Systems and methods having lattice structure for joining components

Abstract

Systems and methods for securing product junctions with a lattice structure. A system includes at least one fabrication system to create a connector having a lattice structure. The force system applies a force to the connector such that material of the product flows into the lattice structure to interleave the material with the lattice structure to secure the joint through the lattice structure.

Description

Technical Field

[0001] The present disclosure relates to manufacturing systems and methods for securing one component of a product to another component of the product, and more particularly to using a grid structure to securely connect two components together. Background Art

[0002] The strength of the connection between two components of a product is important when the product is subjected to various forces and stresses. Various methods can be used to secure the joint, including welding, gluing, fastening, etc. Some types of joints can be produced quickly and efficiently. For example, heat stapling one component of a product to another component of the product may be fast, but relies on limited staple / component interaction to hold the two component parts together.

[0003] There are various types of manufacturing processes to produce or modify products. Printing technology is widely used due to its desirable qualities such as efficiency and flexibility. Various types of 3D printing technologies have been developed for producing objects from metals, ceramics, and polymer materials. Various 3D printing technologies typically each include a build surface, a material delivery system, an energy delivery system, and a control system. The build surface provides a reference surface on which materials are deposited layer by layer to continuously build components according to design details. The material delivery system performs deposition of raw material materials, such as raw material materials in the form of particles, fibers, or filaments, for fusion with previously deposited layers. The energy delivery system adds energy to the raw material materials before, during, and / or after deposition for liquefying / fusing the material into the component being produced. The control system operates each other system when, for example, building the object being produced according to mathematical data definitions.

[0004] Both traditional manufacturing processes and printing processes can be used in various applications to achieve desired results. However, improving the interface strength between two parts of an assembly through the mechanism that connects one part relative to the other remains a goal.

[0005] Therefore, it is desirable to provide improved methods and systems for securing one component to another. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. Summary of the invention

[0006] A system and method for securing a joint of a product with a grid structure is provided. A system includes at least one manufacturing system to produce a connector having a grid structure. A force system applies a force to the connector so that material of the product flows into the grid structure to interweave the material with the grid structure to secure the joint through the grid structure.

[0007] In another embodiment, the grid structure is embodied as a series of units. Each unit is formed by a plurality of structural members that are connected and define open spaces between the structural members.

[0008] In further embodiments, the product includes two components that mate with each other at a joint.

[0009] In further embodiments, the grid structure includes a plurality of interconnected structural members, and the material is embodied as a plurality of elements extending through an open space defined by the plurality of interconnected structural members.

[0010] In further embodiments, the grid structure includes a plurality of structural members connected and defining open spaces between the structural members, wherein the material completely fills the open spaces.

[0011] In further embodiments, the grid structure comprises a series of plates joined together at lines forming a diamond pattern.

[0012] In further embodiments, the grid structure is embodied as a heat staple.

[0013] In further embodiments, a heating system is included to heat the connector.

[0014] In further embodiments, the joint has a geometry along the joint and the grid structure matches the geometry.

[0015] In further embodiments, the grid structure defines open spaces, and the grid structure is designed to maximize penetration of material into the open spaces.

[0016] In many other embodiments, a method for securing a product includes producing a connector having a grid structure by at least one manufacturing system. A force system applies a force to the connector and the product so that material of the product flows into the grid structure to interweave the material with the grid structure to secure a joint through the grid structure.

[0017] In another embodiment, the grid structure is formed as a series of cells. Each cell has a plurality of structural members connected and defining open spaces between the structural members.

[0018] In other embodiments, the product is made from two parts. The parts are mated together at a joint.

[0019] In further embodiments, the grid structure is formed as a plurality of interconnected structural members. Material is forced into the grid structure to be embodied as a plurality of elements extending through the plurality of interconnected structural members.

[0020] In further embodiments, the grid structure is formed as a plurality of structural members connected and defining open spaces between the structural members. The open spaces are completely filled with material.

[0021] In further embodiments, the grid structure is formed as a series of plates joined together at lines in a diamond pattern.

