment, the AM node 1002A can use dual shear receiving pockets to receive the shear panels 1004 on each side. Assembly of the gearbox 1000 can capture shear panels 1004 between adjacent AM nodes 1002 A. At each end of the hexagonal gearbox 1000, the AM nodes 1002A can terminate in a central portion 1003 of the AM node, which, in some embodiments, can operate to couple together and secure the individual AM nodes 1002A, and thereby the shear panels 1004 to which the AM nodes 1002A are coupled.

[0070] Figure 11 Shown is a cross-sectional view (BB, see Figure 11 ), which shows a hexagonal gearbox 1100 constructed using nodes and shear panels. Each of a plurality of AM nodes 1002 is used to connect a pair of corresponding shear panels 1004. The nodes 1002 and shear panels 1004 can be used as an assembly to encapsulate internal structures in the gearbox 1100, such as bearings 1006. The nodes 1002 and corresponding shear panels 1004 can use a variety of possible connection mechanisms, including, for example, tongue and groove configurations as described herein. Alternatively, the nodes may include sockets and / or one or more locating features for receiving panels or other structures. In some embodiments, the nodes may include channels for providing adhesive and drawing vacuum. The nodes may also be simple in construction and may include, for example, recessed areas for receiving panels. In general, the construction of the nodes may be consistent with the application and objectives.

[0071] like Figure 10-11As shown, assembling a gearbox using multiple AM ​​subcomponents allows structures such as shear panels to be captured between AM metal parts. In an exemplary embodiment, a PBF technique such as SLM is used to provide the AM metal parts. The shear panels 1004, in an exemplary embodiment, are planar commercial off-the-shelf (COTS) carbon composite sheets that are configured to seal fluids and transfer shear loads. Carbon composites may be considered because they currently have the highest specific strength among available structural materials. However, shear panels composed of other materials are also possible. The transfer of shear loads may require interfaces on the AM nodes and other AM subcomponents that allow for bonding and sealing, as described above. In this way, a gearbox with an overall lower mass can be constructed.

[0072] Figure 12A A perspective view is shown showing a hexagonal gearbox 1200 formed using the principles described herein. The gearbox 1200 includes a plurality of panels 1202, each of the two sides of the panels 1202 being joined to a corresponding node 1002A to form a hexagonal structure having six panels 1202 and six nodes 1002A. In one embodiment, the nodes 1002A are coupled to opposite sides of the structure via segments 1003. Each panel 1202 in one embodiment is wedged into a socket or slot connection provided on each side of the node 1002A, as shown in FIG. Figure 12B As shown in more detail in .

[0073] Reference Figure 12B , showing that in Figure 12A 1004. FIG. 1002 is an exploded perspective view of a node 1002A used in a structure of FIG. As is apparent from the illustration, the node 1002A has a slightly curved geometry that helps form a portion of a hexagon. Furthermore, the node 1002A in this embodiment includes a recess or receptacle on each side into which the panel 1004 can be secured. In some embodiments, a suitable adhesive can be used to further secure the panel.

[0074] It should be understood that Figure 12A The gearbox 1200 and similar structures for use in mechanized assemblies can take any number of possible shapes and sizes, including symmetrical and asymmetrical shapes, and are not necessarily limited to hexagonal shapes. It should be noted that application of the principles of the present disclosure can enable additive manufacturing of parts ranging in size from small to very large, as large parts can be constructed from multiple constituent AM sub-parts. In addition, COTS parts or other custom parts that are not 3D printed can be incorporated into the overall part, such as with Figure 12A Situations related to gearboxes.

[0075] Figure 13A flow chart 1300 is shown illustrating an exemplary method for additively manufacturing components for use in transport structures or other mechanized assemblies. It should be understood that Figure 13 The steps noted in the foregoing are exemplary in nature, and a different order or sequence of steps, as well as additional or alternative steps, may be employed to achieve similar results, as contemplated by the present disclosure. At step 1302, a first subcomponent may be additively manufactured having a tongue structure, for example, disposed along an edge of a wall of the subcomponent, or otherwise partially or completely around a peripheral region of the subcomponent. Similarly, at step 1304, a second subcomponent may be additively manufactured having a complementary groove structure along a wall edge or peripheral region, such that the groove structure is configured to mate with a tongue structure associated with the first subcomponent when the two subcomponents are joined.

