INTERLOCKING PARTS FORMED BY ADDITIVE MANUFACTURING
Patent Information
- Application Number
- FR2022011342
- Authority / Receiving Office
- FR · FR
- Patent Type
- Patents
- Current Assignee / Owner
- Filing Date
- 2022-10-31
- Publication Date
- 2026-09-11
- Estimated Expiration
- 2042-10-31
AI Technical Summary
Additive manufacturing processes face challenges in producing nested and interlocked parts that require separate support during assembly, which can be incompatible with materials and affect mobility, and controlling clearances in guided mobility connections.
A first part with an opening facing a breakable support element allows a second part to be housed inside, enabling simultaneous production and easy separation, with controlled clearances and improved mechanical connections.
Facilitates manufacturing by reducing components and steps, enhances aesthetic and reduces mass, while ensuring reliable mobility and compliance, particularly in high-temperature environments.
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Abstract
Description
Description Title of the invention: INTERLOCKING PARTS FORMED BY FA- ADDITIVE BRICATION Technical field
[0001] — The present disclosure relates to a set of nested and movable parts between them manufactured by additive manufacturing. It also relates to a aircraft equipment comprising such an assembly. Prior art
[0002] — Generally speaking, additive manufacturing processes make it possible to form a holding complex objects, which would otherwise have needed to be designed with a higher number of parts to assemble together.
[0003] We are particularly interested in the manufacture of sets of separate parts, im- bricked and mobile between them, forming in particular irremovable assemblies. This type of assembly can be produced by an additive manufacturing process by deposition of fused filament, commonly referred to as the FFF process (“Fused Filament Fabrication”). The FFF process consists of depositing material layer by layer from a tray additive manufacturing and in a manufacturing direction perpendicular to the plate.
[0004] — However, when the parts of the assembly are strongly nested together, not all pieces can directly rest on the board when they are manufacturing. Indeed, such parts must rest directly or indirectly on another piece, itself resting on the board, during the creation of the whole. There is then a junction between the corresponding parts. In order to make the parts movable relative to each other, the corresponding parts must be separated at the said junction.
[0005] — For example, it is possible to use a soluble material at the junction between the corresponding parts. Once the parts are formed, the soluble material is dissolved in order to free the pieces from each other. However, the use of a soluble material may be incompatible with materials used for manufacturing parts, for example materials capable of withstanding high temperatures.
[0006] — Alternatively, the corresponding parts can be mechanically separated from each other at the junction. However, the implementation of such a junction can affect the mobility between parts, especially when the junction is made at level of an area where the parts are movable relative to each other.
[0007] Furthermore, when the parts of the assembly are in guided mobility with each other others, for example in mechanical connection of the slide type, the control of the clearances between the parts at the level of the mechanical connection is an important issue. Indeed, games Insufficient clearances can lead to jamming or even blocking between the parts. Conversely, excessive clearances will not ensure proper functioning of the mechanical connection. This document aims to resolve at least in part the problems mentioned above, by proposing a set of nested parts, manufactured by additive manufacturing and making it easier to manufacture the assembly, and in particular the implementation of mobility between the parts. Summary More specifically, this document relates to an assembly manufactured by additive manufacturing comprising: - a first piece, - a second part housed at least partly in the first part, the second part being movable relative to the first part, wherein the first part and the second part are connected to each other by at least one breakable support element, the first part comprising an opening opposite said at least one support element, the opening being configured to allow the removal of at least a portion of said support element through the opening. Then, during the manufacturing of the assembly, the first part can rest directly on an additive manufacturing plate, and the second part can rest on the first part via said at least one support element. Such an assembly makes it possible to facilitate manufacturing and reduce the production time of the assembly having parts nested within each other, by reducing the number of components and eliminating assembly steps. Such an assembly also has improved aesthetics compared to an equivalent object that would have been produced conventionally, that is to say by forming and then assembly operations. In addition, the risks of non-conformity of the parts are advantageously reduced, thanks to the reduction in the number of manufacturing steps. Such an assembly also advantageously has a reduced mass compared to an equivalent object produced conventionally. Furthermore, the first part and the second part are advantageously produced simultaneously. By produced simultaneously is meant that the first part and the second part are not produced separately and then assembled together, but that the second part is directly housed, at least in part, in the first part during the production of the assembly. Then, the assembly can be non-disassemblable, for example for applications requiring the absence of disassembly for safety purposes. The second room can be housed entirely within the first room. Removing at least a portion of the support member through the opening consists in particular of a mechanical operation. The opening can be configured to allow removal of the entire support element. The opening may extend over part, most or all of the dimension of the support member. The opening may open towards the outside of the first room, that is to say opposite an internal volume of the first room housing the second room. The opening may be formed by a rectilinear or curved groove opening into an internal volume