SYSTEM AND METHOD FOR IMPLEMENTING NODE-TO-NODE CONNECTIONS IN A MECHANIZED ASSEMBLIES - Patent application

Abstract

Provides a method for binding nodes and subcomponents. A first additively manufactured node (100a) or subcomponent has a groove (204). A second additively manufactured node (100b) or subcomponent has a tongue (202) configured to extend into and mate with the groove (204), forming a tongue-and-groove connection between the first and second nodes (100a, 100b) or subcomponents. In some embodiments, the tongue-and-groove connection may extend substantially around the circumference of the node (100a) or subcomponent. In other embodiments, a first subcomponent having a fluid conduit interface is coupled to a second subcomponent having a fluid conduit interface via a tongue-and-groove connection, thereby enabling fluid flow between the subcomponents of the resulting integrated component.

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Patent Application No. 15 / 644,719, filed July 7, 2017, entitled "System and Method for Implementing Inter-Node Connections in Mechanized Assemblies," which is incorporated herein in its entirety.

[0002] The present disclosure relates generally to techniques for joining subcomponents, and more particularly to joining nodes and other subcomponents using additively manufactured parts and techniques. [Background technology]

[0003] Three-dimensional (3D) printing, also known as additive manufacturing (AM), has recently offered new opportunities to more efficiently build automobiles and other transportation structures, such as aircraft, ships, motorcycles, buses, and trains. The application of AM processes in industries that manufacture these products has proven to produce structurally efficient transportation structures. For example, automobiles manufactured using 3D printed components can be stronger and lighter, resulting in greater fuel efficiency. Furthermore, AM allows manufacturers to 3D print parts that are significantly more complex and have more advanced features and functionality than parts made with traditional machining and casting techniques.

[0004] Despite these recent advances, many obstacles remain regarding the practical implementation of AM technologies in transportation structures and other mechanized assemblies. For example, regardless of whether AM is used to fabricate the various components of such devices, manufacturers typically rely on labor-intensive and expensive techniques, such as welding and riveting, to join components such as the nodes used in transportation structures. The deficiencies associated with welding and similar techniques equally apply to components that are currently too large to 3D print in a single AM ​​step, such as vehicle gear cases. A particular 3D printer is typically limited to rendering objects with a finite size, which is often determined by the available surface area of ​​the 3D printer's build plate and the printer's volume tolerances. In these cases, manufacturers are often forced to build the component using traditional, expensive, and time-consuming machining techniques. Alternatively, manufacturers may 3D print several subcomponents and then combine them to form a complete, functional component. Summary of the Invention

[0005] Some aspects of techniques for joining nodes and subcomponents using adhesives are described in more detail below with reference to three-dimensional (3D) printing techniques.

[0006] One aspect of the device includes an additively manufactured first node having a groove and an additively manufactured second node having a tongue extending into the groove to form a tongue and groove connection between the first node and the second node.

[0007] Another aspect of the device includes an additively manufactured first subcomponent including a tongue structure disposed along a first peripheral region thereof, and an additively manufactured second subcomponent with a groove structure disposed along a second peripheral region thereof, the tongue structure configured to mate with the groove structure along the first and second peripheral regions.

[0008] Another aspect of the device includes an additively manufactured first subcomponent having a first outer wall and an additively manufactured second subcomponent having a second outer wall, the first and second subcomponents mating via a tongue and groove connection disposed circumferentially around edges of each of the first and second outer walls.

[0009] An aspect of a method for additively manufacturing a component for a transportation structure includes additively manufacturing a first subcomponent comprising a tongue structure disposed along a first peripheral region, additively manufacturing a second subcomponent comprising a groove structure disposed along a second peripheral region, and mating the tongue structure with the groove structure along the first and second peripheral regions.

[0010] 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 disposed circumferentially around edges of each of the first and second outer walls.

[0011] It will be appreciated that other aspects of adhesively bonding nodes and subcomponents will become readily apparent to those skilled in the art from the following detailed description, which shows and describes only a few illustrative embodiments. As will be appreciated by those skilled in the art, bonding additively manufactured nodes and subcomponents may be accomplished in other embodiments without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

[0012] Various aspects of apparatus and methods for adhesively bonding nodes and subcomponents are presented in the detailed description, by way of example and not by way of limitation, in the accompanying drawings. [Brief explanation of the drawings]

[0013] [Figure 1] Figure 1 shows a perspective view of an additively manufactured inter-node joint. [Figure 2] FIG. 2 shows a cross-sectional view of the inter-node joint of FIG. [Figure 3] FIG. 3 shows a top view showing the gear case for the build plate of a large selective laser melting (SLM) machine. [Figure 4] FIG. 4 shows a top view of a build plate 402 showing the gear case shown in relation to the build plate in different orientations. [Figure 5] FIG. 5 shows a perspective view of the gear case of FIG. [Figure 6] Figure 6 shows a cross section illustrating an additively manufactured tongue and groove joint. [Figure 7] FIG. 7 shows an interface plan view illustrating a fluid conduit interface including a cross section of a conduit for transporting fluid between subcomponents. [Figure 8] FIG. 8 shows a perspective view illustrating multiple additively manufactured subcomponents configured to be joined together as a component via multiple tongue and groove connections. [Figure 9] FIG. 9 shows a perspective view illustrating multiple subcomponents with fluid conduit interfaces proximate the walls of the subcomponents for transporting fluid through the composite component. [Figure 10] FIG. 10 shows a side view of a gear case with metal nodes. [Figure 11] Figure 11 shows a cross section showing a hexagonal gear case constructed using nodes and shear panels. [Figure 12A] FIG. 12A is a perspective view showing a hexagonal gear case. [Figure 12B] FIG. 12B shows an exploded perspective view of two exemplary panels that mate with the nodes used in the gear case of FIG. 12A. [Figure 13] FIG. 13 shows a flow diagram illustrating an exemplary method for additively manufacturing components within a transportation structure. [Figure 14]FIG. 14 shows a flow diagram illustrating an exemplary method for additively manufacturing a fluid conduit interface within a component. DETAILED DESCRIPTION OF THE INVENTION

[0014] The detailed description set forth below in connection with the 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 present invention may be practiced. 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 the present disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the present invention to those skilled in the art. However, the present invention may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form, or omitted entirely, in order to avoid obscuring various concepts presented throughout the disclosure.