[0022] In further embodiments, the grid structure is embodied as a heat staple.

[0023] In further embodiments, the heating system heats the connector.

[0024] In further embodiments, the grid structure is formed to match the geometry of the joint.

[0025] In various further embodiments, a product includes one or more components defining a joint. A connector having a grid structure is disposed in the joint, wherein material of the one or more components is interwoven with the grid structure such that the joint is secured by the grid structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present disclosure will hereinafter be described in conjunction with the following drawings, wherein like numerals represent like elements, and wherein:

[0027] Figure 1 is a schematic diagram of a manufacturing system in the process of building a product according to various embodiments;

[0028] Figure 2 According to various embodiments, Figure 1 A schematic diagram of a grid structure unit produced by a portion of a manufacturing system;

[0029] Figure 3 According to various embodiments, Figure 1 A schematic diagram of a grid structure having a plurality of cells produced by a portion of a manufacturing system;

[0030] Figure 4 is a method of connecting two components according to various embodiments Figure 3 a schematic diagram of a portion of a grid structure of; and

[0031] Figure 5 is the use according to the exemplary embodiment Figure 1 systems and Figure 2 and Figure 3 Flowchart of a process for manufacturing a product with a grid structure. DETAILED DESCRIPTION

[0032] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding introduction, summary, or this detailed description.

[0033] refer to Figure 1 , schematically illustrating a manufacturing system 100. In general, the manufacturing system 100 includes a manufacturing system 102, a connector 104, and a product 110, the product including one or more workpieces in the form of a connector 104 and at least one component to be connected to the connector 104, in this example, two components 112, 114. The manufacturing system 102 can be any of a variety of object generation systems that can operate to produce or modify a workpiece, which in the current embodiment is the connector 104 or at least a portion thereof, the component 112, and / or the component 114. The manufacturing system 102 can employ one or more operations in any of a variety of operations such as machining, casting, molding, forming, deforming, bending, perforating, drilling, stamping, cutting, additive manufacturing, 3D printing, etc. In the current embodiment, the manufacturing system 102 includes a printing system 116, such as a machine based on laser powder bed fusion. In other embodiments, another printing technology can be used, such as binder jetting, powder bed fusion using an electron beam, material extrusion / FDM, high speed sintering, selective laser sintering, multi-jet fusion, or another printing technology.

[0034] In an embodiment, the printing system 116 includes an energy delivery system in the form of an energy source 120 (the energy source may be heat-generating), a material deposition system in the form of a material depositor 122, a build chamber 124 defined by a build box 126, and a build platform 128 having an elevator 130. In various embodiments, a gas delivery system (not shown) may be included for delivering an inert gas to the build chamber 124 to provide a favorable environment for the build. The material depositor 122 may be any mechanism for dispensing a material 132, such as a roller, brush, blade, spreader, sprayer, feeder, or other component, from which the connector 104 and / or components 112, 114 are formed.

[0035] In the current embodiment, the printing system 116 is shown as using a powder bed fusion type additive manufacturing / 3D printing technology to produce the connector 104. In other embodiments, the additive manufacturing unit 100 can be configured for or another type of additive manufacturing. It should be understood that the printed connector 104 and parts 112, 114 can be constructed of materials that are one or more materials of metal, ceramic, polymer or other materials or one or more materials including metal, ceramic, polymer or other materials. For example, parts 112, 114 can be made of a polymer that can be molded or otherwise formed, and the connector 104 can be made of metal.

[0036] Thus, the selected fabrication system 102, which may include one or more 3D printing methods, may be customized according to the materials selected for forming the connector 104 and components 112, 114. In other embodiments, additive manufacturing may not be used or may only be partially used, and conventional machining / forming techniques may be employed. For example, the connector 104 and / or components of the connector 104 may be produced by any material forming operation.