of the first part, opposite the support element and opening outwards, opposite said internal volume. The first part and the second part are preferably mechanically connected to each other, connecting portions, respectively of the first part and the second part, forming said mechanical connection. Preferably, the connecting portions of the first part and the second part respectively are located at a distance from the support element. This feature allows for a better mechanical connection between the two parts, limiting the risk of friction or jamming. This prevents the presence of material residue at the mechanical connection between the first part and the second part. Furthermore, positioning the support element at a distance from the mechanical connection allows for better control of the clearances between the connection portions. Said mechanical connection may be a connection allowing at least one translation, for example a sliding connection, and / or at least one rotation, for example a pivot connection. Then, the direction of said translation may advantageously be parallel to the manufacturing direction perpendicular to the additive manufacturing plate. The connecting portions of the first part and the second part respectively may advantageously have rounded edges. This limits or avoids the presence of protruding edges, so as to improve the sliding between the two parts. The connecting portions of the first part and the second part respectively may have a clearance between them of between 0.15 mm and 0.3 mm. Such a characteristic makes it possible to improve the mechanical connection between the first and the second part. When the mechanical connection between the first part and the second part allows at least one translation in one direction, the support element can advantageously extend in a direction perpendicular to the direction of the mechanical connection. Such a feature makes it easier to separate the first part and the second part, for example by pulling on the second part. The first piece and the second piece can each be made in a material capable of withstanding a temperature above at least 180°C. In particular, the first part and the second part may be made of a material incompatible with the use of a soluble material between the first part and the second part during the production of the assembly. In particular, the first and / or the second part can be made of PAEK or PEI, also known under the commercial reference PEEK / PEKK or Ultem 9085, Ultem 1010 respectively. The support element is preferably made of a material different from the first part and / or the second part, for example PAES (Poly Aryl Ether Sulfone). Said support element may for example be made of PES, also known by the commercial reference PES. Such materials are particularly adapted so that the support element has adhesion with the first part and the second part, so as to allow, on the one hand, the smooth running of the manufacturing of the assembly by additive manufacturing, and on the other hand, the easy separation of the first part and the second part at the level of the support element. In one example, the first piece forms a frame and the second piece forms a sliding panel within the frame. Such an assembly may in particular be used as all or part of a storage chest, for example so as to form a door of said chest. The panel may be movable between a retracted position and a closed position. The panel is suitable for covering a mirror of said trunk in the closed position. According to another aspect, there is described a method of additive manufacturing of the assembly as previously described, the method comprising the following steps: - manufacturing by additive manufacturing of the whole, - separation of the first room and the second room, - removal of the support element through the opening of the first part. Removal of the support element may be accomplished using a tool, for example a cutting tool, such as a scalpel. The assembly is manufactured in particular by deposition of molten material. Brief description of the drawings Other characteristics, details and advantages will appear on reading the detailed description below, and on analyzing the attached drawings, in which: |Fig.1] illustrates three partial schematic views of an example assembly according to this document; [Fig.2] illustrates three partial schematic views of the overall example according to this document; [Fig.3] is a partial schematic sectional view of the assembly example according to this document; [Fig.4] illustrates two partial schematic views of the overall example according to this document. Description of the embodiments Reference is now made to Figure 1 A schematically representing an example of an assembly 1 manufactured by additive manufacturing according to the present document. Preferably, such an assembly 1 can be implemented in an aircraft, and in particular such an assembly can comply with the standards relating to fire resistance applicable in such an environment. This document also relates to a manufacturing process for the assembly. In particular, the assembly is manufactured using a fused deposition modeling (FFF) additive manufacturing process. The assembly is then formed by depositing material layer by layer from an additive manufacturing plate and in a manufacturing direction Z perpendicular to the plate. The assembly 1 comprises a first part 10 and a second part 20 housed at least partly in the first part 10, the second part 20 being movable relative to the first part 10. In particular, the second part 20 can be housed entirely in the first part 10. The assembly can comprise more than two parts. The assembly will be described in the non-limiting context of the first part 10 forming a frame (figure 1B) and the second part 20 forming a panel (figure 1C) sliding in the frame. Such an assembly 1 can in particular be used as all or part of a storage chest, for example so as to form a door of said chest. The panel can be movable between a retracted position and a closed position. For example, the panel can cover a mirror of said chest in the closed position, and reveal the mirror in the retracted position. The frame can comprise a window opposite the mirror, the window overlooking the panel in the closed position, and the mirror in the retracted position. The panel and the frame in particular form a non-removable object. Other applications are also conceivable, for