[0015] Additive manufacturing, in the context of joining two or more parts, allows manufacturers of mechanical structures and mechanized assemblies to produce complex-shaped parts at lower cost to consumers, providing significant flexibility and cost-saving benefits. The aforementioned joining techniques relate to the process of connecting AM parts and / or commercial-off-the-shelf (COTS) components. AM parts are printed three-dimensional (3D) parts that are printed by adding layer upon layer of material based on a pre-programmed design. Such parts may be parts used to assemble transportation structures such as automobiles. However, those skilled in the art will understand that parts so manufactured may be used to assemble other complex mechanical products, such as cars, trucks, trains, motorcycles, ships, aircraft, and other mechanized assemblies, without departing from the scope of the present invention.

[0016] In one aspect of the present disclosure, a technique for joining additively manufactured nodes is disclosed. A node is an example of an AM part. A node can be any 3D printed part that includes a socket or other mechanism (e.g., a mechanism for receiving these parts) for receiving components such as tubes and / or panels. A node can have an internal mechanism configured to receive a specific type of component. Alternatively, or in combination, a node can be formed to receive a specific type of component. In some embodiments of the present disclosure, a node can have an internal mechanism for placing a component within the node's socket. However, as one skilled in the art will appreciate, a node can utilize any mechanism, including various shapes, to receive any variety of components without departing from the scope of the present disclosure. For example, a particular node may include a simple inset, groove, or indentation to receive other structures, which may be further joined via adhesive, fasteners, or other mechanisms.

[0017] The nodes described herein may further include structures for joining tubes, panels, and other components for use in transportation structures or other mechanical assemblies. For example, a node may include a joint that can serve as an intersection point for two or more panels, connecting tubes, or other structures. To this end, the node may be configured with openings or spigots configured to receive such other structures, allowing them to tightly fit into the node. The node may join connecting tubes to form a space frame vehicle chassis. The node may also be used to join inner or outer panels to other structures. In many cases, joining individual nodes may be necessary to achieve the goal of enabling the construction of the above-mentioned structures. Various such joining techniques are described below.

[0018] In one embodiment, tongue-and-groove structures are used to connect two or more nodes. FIG. 1 shows a perspective view of an additively manufactured inter-node joint 100. More specifically, inter-node joint sections 100a and 100b are shown joined with a gap 108. The inter-node joint 100 further includes standoff tabs 102a-c disposed around the periphery of the inter-node joint 100. In the exemplary embodiment, the gap 108 is a 0.25 mm gap (or another dimension) configured to allow for appropriate spacing of nodes constructed of dissimilar metals or other materials. This spacing prevents physical contact between the two subcomponents being joined, avoiding galvanic corrosion. This spacing separates the nodes / subcomponents. In addition to providing a seal, a sealant may also function as a spacer. In other embodiments where corrosion is not a concern, the inter-node joint sections 100a and 100b may be flush with one another, eliminating the gap. Each of the inter-nodal joint sections 100 a and 100 b may include a sidewall 110 inside the inter-nodal joint 100 .

[0019] Inter-nodal joint 100 further includes an inlet port 104 to allow adhesive to enter inter-nodal joint 100, and a vacuum port 106 for drawing a vacuum to promote adhesive flow within inter-nodal joint 100. In the illustrated embodiment, each inlet port 104 and vacuum port 106 is constructed in node 100b and is designed to provide adhesive flow to assist in adjoining nodes 100a and 100b, as described below.

[0020] FIG. 2 shows a cross-sectional view of inter-node joint 200 along plane AAAA. In this view, sidewall 110 in FIG. 2 corresponds to sidewall 110 in FIG. 1, and standoff tab 102b in FIG. 2 corresponds to standoff tab 102b in FIG. 1. A gap 108 is shown in sidewall 110 in FIG. 2. Tongue portion 202 of inter-node joint 200 is part of node 100A, includes a first material represented by the diagonal of node 100A, and is disposed generally along a peripheral region 210 of node 100A. In one embodiment, tongue portion 202 extends entirely around peripheral region 210 and is actually a single protrusion disposed around peripheral region 210. Tongue portion 202 protrudes outward along peripheral region 210 associated with node 100B and around node 100A, and the lateral extension of tongue portion 202 can be considered to be out of view in this view. Groove portion 204 of inter-nodal joint 200 is part of node 100B and is located generally along the peripheral region 212 of node 100b. Groove portion 204 may, but need not, be composed of the material of node 100b. This material is represented by a diagonal line in node 100b, which runs in the opposite direction to the diagonal line of node 100a. In one embodiment, groove portion 204 extends around the entire perimeter of peripheral region 212 and is effectively a single depression in node 100b that spans the entire perimeter of peripheral region 212. Groove portion 202 is inset along the peripheral region 212 associated with node 100a and runs laterally around the perimeter of node 100b, and in this view can also be considered to be exiting the view. A tongue 202 and groove 204 are positioned on each node 100a and 100b, and when the two nodes are properly placed and in contact, the tongue 202 aligns with the groove 204 and can fit into the groove 204 around the peripheral regions 210, 212.

[0021] In an exemplary embodiment, groove 204 includes a centering feature 208, which is a narrowed area that widens the opening of groove 202 and allows tongue 202 to properly mate with groove 204, thereby assisting in centering inter-nodal joint 200. In another exemplary embodiment, a leakage sealant reservoir 226 is provided on each side of 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 the applied adhesive.