[0037] In the current embodiment, the printing system 116 is configured for applying a material 132 in powder form by the material depositor 122. Melting / fusion of the material 132 is selectively performed by the energy source 120 via controlled exposure. The material 132 is applied to the build platform 128 by the spreader 134 of the material depositor 122 in a series of continuous layers. The connector 104 and / or the components 112, 114 are sequentially built in layers on the build platform 128, which is moved via the elevator 130 during the build. When the forming process of a given layer is completed, the build platform 128 can be reduced by the amount of layer thickness, and the next material layer can be applied. This process is repeated until the entire design geometry of the workpiece or its designated component is generated.

[0038] In various embodiments, a workpiece, such as a connector 104 and / or components 112, 114 constructed by a production system 102 (printing system 116 in the current embodiment), can be part of another product 110, which can include other physical components. The connector 104 portion of the product 110 can be referred to as a "stitch" because it is formed and then interacts with another component or multiple components 112, 114 of the product 110. The connector 104 includes or is embodied as a grid structure 140. In some embodiments, the grid structure 140 can extend completely through the connector 104. In some embodiments, the grid structure 140 can only exist on a portion of the connector 104. In other embodiments, the entire surface 142 of the connector 104 can include the grid structure 140. In general, the grid structure 140 can be included on any area of ​​the connector 104 where it is desired to be coupled to another component (such as components 112, 114).

[0039] like Figure 1As shown, the manufacturing system 102 can be used to produce connectors 104, components 112 and / or components 114. One or more components 112, 114 have a joint 115 intended for connection together, wherein the edge 136 of the component 112 is fixed in place relative to the edge 138 of the component 114. The components 112, 114 are positioned (such as in a fixing station 118) so that the edges 136, 138 are arranged adjacent to or against each other. In some examples, the edges 136, 138 can overlap. The connector 104 is moved to a position to be arranged above the joint 115. In the nailing station 148, pressure such as by the force system 144 and / or heat such as by the heating system 146 are applied to the connector 104, and the connector is embedded in one or more components 112, 114. Therefore, the joint 115 is fixed, and the one or more components 112, 114 are fixed together.

[0040] refer to Figure 2 and Figure 3 as well as Figure 1 , the grid structure 140 will be described in more detail. Generally speaking, the grid structure 140 includes a framework having components called structural members 150, which are interconnected to define spaces 152, which are open between the structural members 150 in two or three dimensions or in some ways that can be called 2.5 dimensions. The structural members 150 are generally the physical load-bearing components of the grid structure 140. The grid structure 140 can fill a volume such as the connector 104, or can conform to a surface such as the surface 142 of the connector 104. In embodiments where the grid structure 140 is only on the surface 142, the connector can have a solid center or an open center. The grid structure 140 can be a construction based on repeating unit cells 154, which are composed of specific shapes or random patterns in a network of any complexity or simplicity. The repeating unit cells 154 can have any physical dimensions customized to the application. The grid structure 140 can be periodic, aperiodic or random. Generally speaking, the grid structure 140 includes structural members 150 of any shape to define open spaces 152 for receiving intervening materials.

[0041] The grid structure 140 may be honeycomb-shaped, having Figure 2 A unit 154 and Figure 3140. In the example, the cells 154 are X-shaped, or may be referred to as diamond-shaped when additional rows are added. Each cell 154 has four structural members 150, which are labeled as members 157-160. Each of the members 157-160 is formed as a plate, and the members 157-160 of a cell 154 are connected at line 162. In other embodiments, the members 157-160 may be beams, surfaces, plates, trusses, cells, meshes, nodes, struts, which are assembled together in an ordered, repeating, or random pattern. The members 157-160 may be interlocking, interwoven, interconnected, or otherwise interconnected material patterns to form the grid structure 140. In other embodiments, rather than an X / diamond shape, cells 154 may be triangles, stars, octagons, hexagons, rhombuses, tetrahedrons, solids of revolution, pyramids, body-centered cubes, spirals, or any configuration that includes a member (such as structural member 150) and defines an open space (such as space 152). Figure 3 In the series of cells 154 shown, each cell 154 is connected to its adjacent cells 154 at two lines (e.g., lines 164, 166). Figure 3 A row of cells 154 is shown in FIG. 1 , however, the cells may be arranged in any number of rows, columns, and depths in three dimensions.