example a retractable shelf directly housed in a seat, or hinge mechanisms. The first part 10 and the second part 20 may each be made of a material capable of withstanding a temperature greater than at least 180°C, in particular in order to comply with standards relating to fire resistance. The first part 10 and the second part 20 may be made of a material incompatible with the use of a soluble material between the first part 10 and the second part 20. during the realization of the whole. In particular, the first part and / or the second part can be made of PAEK or PEI, also known under the commercial reference PEEK / PEKK or Ultem 9085, Ultem 1010 respectively. The first part 10 and the second part 20 are connected to each other by at least one breakable support element 30. More precisely, during the production of the assembly, the first part 10 rests directly on the additive manufacturing plate, and the second part 20 rests on the first part 10 via said at least one support element 30. In other words, the support element 30 serves as a support for the production of the second part 20. Thus, it is possible to manufacture assemblies in which at least one of the parts cannot rest directly on the manufacturing plate, and needs to be produced on a support means. The implementation of the support element therefore allows the production of assemblies having parts that are highly nested with each other, which would have been difficult to manufacture otherwise. The support element is preferably made of a material different from the first part and / or the second part, for example PAES (Poly Aryl Ether Sulfone). Said support element may for example be made of PES, also known by the commercial reference PES. Such materials are particularly adapted so that the support element has adhesion with the first part and the second part, so as to allow, on the one hand, the smooth running of the manufacturing of the assembly by additive manufacturing, and on the other hand, the easy separation of the first part and the second part at the level of the support element. Figures 2A, 2B, and 2C represent partial views of the assembly 1. The first part 10 comprises an opening 11 opposite said at least one support element 30. In particular, the opening 11 opens, on the one hand, towards an internal volume of the first part 10 housing the second part 20 and opposite the support element 30, and, on the other hand, towards the outside of the first part 10, that is to say opposite said internal volume of the first part 10. This opening 11 is configured to allow the removal of at least a portion of said support element 30 through the opening 11, and in particular of the entire support element 30. The opening 11 may, for example, extend over a portion, a major portion or the entire dimension of the support element 30. In addition, the opening 11 may be formed, for example, by a straight or curved groove. The removal of at least a portion of the support element 30 through the opening 11 consists in particular of a mechanical operation, for example manual. The removal can for example be carried out by delamination or by traction, and can be carried out without or with the aid of a tool, for example a cutting tool, such as a scalpel. The opening 11 must then allow sufficient access for the removal of the support element 30. The assembly can then be assembled with another element covering the opening, in order to limit access to said opening. For example, in the example of the sliding panel in a frame, the frame can be covered with a storage net covering the opening. The manufacturing process of the assembly advantageously comprises the following steps: - manufacturing by additive manufacturing of set 1, - separation of the first part 10 and the second part 20, - removal of the support element 30 through the opening 11 of the first part 10. The removal of the support element 30 may occur concomitantly or after the separation of the first part 10 and the second part 20. The assembly advantageously has a reduced production time and easier manufacturing compared to an equivalent object that would have been produced conventionally, that is to say by forming and then assembly operations. Indeed, the number of components is reduced and the assembly steps eliminated compared to the equivalent object produced conventionally. Such an assembly also has improved aesthetics and reduced mass compared to the equivalent object produced conventionally. Furthermore, the first part 10 and the second part 20 are advantageously produced simultaneously. By produced simultaneously is meant that the first part 10 and the second part 20 are not produced separately and then assembled to each other, but that the second part 20 is directly housed, at least in part, in the first part 10 during the production of the assembly 1. The assembly 1 may be non-dismountable, for example for applications requiring the absence of disassembly for safety purposes. [Fig. 3] represents a sectional view of the assembly perpendicular to the manufacturing direction of the assembly. The first part 10 and the second part 20 are in particular mechanically connected to each other. Connecting portions 12, 21, respectively of the first part 10 and the second part 20, form said mechanical connection. In particular, the mechanical connection may be a connection allowing at least one translation (in the direction Z illustrated as an example in [Fig. 3]), for example a sliding connection, and / or at least one rotation, for example a pivot connection. The mechanical connection between the first part 10 and the second part 20 of the example illustrated in Figures 1 to 4 is a sliding connection. For implementation of the sliding connection, the second part 20 comprises at least one connection portion 21, for example two connection portions 21 at two opposite ends of the second part 20. Each connection portion 21 of the second part 20 can for example form a projection on the second part 20. Each connection portion 21 of the second part 20 can then be housed in a cavity formed by the corresponding connection portion 12 of the first part 10. For example, the connection portions 21 of the second part 20, as well as the cavities of the first part 10 receiving said connection portions 21 of the second part 20 can be of rectangular section. The direction of translation, permitted by the mechanical connection between the first part 10 and the