[0022] As shown in connection with FIGS. 1 and 2 , adhesive port 104 and vacuum port 106 are provided, respectively. In one embodiment, sealant is first applied to sealant groove 220 of node 100a. The two nodes 100a and 100b can then be firmly aligned and secured in place using standoff tabs 102a-c as alignment points. A vacuum may be applied at vacuum port 106 to ensure the nodes are sealed. Once a complete seal is achieved, adhesive may be applied through inlet port 104. In one embodiment, the internal structure of vacuum port 106 is similar to that of inlet port 104. The action of the adhesive and vacuum causes the adhesive to seep into the space between tongue 202 and groove 204, and the adhesive flows into this space around peripheral regions 210, 212 until it properly saturates the tongue-and-groove connection around the peripheral regions.

[0023] In one embodiment, the standoff tabs 120a-c may also be used to help prevent sealant push-back 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 may be allowed to cure. The vacuum pressure during the adhesive flow process may be monitored and may indicate complete adhesive fill. Once curing is complete, in one embodiment, the standoff tabs may be broken.

[0024] This technology allows nodes to be efficiently and permanently joined together. The use of AM in one embodiment creates the structure necessary to effect the joining of nodes, eliminating the need for additional processes other than the application of adhesives and / or sealants, such as welding or the use of various external fastening mechanisms.

[0025] In another aspect of the present disclosure, techniques are disclosed for joining subcomponents of larger additively manufactured components, such as engines, transmissions, gear cases, etc. In the following discussion, the disclosure is illustrated in the context of an additively manufactured gear case within a transmission of a transportation structure. However, it will be understood that the teachings of the present disclosure are not so limited and that any number and type of additively manufactured components may be assembled using the principles described herein.

[0026] Gear Cases and Other Components. Exemplary embodiments are presented herein in the context of gear cases and related components used in mechanized assemblies. Rotating shaft power transmissions typically involve shafts supported on lubricant-cooled bearings. Support forces in such structures, generated primarily from gravity and unbalance forces, can be insufficient. In multi-speed transmissions, gears can be used to provide a speed differential to match the input shaft speed with the output. Multi-shaft transmissions are common, with gears on each shaft spaced a "center distance" apart, with the gear teeth meshing with the outer diameters of the gears. As a result of this meshing, multi-shaft transmissions using involute gear profiles can generate shaft-spreading forces due to pressure angles at the contact points between the gears. The spreading force is typically reacted through bearings and, from there, through a casing called a gear case.

[0027] Gear meshing commonly utilizes lubricants to extend gear life to a useful level. The lubricant can carry away frictional heat and provide cooling. For example, in auto racing applications, the gear case can also respond to loads from the suspension, aerodynamic loads of the vehicle, and other sources. Therefore, in such situations, the gear case can be subject to complex loading, can be fluid-tight, and can operate at significantly higher temperatures in high-power applications. Metal gear case construction is often applied in power transmission applications, with light alloys of aluminum, magnesium, and titanium being the most common materials.

[0028] Several different AM techniques may be well-suited for building gear cases and other labor- or power-intensive components within transportation structures or other mechanized assemblies. Such 3D printing techniques may 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 fusing of metal powders. Like other 3D printing techniques, SLM, SLS, and other powder bed fusion (PBF) systems create build pieces layer by layer. Each layer, or "slice," is formed by depositing a layer of powder and exposing portions of the powder to an energy beam. The energy beam is applied to the fused areas of the powder layer that match the cross-section of the build piece within the layer. The molten powder cools and fuses to form the slice of the build piece. This process is repeated to form the next slice of the build piece, and so on. Each layer is deposited on top of the previous layer. The resulting structure is a build piece that is assembled from the ground up, slice by slice. SLS and various other PBF techniques may be suitable for building gear cases and other transportation structure components. However, it will be appreciated that other AM techniques, such as fused deposition modeling (FDM), may also be used in such applications.

[0029] Conventional gear case construction uses castings, which can be thin-walled to reduce mass. However, large transmissions have constraints related to the tooling of the casting patterns. These constraints, among other factors, can result in minimum wall thicknesses that are greater than necessary for the expected loading conditions due to the dimensional stability of conventional tooling. Furthermore, using conventional casting techniques, the minimum wall thickness can be significantly greater than necessary to ensure fluid tightness, especially considering the fact that pressure differentials across the case can be relatively low in many applications.

[0030] Conversely, as noted above, these and other conventional AM techniques, including (among others) selective laser melting 3D printers, are currently limited in maximum dimensions and can therefore only render structures up to a maximum size. FIG. 3 illustrates a gear case 300 shown in association with a build plate 302 associated with an exemplary large selective laser melting machine. As is apparent from the figure, the build plate 302 is substantially smaller than the gear case 300. Thus, conventional selective laser melting printers and other AM techniques may require various components, such as the gear case 300, to be constructed as multiple subcomponents. This contrasts with conventional manufacturing techniques, which may typically cast the body of the gear case as a single component. Accordingly, one aspect of the present disclosure addresses a solution for integrating multiple AM ​​components into a single component that possesses sufficient properties and characteristics to accommodate the component's intended purpose. For example, addressing the challenges faced by collaterally assembling subcomponents into an integrated AM component is particularly important when transporting fluids within the component is a necessary or desirable feature of the constructed component.

[0031] 4 illustrates a gear case 400 shown in relation to a build plate 402, with the build plate 402 positioned at different orientations. In this example, a conventional PBF printer (e.g., a selective laser melting 3D printer) has the ability to render the gear case 400 using two sub-components printed at a relative angle that is orthogonal to one another, depending on the size of the gear case 400. Thus, as FIG. 4 illustrates, in some embodiments, it may be desirable to minimize the number of sub-components by taking advantage of the shape of the component being designed.