[0042] Reference again Figure 1 , components 112, 114 and connector 104 are formed by manufacturing system 102 for the purpose of the application in which they will be performed. In the current embodiment, components 112, 114 are panels made of polymers. Joint 115 is designed to be fixed by "heat staples" in the form of connector 104. Because connector 104 has a grid structure 140, it is fully integrated into the material of components 112, 114 when heat and / or pressure is applied. In an embodiment, force system 144 can be a mechanical, electrical, pneumatic and / or hydraulic device, such as a press, a clamp, a gun, a weight, or any device configured to apply pressure to connector 104 to drive it into the material of components 112, 114. Force system 144 can be used alone or in combination with heating system 146. Heating system 146 can be any system that heats connector 104, such as electricity, gas, ultrasound, laser and / or other heat generation / induction devices.

[0043] refer to Figure 4During coupling, the connector 104 is embedded in the material 180 of the components 112, 114, and / or the material 180 flows into the spaces 152 around the structural member 150, and the material 180 forms elements 182 that fill the spaces 152. The flow of material 180 completely permeates the spaces 152 of the grid structure 140, wherein the elements 182 are interwoven with the structural member 150. After coupling, the material 180 solidifies in the spaces 152 as the elements 182 lock the connector 104 to the components 112, 114. At least some of the elements 182 may be completely separated from another material 180 of the respective components 112, 114 and embedded in the grid structure 140. Thus, in addition to surface level interactions, full integration and interaction of the material 180 of the components 112, 114 with the grid structure 140 is produced.

[0044] In a non-grid thermal stapling type process, where a staple is placed into another part with a perforation level interaction, there are only a finite number of penetration points that can hold the two parts together. f ) is the applicable friction coefficient (μ) and normal force (F N ) function, we can use the relation F f =μF N Indicates. The friction between typical heat-stitched components tends to be low because the retention is mainly provided by the staples themselves. For example, when the force applied between the heat-stitched components reaches the slip threshold, they will move relative to each other. If this movement is not desired, it can be described as a failure of the relevant product.

[0045] In an embodiment, depending on the material used, an adhesion force (F a ). Adhesion is proportional to the contact surface area (A) and can be expressed by the following relationship: F∝A. Adhesion occurs between two surfaces through chemically induced bonding, such as when chains of two polymers connect to each other, or when the materials undergo another form of chemical reaction. For typical heat-stitched parts, such as polymer parts and metal staples, adhesion is low. Therefore, the sum of friction and adhesion provides only a modest force-carrying capacity.

[0046] In the current embodiment where full interaction of the material 180 with the lattice structure 140 occurs between the structural members 150 and the elements 182, the material of the components 112, 114 is interwoven with the material of the connector 104. Thus, rather than relying on surface level friction / adhesion to hold the product 110 together, a large number of structural members 150 and elements 182 secure the product 110. The relative component forces 170, 172 and connector forces 176 are carried by the large number of structural members 152 and elements 182. Shear / tensile strength plays a role in holding the components 112, 114 in place relative to the connector 104. Any force applied between the connector 104 and the components 112, 114 is distributed over a large number of locations (structural members 150 and elements 182), and the average stress per unit area of ​​material is low. This is because stress (σ) is a function of force (F) and area (A), where Because in the present embodiment, the total area is large due to the sum of all structural members 150 and / or elements 182, the average stress is relatively low and product failure is avoided over a larger stress bandwidth.