[0076] Next, at step 1306, the corresponding tongue and groove structures associated with the first and second subcomponents can be matched to form the resulting AM component. Various techniques can be used to achieve the matching process. As an example, at step 1306A, a sealant can be applied between the corresponding areas of the tongue and groove sections, for example to control the flow of adhesive, to promote a strong vacuum, and / or to assist in fixing the two subcomponents. At step 1306B, one or more centering features can be used to assist in matching the subcomponents. At step 1306C, a suitable adhesive can be applied via a filling port, and a separate vacuum port can be implemented to evacuate the vacuum, which causes the adhesive to spread throughout the space between the tongue and groove joints. At step 1306d, a set of clamping mechanisms can be used to assist in providing a gap between the corresponding edges of the peripheral area to accommodate the coexistence of different metals or other materials at the area of ​​the joint. As noted above, the gap provided can operate to prevent galvanic corrosion of the material.

[0077] Figure 14 A flow chart 1400 is shown illustrating an exemplary method for additively manufacturing a fluid conduit interface in a component to allow fluid to flow in the component. Figure 13 As such, the number, order, and type of steps to achieve these objectives may vary depending on the configuration and objectives. At step 1402, additive manufacturing of the first subassembly includes additively manufacturing a first fluid conduit interface extending generally adjacent to a first peripheral region associated with the first subassembly. In some embodiments as described above, the fluid conduit interface may be integrated with the wall of the first subassembly to accommodate mass and volume reduction. The first fluid conduit interface may be partially or completely surrounded by a tongue-and-groove connection, or may otherwise include a tongue-and-groove connection, which may be a protruding tongue or a recessed groove.

[0078] At step 1404, additive manufacturing of the second subassembly includes additively manufacturing a second fluid pipe interface that extends generally adjacent to, or is integrated as part of, a second peripheral region associated with the second subassembly. The second fluid pipe interface is partially or completely surrounded by a complementary tongue-and-groove connection, or otherwise includes a complementary tongue-and-groove connection configured to mate with the tongue-and-groove connection associated with the first fluid pipe interface.

[0079] Next, at step 1406, the first and second subassemblies are mated using the tongue-and-groove connection of the fluid tube interface, and in some embodiments, the subassemblies themselves are mated simultaneously using separate tongue-and-groove connections associated with the first and second subassemblies, as described above with reference to FIG. Figure 13 As described. In an exemplary embodiment, step 1406 may include one or more procedures associated with the mating process. For example, fill and vacuum ports may be additively manufactured or co-printed with the subassembly to assist in applying the adhesive. Additionally, adhesive may be added to the spaces between applicable tongue-and-groove joints to thereby ensure that the fluid tube interfaces are substantially flush with one another and to allow fluid to flow along the perimeter of the resulting integrated component. As shown with respect to Figure 13 As such, these steps may occur in any order depending on the implementation, and additional or alternative steps may be employed to secure the subassemblies and their corresponding interfaces.

[0080] The foregoing description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to the exemplary embodiments presented throughout this disclosure will be apparent to those skilled in the art, and the concepts disclosed herein may be applied to other technologies for printing and joining nodes and subcomponents. Accordingly, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but are to be given the full scope consistent with the language requirements. All structure and function equivalent to the elements of the exemplary embodiments described throughout this disclosure that are known or later become known to those skilled in the art are intended to be encompassed by the claims. In addition, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is expressly recited in the claims. No claim element will be construed under 35 USC § 112(f) or similar law in the applicable jurisdiction unless the element is expressly recited using the phrase "device for..." or, in the case of a method claim, the element is recited using the phrase "step for..."

Claims

1. A device for implementing node connections in a component, comprising: an additively manufactured first node comprising a first fluid pipe interface and a first groove disposed along a first region thereof, wherein the first fluid pipe interface comprises a first fluid pipe segment; and An additively manufactured second node includes a second fluid pipe interface and a first protrusion disposed along a second region thereof, the first protrusion extending into the first groove such that the first fluid pipe interface couples to the second fluid pipe interface to allow fluid to flow between the first node and the second node.

2. The device according to claim 1, wherein The first node further includes a channel for injecting adhesive extending from an outer surface of the first node to the first groove. 3 . The apparatus of claim 1 , further comprising an adhesive interposed between the first protrusion and the first groove.

4. The device according to claim 1, wherein The first protrusion includes a centering feature.

5. The device according to claim 4, wherein The centering feature includes a proximal portion of the first protrusion having a clearance fit with the first slot.

6. The apparatus according to claim 1, wherein The first and second nodes form a connection between the first protrusion and the first groove and cooperate to form a sealant reservoir on each side of the connection.

7. The apparatus according to claim 1, wherein The first fluid pipe interface is coupled to a second protrusion, the second protrusion closing the first fluid pipe interface, wherein the second fluid pipe interface is coupled to a second groove that closes the second fluid pipe interface and into which the second protrusion fits, The mated second protrusion and second groove are sealed to allow fluid to flow between the first node and the second node.