[0032] As mentioned above, using AM to render a component into multiple subcomponents presents unique challenges. These challenges are particularly evident in the case of transport structural parts, such as gear cases, which may require the transport of fluid lubricants or coolants. Fluid transport conduits in such gear cases, when integrated with the gear case walls, can generally be constructed with low mass. This advantageously provides a lighter gear case and adds additional volume within the gear case to accommodate internal structures. However, when fluid transport is desired or required in an integrated AM component, such as a gear case, the subcomponents that form the component or gear case must be assembled in a manner that reliably seals the fluid transport between the subcomponents to avoid fluid leakage and resulting component failure.

[0033] Thus, in another aspect of the present disclosure, a component of a transportation structure is additively manufactured as multiple subcomponents that are joined, at least in part, using one or more tongue-and-groove connections to form a uniform, securely integrated component. For example, using the principles described herein, a load-bearing gear case may be constructed using multiple AM ​​subcomponents that are seamlessly integrated to form a single gear case. Thin-walled structures, such as gear cases, can be joined from their constituent AM subcomponents.

[0034] FIG. 5 shows a perspective view of the gear case 500 of FIG. 3. In this exemplary embodiment, the gear case 500 is 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 gear case 500 are seamlessly joined at the wall 505 that extends around the line 502 to form the single component 500, as described in further detail below. Unlike conventional techniques that have unnecessarily thick walls that add undesirable mass and volume, resulting in a larger gear case that reduces the performance of the associated transport structure, the walls 505 of the gear case 500 of FIG. 5 can be 3D printed to the exact specifications necessary to withstand the associated pressures without adding unnecessary material.

[0035] In one embodiment, a tongue-and-groove connection is used to join the subcomponents. A tongue-and-groove connection may also include the use of an adhesive that responds to loads between components in shear. FIG. 6 shows a cross-section of an additively manufactured tongue-and-groove joint 600 running along each edge of a gear case wall 605, with one wall associated with a first subcomponent and one wall associated with a second subcomponent. Specifically, FIG. 6 shows a cross-section of the wall edge at intersection 502 (FIG. 5), with the edge going in and out of the figure. The joint 600 includes a wall edge 607 that can correspond to and be associated with a first subcomponent 601B and a second subcomponent 601A. The joint 600 further includes a tongue 602 and a groove 604. In one embodiment, the tongue 602 is disposed along a first peripheral region 635 of the first subcomponent 601B of the gear case 500 (FIG. 5), and the groove 604 is disposed along a second peripheral region 633 of the second subcomponent 601A of the gear case 500. As can be seen from the figure, in this embodiment, tongue 602 and groove 604 are tapered to facilitate assembly (i.e., to facilitate insertion of the tongue into the groove), and edges 607 of wall 605 are touching or adjacent.

[0036] The gap 606 between the tongue 602 and groove 604 can be filled with adhesive. For example, the adhesive can be injected using vacuum infusion through an external fill port 610 located on a first side of the subcomponent 601A while drawing a vacuum through a vacuum port 608 located on a second side of the subcomponent 601A to spread the adhesive through the gap 606.

[0037] Subcomponents 601A-B may further include seal grooves 612A and 612B, which may be incorporated into edge 607 of subcomponent 601B in one embodiment. In an exemplary embodiment, seal grooves 612A-B are filled with elastomeric sealants 614A-B, which may be cured prior to adhesive injection to control and limit adhesive flow. This curing also allows for the creation of a strong vacuum during adhesive injection through deformation of the sealant around protruding seal compression features 616A-B and seal expansion voids 618A-B, which are features located on edge 607 of subcomponent 601A. Gap 606 between tongue 602 and groove 604 may also be a nominal thickness. In one embodiment, gap 606 is approximately 500 μm, although many other thicknesses are possible. Gap 606 may be appropriately maintained using a centering feature 620 located at the widest point of groove 604.

[0038] Additionally, in an exemplary embodiment, the joint portions of the edges 607 located outside the seal grooves 612A-B (i.e., to the right of the seal groove 612B and to the left of the seal groove 612A) can be designed to have voids (not shown) between the joined subcomponents 601A-B to prevent fretting and galvanic corrosion between the dissimilar metals. The joint clamping mechanisms 622A, 623A and 622B, 623B can assist in maintaining such voids. The clamping mechanisms 622A, 623A and 622B, 623B can have materials that exaggerate the interface surfaces that provide the voids when the clamping mechanism 622A contacts the clamping mechanism 623A on one side of the wall 605 and when the clamping mechanism 622B contacts the clamping mechanism 623B on the other side of the wall 605.

[0039] In one embodiment, the void extends across the entire subcomponent interface (edge ​​607). However, the void may be filled with adhesive or sealant in the inner areas of the seal grooves 612A-B, but the void may be unfilled in the outer areas of the seal grooves 612A-B. Seal expansion voids 618A-B on the subcomponent 601A may allow sealant from the seal grooves 612A-B to expand as needed to provide a strong seal. In another embodiment, the vacuum port 608, fill port 610, and clamping mechanisms 622-23A and 622-23B may be notched to allow for break-out removal of the attachment mechanisms 613A and 613B after the joint is fully bonded.

[0040] In another aspect of the present disclosure, a component includes a fluid conduit that runs substantially along or adjacent to one of the component's walls. In one embodiment, the fluid conduit is integrated with the wall of gear case 500 (FIG. 5) to achieve the aforementioned benefits. In other embodiments, the fluid conduit is spaced from but adjacent to the component's wall. In yet other embodiments, the fluid conduit is internal to the subcomponent at some desired location.

[0041] A fluid conduit, which may carry a lubricant, coolant, or another suitable fluid, may span the joint defined by edges 607 of subcomponents 601A and 601B. If a fluid conduit is required to span such a joined joint, the joint may be sealed around both the fluid conduit and the gear case wall 605.