[0047] like Figure 4 As shown in , when stress is generated between the components of the product 100 (connector 104 and parts 112, 114), the sum of the forces 170, 172 on the parts 112, 114 is offset by the sum of the forces 176 on the connector 104. Because the forces 170, 172, 176 are carried by the sum of all areas of the structural member 150 and the element 182, they are distributed over a large area. A large number of areas result in a large total area for applying force, thereby generating low stress at each location in the two-dimensional-three-dimensional space. In an embodiment where the material 180 has a lower strength than the material of the connector 104, the space 152 can be designed to be substantially larger than the cross-sectional area of ​​the structural member 150. Therefore, the stress on the material 180 in any given space 152 is low, and the parts 112, 114 are fixed in the best manner by the connector 104. In addition, because the friction and adhesion strength are functions of the surface area, the amount of force that the interface between the connector 104 and the parts 112, 114 can carry from the perspective of friction and adhesion is also increased.

[0048] For example, the friction / adhesion strength between the connector 104 and the components 112, 114 can be optimized. Through the physical structural interference caused by the grid structure 140 and the interwoven material 180 between the connector 104 and the components 112, 114, significantly higher normal forces can be sustained at the interface. In addition, the connector 104 and the components 112, 114 result in a higher contact surface area and higher load-bearing capacity due to friction and adhesion through the interwoven characteristics of the grid structure 140. In summary, the load-bearing capacity of the product 110 between the connector 104 and the components 112, 114 is increased in three ways, including higher shear / tensile strength, higher friction strength, and higher adhesion strength.

[0049] Reference again Figure 1 , the product 110 exiting the forming system 108 includes the connector 104 in which the components 112, 114 are fully integrated together. In addition to the surface level interaction, there is a complete interaction and integration between the connector 104 and the components 112, 114 as the material 180 flows through the grid structure 140, saturating, contacting and bonding the entire grid structure 140. The geometry of the grid structure 140 with the spaces 152 enables the material 180 to flow through and interact with the structural member 150. The grid structure 140 is configured to maximize the penetration of the material 180 into the open spaces 152. The strength of the connection is not limited to the friction and shear forces of the connection, but also includes the area of ​​material 180 in the spaces 152, which distributes the forces / stresses over multiple segments having an equivalent cross-sectional area that is very large relative to the surface interface between the connector 104 and the components 112, 114.

[0050] refer to Figure 5 , a method 200 for connecting components (such as connector 104 and components 112, 114) to a grid structure is shown, such as in a stapling operation. It will be understood from the present disclosure that the order of operations within method 200 is not limited to the following. Figure 5The method 200 is not performed in the order shown, but may be performed in one or more variations of the order where applicable and in accordance with the present disclosure. The method 200 begins when an item such as a product 110 is designed (202). The product 110 may include a connector 104 or multiple connectors 104, which are designed (202) to fix one or more components (such as components 112, 114) together. The connector 104 may be a structural item such as a staple. Generally speaking, the components 112, 114 are designed to mate / connect with one or more connectors 104. In some embodiments, the components 112, 114 may be designed for applications without the connector 104, and one or more of the connectors 104 may be used to repair the components 112, 114. The connector 104 and the components 112, 114 may be made of any material, whether a common material or a different material from each other. In an embodiment, the joint 115 has a defined geometry in three dimensions, and the grid structure 140 has a shape that matches the defined geometry. For example, a custom connector 104 having a grid structure 140 may be produced, such as by additive manufacturing, to match component geometry, such as for joining along a crack in the components 112 , 114 .

[0051] In summary, connector 104 and components 112, 114 can be designed (202) to be connected together to form a product, such as product 110, or to form a product from components 112, 114 that can be repaired after field use with connector 104. After the step of designing (202), connector 104 can be fabricated (204), such as by fabrication system 102. Components 112, 114 are also produced, and connector 104 can be fabricated (204), such as by fabrication system 102. In one example, components 112, 114 can be molded, such as molded from one or more polymers. In another example, components 112, 114 can be made of glass.

[0052] The connector 104 is fabricated (204) to have at least one portion that includes a grid, such as a grid structure 140. The connector 104 can be fabricated (204) by any means that produces a connector 104 having a grid structure 140. When fabricated (204), the connector 104 includes one or more regions of the grid structure 140. The grid structure 140 is configured to be formed by the fabrication system 102. As part of the design (202) step, the details of the grid structure 140 can be generated in a computer-aided design (CAD) system and can be adjusted. The properties (mechanical properties, thermal properties, etc.) of the grid structure 140 are determined by the type of grid and other design parameters (such as unit cell size and component thickness). The grid structure 140 is optimized to maximize strength (shear / stretch and adhesion / friction), address deformation mechanisms, maximize surface area, optimize cell size and density, optimize component thickness, cell orientation, and other parameters.