second part 20, can advantageously be parallel to the manufacturing direction of the assembly. This allows for improved control of the geometry of the mechanical connection, and in particular of the clearances J between the connection portions 12, 21 of the first part 10 and the second part 20. Control of said clearances is all the more critical for an application to materials capable of withstanding temperatures above 180°C. Indeed, the use of this type of material causes shrinkage and warping problems that can be significant. Producing the mechanical connection parallel to the manufacturing direction of the assembly therefore makes it possible to limit the impact of these shrinkage and warping phenomena on the control of said clearances and therefore on the functionality of the mechanical connection.This technical characteristic therefore makes it possible to obtain sufficiently large clearances to avoid jamming or even blocking between the parts, and, on the other hand, sufficiently small to ensure good guidance between the parts at the slide connection. For example, the connecting portions 12, 21 respectively of the first part 10 and the second part 20 may have between them a clearance J of between 0.15 mm and 0.3 mm. Such a characteristic makes it possible to improve the mechanical connection between the first 10 and the second 20 parts. It may be noted that the values of the clearances depend among other things on the manufacturing and machine parameters, and on the materials of the parts. In addition, the connecting portions 12, 21 respectively of the first part 10 and of the second part 20 may advantageously have rounded edges. This makes it possible to limit, or even avoid, the presence of protruding edges, so as to improve the sliding between the first 10 and the second 20 parts. The support element 30 can advantageously extend in a direction perpendicular to the direction of the mechanical connection between the first part 10 and the second part 20. Such a characteristic makes it possible to facilitate the separation between the first part 10 and the second part 20, for example by traction on the second part 20, that is to say by a movement in a direction perpendicular to the direction in which the support element extends. Figures 4A and 4B respectively illustrate a view of the assembly 1, and an enlarged view of a part circled in dotted lines in Figure 4A. Preferably, the connecting portions 12, 21 respectively of the first part 10 and the second part 20 are located at a distance from the support element 30. Thus, the presence of material residues at the mechanical connection between the first part 10 and the second part 20 is avoided. This allows a better mechanical connection between the two parts, by limiting the risks of friction or jamming. In addition, the placement of the support element 30 at a distance from the mechanical connection allows better control of the clearances between the connecting portions 12, 21 respectively of the first part 10 and the second part 20, due to the absence of elements to be removed at the mechanical connection. More specifically, the second part 20 may comprise a transition portion 22 connecting the support element 30 to the connecting portion 21 of the second part 20. This transition portion 22 may in particular be suspended, i.e. facing an empty volume in the manufacturing direction (perpendicular to the additive manufacturing plate). This suspended shape makes it possible to achieve the distance between the support element 30 and the mechanical connection between the first part 10 and the second part 20. Thus, during the production of the assembly, the second part 20 can rest on the support element 30 and then expand incrementally as it is produced layer by layer, so as to form the suspended transition portion 22.
Claims
Claims
1. Assembly (1) manufactured by additive manufacturing comprising: - a first part (10), - a second part (20) housed at least partly in the first part (10), the second part (20) being movable relative to the first room (10), wherein the first part (10) and the second part (20) are connected between them by at least one breakable support element (30), the first part (10) comprising an opening (11) opposite said at least one support element (30), the opening (11) being configured to allow the removal of at least a portion of said support element (30) through the opening (11).
2. An assembly (1) according to claim 1, wherein the first part (10) and the second part (20) are mechanically connected to each other the other, connecting portions (12, 21), respectively of the first part (10) and the second part (20), forming said connection mechanical.
3. An assembly (1) according to claim 2, wherein the portions of connection (12, 21) respectively of the first part (10) and of the second part (20) are located at a distance from the support element (30).
4. Assembly (1) according to one of claims 2 or 3, in which the connecting portions (12, 21) respectively of the first part (10) and of the second part (20) have rounded edges.
5. Assembly (1) according to one of claims 2 to 4, in which the connecting portions (12, 21) respectively of the first part (10) and of the second part (20) have between them a clearance (J) of between 0.15mm and 0.3mm.
6. Assembly (1) according to one of claims 2 to 5, in which the connection mechanical between the first part (10) and the second part (20) at- allowing at least one translation in one direction (Z), the element of support (30) extending in a direction perpendicular to said direction (Z) of the mechanical connection.
7. Assembly (1) according to one of claims 1 to 6, in which the first part (10) and the second part (20) are each made in a material capable of withstanding a temperature greater than at least 180°C.
8. Assembly (1) according to one of claims 1 to 7, in which the first part (10) forms a frame and the second part (20) forms a sliding panel in the frame.
9. Method for additive manufacturing of the assembly (1) according to one of the claims- indications 1 to 8, the method comprising the following steps: - manufacturing by additive manufacturing of the assembly (1), - separation of the first part (10) and the second part (20), - removal of the support element (30) through the opening (11) of the first room (10).
10. A method according to claim 9, wherein the manufacture of the assembly (1) is produced by deposition of molten material.