[0042] FIG. 7 illustrates a plan view of a fluid conduit interface 700, including a cross-section of a fluid conduit 704 for transporting fluid between subcomponents. That is, FIG. 7 illustrates a cross-section of a joint where fluid moves in a direction into and out of the figure relative to the viewer. The plan view shows the fluid conduit interface 700 near a wall 710 of a first subcomponent, which can be configured to securely mate with a similarly structured fluid conduit interface of a second subcomponent. The fluid conduit interface 702 can further include a generally flat section 706 designed to be positioned substantially flush with a similar section on another subcomponent. In other embodiments, the section 706 can be contoured or have another shape. The fluid conduit interface 700 can also include an outer wall 708 disposed about its periphery and adjacent to the subcomponent wall 710. Additionally, the fluid conduit interface 700 can include a tongue-and-groove joint 702. In an exemplary embodiment, the tongue-and-groove joint 702 includes a tongue protrusion projecting perpendicular to the plane of the figure and configured to mate with a similar groove section associated with a fluid conduit interface of another subcomponent. Alternatively, the tongue and groove joint 702 may include a bayonet groove in the plane of the figure and be designed to receive a similar tongue section associated with a fluid conduit interface of another component. In some embodiments, as shown in Figure 7, the tongue and groove joint 702 need not extend completely around the entire circumference of the fluid conduit, but rather may be constructed to extend partially along or near such circumference.

[0043] FIG. 8 is a perspective view illustrating multiple AM ​​subcomponents 802, 806, 808 configured to be joined together as a component via multiple tongue-and-groove connections. For clarity, a substantially cylindrical set of subcomponents is shown. However, a wide variety of shapes, sizes, and configurations of the subcomponents are possible, depending on the nature and overall configuration of the component. Additionally, for clarity, internal structures that may be contained within the subcomponents or components have been omitted from the illustration.

[0044] In this exemplary embodiment, each of subcomponents 802 and 806 constitutes a portion of a cylindrical structure. Subcomponent 802 may include an outer wall 815 having an edge 809 that includes, in this example, a tongue protrusion 804. Similarly, subcomponent 806 may be configured to have a groove connection 855 that receives and mates with tongue protrusion 804. Generally, depending on the configuration, tongue and groove connection 804 may include either a tongue or a groove and may be configured to mate with a corresponding (partially hidden from view) edge of said subcomponent 806. Similarly, tongue protrusion 827 (or, in other cases, a groove connection) may be disposed on another edge 810 of subcomponent 802 and configured to mate with a corresponding groove connection 858 of subcomponent 806.

[0045] 8 further illustrates a cylindrically shaped subcomponent 808, which in this embodiment is designed to fit flush against the mated combination of subcomponents 802 and 806. Subcomponent 808 may include an outer wall having an edge 811, and another tongue and groove connection 812 may be disposed on edge 811 around the peripheral region of subcomponent 808. Tongue and groove connection 812 may then mate with a mating corresponding tongue and groove connection (not visible from view) provided by the distal ends of subcomponents 802 and 806.

[0046] It should be noted that, depending on the configuration, the tongue and groove connections of the various subcomponents may be substantially orthogonal or at different angles to one another. For example, in this embodiment, tongue and groove connection 804 is substantially orthogonal to tongue and groove connection 812. In other embodiments, tongue and groove connection 812 need not traverse the entire circumference of subcomponent 808, and tongue projections 804 and 827 similarly need not traverse the entire length of respective edges 809 and 810 of subcomponent 806.

[0047] 9 shows a perspective view of multiple subcomponents having a fluid conduit interface 922 proximate a wall of the subcomponent 902 for transporting fluid in a sealed manner through the combined, integrated component. The subcomponent 902 includes an edge 909 having a tongue-and-groove connection 904 that can be configured to mate with a corresponding tongue-and-groove connection on the subcomponent 906 to form an integrated combination of the subcomponents 902 and 906. Additionally, a fluid conduit 914 is shown, which can be integrated with or positioned proximate a wall of the subcomponent 902 and configured to transport fluid within the integrated component. The subcomponent 902 can further include a fluid conduit interface 922 that includes a fluid conduit segment 921. In one embodiment, the fluid conduit interface 922 can be configured to mount substantially flush with a corresponding fluid conduit interface 941 on the subcomponent 908. In this manner, fluid conduit segment 921 can be seamlessly aligned with fluid conduit segment 914 of subcomponent 908, allowing fluid to flow through the resulting integrated component.

[0048] Subcomponent 908 in this embodiment is a generally cylindrical structure including a wall with an edge 911 along which a tongue and groove connection 912 may be disposed for mating with subcomponents 902 and 906 along their peripheral regions. As described above, fluid conduit interface 941 of subcomponent 908 may include a generally flat section 913 configured to be disposed substantially flush with a corresponding section (not visible from view) on fluid conduit interface 922 of subcomponent 902.

[0049] Fluid conduit interface 941 of subcomponent 908 may further include another tongue and groove connection 915 configured to mate with a corresponding tongue and groove connection disposed on fluid conduit interface 922 of subcomponent 902. The corresponding tongue and groove connection on fluid conduit interface 922 of subcomponent 902 is substantially similar in geometric configuration to fluid conduit interface 941, except that the tongue and groove connection may include an inverted mating configuration, i.e., if tongue and groove connection 915 is a tongue, it may include a groove, and vice versa.

[0050] Although not required, in the exemplary embodiment, section 913 is substantially flat so that it presses snugly against a corresponding flat section of subcomponent 902. In other embodiments, section 913 may not be flat or may include structure suitable for receiving a seal around fluid conduit 814. In other embodiments, section 913 may be shaped or textured, or may include another suitable shape, to abut a complementary section on fluid conduit interface 922 of subcomponent 902. The resulting component has a solid and flush joinder at each fluid conduit interface 922, 941 that allows for unimpeded flow of fluid within the component. In various embodiments, depending on the AM component being fabricated, one or more orifices (not shown) may be incorporated into the subcomponent to allow tubes to protrude and / or fluid to be supplied to or from an external source.