8. The apparatus according to claim 1, wherein The first fluid pipe interface is coupled to a second groove, the second groove enclosing the first fluid pipe interface, wherein the second fluid pipe interface is coupled to a second protrusion that closes the second fluid pipe interface and cooperates with the second groove, The mated second protrusion and second groove are sealed to allow fluid to flow between the first node and the second node.

9. The apparatus according to claim 1, wherein The second fluid pipe interface includes a second fluid pipe segment to allow fluid to flow between the first node and the second node.

10. The apparatus according to claim 1, wherein The first protrusion cooperates with the first slot to form at least a portion of a component for a transport structure.

11. The apparatus according to claim 10, wherein The components include vehicle components.

12. The apparatus according to claim 10, wherein The components include a gearbox.

13. The apparatus according to claim 10, wherein The components include a load-bearing component.

14. An apparatus for implementing node connections in an assembly, comprising: an additively manufactured first subcomponent comprising a first fluid tube interface and a first protrusion disposed along a first region thereof; and an additively manufactured second subcomponent comprising a second fluid pipe interface and a first groove structure disposed along a second region thereof, The first protrusion cooperates with the first groove structure along first and second regions forming at least a portion of the vehicle component to couple the first fluid pipe interface to the second fluid pipe interface to allow fluid to flow between the first and second subcomponents.

15. The apparatus according to claim 14, wherein The first fluid pipe interface includes a first fluid pipe segment to allow fluid to flow between the first subassembly and the second subassembly.

16. The apparatus according to claim 14, wherein The second fluid pipe interface includes a second fluid pipe segment to allow fluid to flow between the first subassembly and the second subassembly.

17. An apparatus for implementing node connections in an assembly, comprising: an additively manufactured first subcomponent comprising a first fluid pipe interface and a first protrusion disposed along a first region thereof, wherein the first fluid pipe interface is coupled to a second protrusion that encloses the first fluid pipe interface and extends outwardly from the first region; and an additively manufactured second subcomponent comprising a second fluid tube interface and a first slot structure disposed along a second region thereof and coupled to the first protrusion, The second fluid pipe interface is coupled to a second groove structure that closes the second fluid pipe interface and allows the second protrusion to fit therein, so that the mating second protrusion and the second groove structure are sealed to allow fluid to flow between the first subcomponent and the second subcomponent.

18. An apparatus for implementing node connections in an assembly, comprising: an additively manufactured first subcomponent comprising a first fluid pipe interface and a first protrusion disposed along a first region thereof, wherein the first fluid pipe interface is coupled to a second channel structure enclosing the first fluid pipe interface; and an additively manufactured second subcomponent comprising a second fluid tube interface and a first slot structure disposed along a second region thereof and coupled to the first protrusion, The second fluid pipe interface is coupled to a second protrusion that closes the second fluid pipe interface and cooperates with the second groove structure so that the mating second protrusion and second groove structure are sealed to allow fluid to flow between the first subassembly and the second subassembly.

19. A method for additively manufacturing a component for a transport structure, comprising: additively manufacturing a first subcomponent comprising a first fluid tube interface and a first protrusion disposed along a first region thereof; additively manufacturing a second subcomponent comprising a second fluid tube interface and a first groove disposed along a second region thereof; engaging the first protrusion with the first groove along the first region and the second region such that the first fluid tube interface mates with the second fluid tube interface to allow fluid to flow between the first subassembly and the second subassembly; and A portion of a vehicle component is formed with the first subassembly and the second subassembly.

20. The method according to claim 19, wherein The first fluid pipe interface includes a first fluid pipe segment to allow fluid to flow between the first subassembly and the second subassembly.

21. The method according to claim 19, wherein The second fluid pipe interface includes a second fluid pipe segment to allow fluid to flow between the first subassembly and the second subassembly.

22. The method according to claim 19, wherein The first fluid pipe interface includes a second protrusion and the second fluid pipe interface includes a second groove, and wherein mating of the first fluid pipe interface with the second fluid pipe interface includes coupling the first fluid pipe interface to the second groove and coupling the second fluid pipe interface to the second protrusion such that the coupled second protrusion and the second groove form a seal to allow fluid to flow between the first subcomponent and the second subcomponent.

23. The method according to claim 19, wherein The first fluid pipe interface includes a second groove and the second fluid pipe interface includes a second protrusion, and wherein mating of the first fluid pipe interface with the second fluid pipe interface includes coupling the first fluid pipe interface to the second protrusion and coupling the second fluid pipe interface to the second groove such that the coupled second protrusion and second groove form a seal to allow fluid to flow between the first subcomponent and the second subcomponent.

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