[0053] The method 200 is performed by positioning (206) the connector 104 over the area to be connected, such as at the joint 115. The force system 144 is operated to force (208) the connector into the components 112, 114 at the joint 115. The force system 144 can be used alone or in combination with the heating system 146. The heating system 146 can be used to heat (210) the connector 104 to a temperature above the melting point of the material 180 of the components 112, 114 before or after applying the force 208. In some embodiments, the joint 115 can be fixed first, such as by an adhesive, and the grid structure 140 of the connector 104 can be added to enhance the joint connection with better permeability and joint strength.

[0054] The connector 104 is forced (208) into the material 180, such as by the pressure of a force system. The material 180 flows around the structural member 150 and into the space 152. The grid structure 140 can be configured to optimize the flow of the material 180 into the space 152, such as by part of the design (202) step. The behavior of the material 180 under the action of the force 208 and / or heat 210 can be considered the behavior of a liquid. The CAD system used can use available fluid dynamics modeling software to take into account rheology, including the flow direction of the material 180, the temperature of the connector 104, the applied force 208, the surface interactions between the materials involved, and any other control parameters to ensure that the material 180 is fully integrated into the grid structure 140. In a specific example, the size of the structural member 150 can be increased to conduct more heat and increase the flow of the material 180 into the grid structure 140. In some embodiments, the space 152 can be tapered. For example, as material 180 moves through grid structure 140 , the size of area 152 for open flow may change to maintain flow (eg, downstream area 152 smaller or larger than upstream area 152 ). This design ensures that material 180 completely fills open area 152 .

[0055] With the material 180 fully integrated with the grid structure 140, the heat 210 and the force 208 are stopped (212). As the material 180 solidifies, it locks the components 112, 114 in place via the connector 104. The material 180 in solid form then resides within the grid structure 140. The method 200 ends with the components 112, 114 being secured at the joint 115 (214).

[0056] Although at least one exemplary embodiment has been proposed in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the exemplary embodiment or multiple exemplary embodiments are only examples and are not intended to limit the scope, applicability or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing the exemplary embodiment or multiple exemplary embodiments for those skilled in the art. It should be understood that various changes can be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A system for securing a product at a joint, the system comprising: at least one fabrication system configured to produce a connector having a grid structure; A force system is configured to apply a force to the connector and the product to cause material of the product to flow into the grid structure to interweave the material with the grid structure to secure the joint via the grid structure.

2. The system of claim 1, wherein the grid structure comprises a series of cells, wherein each cell is formed by a plurality of structural members connected and defining open spaces between the structural members.

3. The system of claim 1, wherein the grid structure comprises a plurality of interconnected structural members and the material comprises a plurality of elements extending through an open space defined by the plurality of interconnected structural members.

4. The system of claim 1, wherein the grid structure comprises a plurality of structural members connected and defining open spaces between the structural members, wherein the material completely fills the open spaces.

5. The system of claim 1, wherein the grid structure comprises a series of plates joined together at lines forming a diamond pattern.

6. The system of claim 1, wherein the grid structure comprises heat staples.

7. The system of claim 1, comprising a heating system configured to heat the connector.

8. The system of claim 1, wherein the joint includes a geometric shape along the joint, and the grid structure matches the geometric shape.

9. A method for fixing a product, the method comprising: Producing a connector having a grid structure by at least one manufacturing system; as well as A force is applied to the connector and the product by a force system, causing material of the product to flow into the grid structure to interweave the material with the grid structure to secure the joint via the grid structure.

10. The method of claim 9, comprising forming the grid structure into a series of cells, wherein each cell has a plurality of structural members connected and defining open spaces between the structural members.

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