[0051] As shown above in Figures 7-9, the ability to create interconnected internal voids for fluid flow allows for the creation of other fluid transport mechanisms within the component. One such example includes the use of a fluid-to-fluid heat exchanger within a gear case. However, many different embodiments and applications are possible depending on the nature and structure of the AM component.

[0052] In another aspect of the present disclosure, AM components for transportation structures and other mechanized assemblies can be designed and assembled using multiple nodes connecting shear panels. In one embodiment, a gear case for a transportation structure is assembled using multiple AM ​​subcomponents to integrate multiple shear panels into one component for use in a transportation structure or other mechanized assembly.

[0053] FIG. 10 shows a side view of a hexagonal gear case 1000 with AM nodes 1002A, which, in an exemplary embodiment, can be additively manufactured using a suitable metal material. The AM nodes 1002A can be configured to include one or more interfaces for bearings, shafts, and other structures internal to the gear case 1000 where the gear case 1000 can bear a planar shape. In this illustration, two shear panels 1004 of the hexagonal gear case 1000 can be secured between respective AM nodes 1002A. The AM nodes 1002A can include extension structures or inserts (not shown) to mate with each side of the shear panels 1004, for example, via tongue-and-groove connections, adhesive, or another suitable joining mechanism. The AM nodes 1002A can be configured with sockets or inserts to locate the shear panels 1004 during assembly. The AM nodes 1002A can also provide sealing interfaces for the shear panels 1004. In an exemplary embodiment, the AM nodes 1002A may use dual shear receiving pockets on each side to accept shear panels 1004. Assembly of the gear case 1000 may trap the shear panels 1004 between adjacent AM nodes 1002A. At each end of the hexagonal gear case 1000, the AM nodes 1002A may terminate in a central portion 1003 of the AM node, which in some embodiments may operate to couple and secure the various AM nodes 1002A, and therefore the shear panels 1004 to which they are coupled, to one another.

[0054] FIG. 11 shows a cross-sectional view (BB, see FIG. 11 ) depicting a hexagonal gear case 1100 constructed using nodes and shear panels. Each of the multiple 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 enclose internal structures within the gear case 1100, such as bearings 1006. The nodes 1002 and corresponding shear panels 1004 can use several possible connection mechanisms, including, for example, a tongue-and-groove configuration as described herein. Alternatively, the nodes can include one or more positioning features for receiving sockets and / or panels or other structures. In some embodiments, the nodes can include channels for providing adhesive and drawing vacuum. The nodes can also be simple in structure, for example, they can include a plug-in area for receiving a panel. In general, the configuration of the nodes can be as appropriate for the application and purpose.

[0055] As shown in Figures 10-11, the assembly of a gear case using multiple AM ​​subcomponents allows structures such as shear panels to be captured between AM metal parts. In an exemplary embodiment, the AM metal parts are rendered using a PBF technique such as SLM. In an exemplary embodiment, the shear panel 1004 is a commercial-off-the-shelf (COTS) flat carbon composite sheet configured to seal fluids and transmit shear loads. Carbon composites may be considered because they currently have the highest strength-to-weight ratio of any available structural material. However, shear panels constructed from other materials are also possible. As mentioned above, shear load transmission may require interfaces on AM nodes and other AM subcomponents that enable bonding and sealing. In this manner, a gear case with an overall smaller mass may be constructed.

[0056] 12A shows a perspective view illustrating a hexagonal gear case 1200 formed using the principles described herein. The gear case 1200 includes a plurality of panels 1202, each of two sides of which is joined with a respective node 1002A to form a hexagonal structure having six panels 1202 and six nodes 1002A. In one embodiment, the nodes 1002A are joined to opposite sides of the structure via sections 1003. Each panel 1202 in one embodiment is pressed into a socket or groove connection located on each side of the node 1002A, as shown in more detail in FIG. 12B.

[0057] Referring to Figure 12B, an exploded perspective view of a node 1002A used in the structure of Figure 12A is shown. As is evident from this view, the node 1002A has a slightly curved geometry that serves to form a portion of a hexagon. Additionally, the node 1002A in this embodiment includes a spigot or socket on each side into which panel panels 1004 can be secured. In some embodiments, a suitable adhesive may be used to further secure the panels.

[0058] It should be understood that the gear case 1200 of FIG. 12A, and similar structures for use in mechanized assemblies, can take on any number of possible shapes and sizes, including symmetrical and asymmetrical shapes, and need not be limited to a hexagon. It should be noted that application of the principles of the present disclosure enables additive manufacturing of components ranging in size from small to extra-large, as larger components can be constructed from multiple constituent AM subcomponents. Additionally, non-3D printed COTS or other custom parts can be incorporated into the overall component, as in the case of the gear case of FIG. 12A.

[0059] FIG. 13 shows a flow diagram 1300 illustrating an exemplary method for additively manufacturing components for use in transportation structures or other mechanized assemblies. It should be understood that the steps identified in FIG. 13 are exemplary in nature, and that a different order or sequence of steps, or additional or alternative steps, may be undertaken as contemplated by this disclosure to achieve similar results. In step 1302, for example, a first subcomponent may be additively manufactured having a tongue structure disposed along an edge of a wall of the subcomponent, or a tongue structure disposed partially or completely around a peripheral region of the subcomponent. Similarly, in step 1304, a second subcomponent may be additively manufactured having a complementary groove structure along an edge or peripheral region of a wall, such that when the two subcomponents are joined, the groove structure is configured to mate with the tongue structure associated with the first subcomponent.

[0060] Thereafter, in step 1306, the respective tongue-and-groove structures associated with the first and second subcomponents may be mated to form the resulting AM component. The mating process may be accomplished using a variety of techniques. As an example, in step 1306A, a sealant may be applied between the respective areas of the tongue-and-groove sections, for example, to contain adhesive flow, promote a strong vacuum, and / or assist in securing the two subcomponents. In step 1306b, one or more centering mechanisms may be used to assist in mating the subcomponents. In step 1306c, a suitable adhesive may be applied through a fill port, and a separate vacuum port may be implemented to draw a vacuum that spreads the adhesive in the space between the tongue-and-groove connections. In step 1306d, a set of clamping mechanisms may be used to help provide voids between the respective edges of the peripheral regions to accommodate the coexistence of dissimilar metals or other materials in the joining area. As noted above, the provided voids may function to prevent galvanic corrosion of the materials.

[0061] FIG. 14 shows a flow diagram 1400 illustrating an exemplary method for additively manufacturing a fluid conduit interface within a component to enable fluid flow within the component. As shown in FIG. 13, the number, order, and type of steps to achieve these objectives may vary depending on the configuration and objective. In step 1402, additive manufacturing of a first subcomponent includes additively manufacturing a first fluid conduit interface that runs substantially adjacent to a first peripheral region associated with the first subcomponent. In some embodiments described above, the fluid conduit interface may be integrated into the wall of the first subcomponent to accommodate reduced mass and volume. The first fluid conduit interface may be partially or completely surrounded by a tongue-and-groove connection, which may be either a protruding tongue or a bayonet groove, or may otherwise include this tongue-and-groove connection groove.

[0062] In step 1404, AM of the second sub-component includes additively manufacturing a second fluid conduit interface that runs substantially adjacent to or is integrated as part of a second peripheral region associated with the second sub-component, the second fluid conduit interface being partially or completely surrounded by or otherwise including a complementary tongue and groove connection configured to mate with a tongue and groove connection associated with the first fluid conduit interface.

[0063] Thereafter, in step 1406, the first and second subcomponents are mated using tongue-and-groove connections at their fluid conduit interfaces; in some embodiments, the subcomponents themselves are mated simultaneously using separate tongue-and-groove connections associated with the first and second subcomponents, as described above with reference to FIG. 13 . Step 1406, in exemplary embodiments, 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 subcomponents to aid in adhesive application. Additionally, adhesive may be added to spaces between applicable tongue-and-groove connections to ensure that the fluid conduit interfaces are substantially flush with one another and allow fluid to flow along the periphery of the resulting integrated component. As shown in FIG. 13 , these steps may occur in any order depending on the implementation, and additional or alternative steps may be used to protect the subcomponents and their respective interfaces.

[0064] The foregoing description is provided to enable those skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other technologies for printing and combining nodes and subcomponents. Accordingly, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but are to be accorded the full scope consistent with the claims' language. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or that will become known to those skilled in the art are intended to be encompassed within the scope of the claims. Furthermore, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is expressly recited in the claims. No element of a claim shall be construed under the provisions of 35 U.S.C. 112(f) or similar laws of any applicable jurisdiction unless that element is expressly recited using the phrase "means for," or, in a method claim, unless that element is recited using the phrase "step for."

Claims

1. A method for manufacturing a fluid-transfer-type semiconductor device, comprising: an additively manufactured first node having a first fluid conduit interface and a first groove disposed along a first region of the additively manufactured first node; an additively manufactured second node having a first protrusion disposed along a second fluid conduit interface and a second region of the additively manufactured second node, the first protrusion extending into the first groove to form a connection between the first node and the second node; the first fluid conduit interface has a second groove substantially surrounding the first fluid conduit interface; the second fluid conduit interface has a second protrusion that substantially surrounds the second fluid conduit interface and fits into the second groove; The first fluid conduit interface is coupled to the second fluid conduit interface to allow fluid flow between the first node and the second node.

2. The device of claim 1 , further comprising an adhesive between the first protrusion and the first groove.

3. The device of claim 1 , wherein the first protrusion comprises a centering feature.

4. The device of claim 3 , wherein the centering mechanism includes a proximal portion of the first protrusion having a gap that mates with the first groove.

5. The apparatus of claim 1 , wherein the first and second nodes cooperate to form a sealant reservoir on each side of the connection.

6. an additively manufactured first subcomponent comprising a first fluid conduit interface and a first protrusion disposed along a first region of the first additively manufactured subcomponent; an additively manufactured second subcomponent, the second subcomponent comprising a second fluid conduit interface and a first groove structure disposed along a second region of the additively manufactured second subcomponent; the first protrusion is configured to mate with the first groove structure along the first and second regions; the first fluid conduit interface has a second groove structure substantially surrounding the first fluid conduit interface; the second fluid conduit interface has a second protrusion that substantially surrounds the second fluid conduit interface and mates with the second groove structure; The device, wherein the first fluid conduit interface is coupled to the second fluid conduit interface to allow fluid flow between the first subcomponent and the second subcomponent.

7. 7. The apparatus of claim 6, wherein when the first protrusion mates with the first groove structure, the additively manufactured first sub-component and the additively manufactured second sub-component form a component for use in a transportation structure.

8. The apparatus of claim 7 , wherein the component comprises a gear case.

9. The apparatus of claim 7 , wherein the component comprises a load-bearing component.

10. The device of claim 6 , wherein the first projection and the first groove structure are configured to seal the first and second regions of the first and second subcomponents, respectively.

11. The device of claim 7 , further comprising an adhesive applied between the first protrusion and the first groove structure.

12. The device of claim 7 , further comprising a centering mechanism longitudinally disposed within one side of the first projection.

13. 8. The apparatus of claim 7, further comprising first and second seal grooves longitudinally disposed along the first region adjacent first and second sides of the first projection, the seal grooves configured to receive a compliant seal.

14. 14. The apparatus of claim 13, further comprising at least one clamping mechanism disposed between the first region and the second region and adjacent the first or second seal groove, the at least one clamping mechanism configured to provide a void between edges of the first and second regions to prevent galvanic corrosion of dissimilar materials.

15. The apparatus of claim 14 , wherein the at least one clamping mechanism is removable.

16. The device of claim 7 , further comprising at least one sealing expansion void channel longitudinally disposed along the second region adjacent the first groove structure.

17. The device of claim 7 , further comprising at least one seal compression mechanism longitudinally disposed along the first region adjacent the first projection.

18. The apparatus of claim 8 , wherein the first and second regions comprise at least a portion of an outer wall of the gear case.

19. an additively manufactured first subcomponent comprising a first fluid conduit interface and a first protrusion disposed along a first region of the first additively manufactured subcomponent; an additively manufactured second subcomponent comprising a second fluid conduit interface and a first groove structure disposed along a second region of the additively manufactured second subcomponent; the first protrusion is configured to mate with the first groove structure along the first and second regions; the first fluid conduit interface has a second protrusion substantially surrounding the first fluid conduit interface; the second fluid conduit interface has a second groove structure that substantially surrounds the second fluid conduit interface and mates with the second protrusion; The mated second projection and second groove structure are sealed to allow fluid flow between the first and second subcomponents.

20. Additively manufacturing a first subcomponent, the first subcomponent comprising a first fluid pipe interface and a first protrusion disposed along a first region of the first subcomponent, the first fluid pipe interface including a second protrusion; additively manufacturing a second subcomponent, the second subcomponent comprising a second fluid conduit interface and a first groove structure disposed along a second region of the second subcomponent, the second fluid conduit interface including the second groove; and mating the first fluid conduit interface with the second fluid conduit interface such that the second protrusion and the second groove form a seal to allow fluid flow between the first subcomponent and the second subcomponent by mating the first protrusion with the first groove structure along the first and second regions.

21. 21. The method of claim 20, wherein when the first protrusion mates with the first groove structure, the first additively manufactured sub-component and the second additively manufactured sub-component form a component of a transport structure.

22. The method of claim 21 , wherein the component comprises a gear case.

23. The method of claim 21 , wherein the component comprises a load-bearing component.

24. 21. The method of claim 20, further comprising sealing the first and second regions via the first projection and first groove structure.

25. The method of claim 20, further comprising applying an adhesive between the first protrusion and the first groove structure.

26. 21. The method of claim 20, further comprising using a centering feature located within one side of the first projection to mate the first projection and the first groove structure.

27. 26. The method of claim 25, further comprising forming first and second seal grooves disposed along the first region adjacent first and second sides of the first projection, the seal grooves configured to receive a compliant seal.

28. 28. The method of claim 27, further comprising using at least one clamping mechanism disposed between the first region and the second region and adjacent the first or second seal groove to form a void between edges of the first and second regions, the void operable to prevent galvanic corrosion between dissimilar materials.

29. The method of claim 22 , wherein the first and second regions comprise at least a portion of an outer wall of the gear case.

30. Additively manufacturing a first subcomponent, the first subcomponent comprising a first fluid pipe interface and a first protrusion disposed along a first region of the first subcomponent, the first fluid pipe interface including a second groove; additively manufacturing a second subcomponent, the second subcomponent comprising a second fluid conduit interface and a first groove structure disposed along a second region of the second subcomponent, the second fluid conduit interface including a second protrusion; and mating the first fluid conduit interface to the second fluid conduit interface such that the second protrusion and the second groove form a seal to allow fluid flow between the first subcomponent and the second subcomponent by mating the first protrusion with the first groove structure along the first and second regions.

31. The method of claim 21 , wherein the component comprises a vehicle component.

32. The method of claim 20 , wherein the first fluid conduit interface comprises a first fluid conduit segment that allows fluid to flow between the first subcomponent and the second subcomponent.

33. The method of claim 20 , wherein the second fluid conduit interface comprises a second fluid conduit segment that allows fluid to flow between the first subcomponent and the second subcomponent.

34. A method for manufacturing a fluid-transfer-insulating device, comprising: an additively manufactured first node having a first fluid conduit interface and a first groove disposed along a first region of the additively manufactured first node; an additively manufactured second node having a first protrusion disposed along a second fluid conduit interface and a second region of the additively manufactured second node, the first protrusion extending into the first groove to form a connection between the first node and the second node; the first fluid conduit interface has a second protrusion substantially surrounding the first fluid conduit interface; the second fluid conduit interface has a second groove that substantially surrounds the second fluid conduit interface and into which the second protrusion is fitted; The mated second projection and second groove are sealed to allow fluid communication between the first node and the second node.

35. The apparatus of claim 1 , wherein the first fluid conduit interface comprises a first fluid conduit segment that allows fluid to flow between the first node and the second node.

36. The apparatus of claim 1 , wherein the second fluid conduit interface comprises a second fluid conduit segment that allows fluid to flow between the first node and the second node.

37. 10. The apparatus of claim 1, wherein when the first protrusion mates with the first groove, the additively manufactured first node and the additively manufactured second node form a component for use in a transportation structure.

38. 38. The apparatus of claim 37, wherein the component is a vehicle component.

39. 38. The apparatus of claim 37, wherein the component comprises a gear case.

40. 38. The apparatus of claim 37, wherein the component comprises a load-bearing component.

41. 7. The method of claim 6, wherein the first fluid conduit interface comprises a first fluid conduit segment that allows fluid to flow between the first subcomponent and the second subcomponent. Device.

42. The device of claim 6 , wherein the second fluid conduit interface comprises a second fluid conduit segment that allows fluid communication between the first subcomponent and the second subcomponent.

43. The apparatus of claim 7 , wherein the component is a vehicle component.

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