Methods for joining metallic support structures for vehicles

Abstract

A method for joining metallic structures of a vehicle is provided. The method includes arranging the plurality of metallic structures and bonding the plurality of metallic structures. A support structure for a vehicle is also provided. The vehicle includes a panel, and the support structure includes a metallic panel having a raised portion with a geometric shape integrally formed with and protruding from a surface, and a recessed portion adjacent the raised portion. A non-metallic adhesive is applied to the raised portion or the recessed portion, and a weld is applied a predetermined distance from the adhesive at a coupling location.

Description

METHODS FOR JOINING METALLIC SUPPORT STRUCTURES FOR VEHICLESCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] The present application is a PCT application, which claims priority to U.S. provisional application 63 / 718,943 filed November 11, 2024 and U.S. provisional application 63 / 718,949 filed November 11, 2024, the contents of each are hereby incorporated by reference.BACKGROUND

[0002] Many vehicles, including aircraft, utilize frames and additional panels to transfer loading experienced during operation in the air and on the ground. The vehicle traditionally includes numerous parts assembled together. Assembly includes fastening a plurality of parts together using fastening devices, such as nuts and bolts, and / or adhesives to allow loading to transfer between the parts.

[0003] Assembling a structural part from numerous sub-parts poses drawbacks. Unlike a continuous structure, structures made from numerous sub-parts rely on the fastening devices to transfer a load from one part to the next. Metal fastening devices may add considerable weight to the aircraft. Adding extra weight to the aircraft may reduce performance of the aircraft, including reduced range, maneuverability', and / or energy' efficiency. Further, such fastening devices often require holes to be drilled in mating sub-parts, which may cause damage and may weaken the structural capabilities of the parts. High load transfer through the fastening devices may increase local stresses on the parts at the fastening device locations, which may require inspection, resulting in extended periods of downtime for the aircraft.

[0004] Thus, there is a need to develop methods for joining structural parts of vehicles whileeffectively transferring a load through the structure without adding weight. It is with respect to these and other considerations that the disclosure made herein is presented.SUMMARY

[0005] Embodiments described herein relate to methods of joining metallic structures for vehicles. The coupling methods described herein may provide a secure coupling between metallic structures with increased strength while reducing overall aircraft weight.

[0006] In an example embodiment, a method for joining metallic structures of a vehicle is provided. The method includes arranging the plurality of metallic structures and bonding the plurality of metallic structures. Bonding includes preparing at least a first surface of a first metallic structure of the plurality of metallic structures for bonding, applying a non-metallic adhesive to at least the first surface, and applying pressure to the plurality of metallic structures to form a joint between the plurality of the metallic structures. The method further includes welding at least a portion of the joint to secure the plurality of metallic structures together to form a metallic weld.

[0007] In a first example embodiment, refill friction stir spot welding (RFSSW) is used to weld the joint.

[0008] In another example embodiment, preparing the first surface for bonding includes a chemical cleaning of degreasing the first surface of the first metallic structure, and a mechanical cleaning of roughening the first surface of the first metallic structure to increase the surface area.

[0009] In a further example embodiment, bonding the portion of the joint further includes curing the adhesive for a first predetermined period of time.

[0010] In an additional example embodiment, the method includes coupling a frame to the plurality of metallic structures to secure the arrangement of the plurality of the metallicstructures.

[0011] These as well as other aspects, advantages, and alternatives will become apparent to those of ordinary skill in the art by reading the following detailed description, with reference, where appropriate, to the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1A is an isometric view of a vehicle having a vehicle body and a support structure, according to an exemplary' embodiment of the present invention.

[0013] Figure IB is an isometric view of the support structure of Figure 1A, according to an exemplary embodiment of the present invention.

[0014] Figure 1C is an isometric view of a portion of the vehicle body of Figure 1 A with the support structure of Figure IB, according to an exemplary embodiment of the present invention.

[0015] Figure 2 is an isometric view of a prior art body panel.

[0016] Figure 3A is an isometric view of a mold for a support structure, according to an exemplary embodiment of the present invention.

[0017] Figure 3B is an isometric view of the support structure formed using the mold of Figure 3A, according to an exemplary embodiment of the present invention.

[0018]

[0019] Figure 3C is an isometric view of the support structure formed with the mold of Figure 3A, according to an exemplary embodiment of the present invention.

[0020] Figure 3D is an exploded isometric view of a plurality of the support structures of Figure 3B, forming a panel with an optional frame, for use with the vehicle of Figure 1A, according to an exemplary embodiment of the present invention.

[0021] Figure 3E is an isometric view of the support structure of Figure 3B with a panel, according to an exemplary embodiment of the present invention.

[0022] Figure 3F is an isometric view of another mold for a support structure, according to an exemplary embodiment of the present invention.

[0023] Figure 3G is an isometric view of a support structure formed using the mold of Figure 3F, according to an exemplary embodiment of the present invention.

[0024] Figure 3H is an isometric view of a further mold for a support structure, according to an exemplary' embodiment of the present invention.

[0025] Figure 31 is an isometric view7of a support structure formed using the mold of Figure 4, according to an exemplary7embodiment of the present invention.

[0026] Figure 4 is a method of coupling one or more support structures, according to an exemplary embodiment of the present invention.

[0027] Figures 5A, 5B, 5C, and 5D are cross-sectional views of a tool used to implement another coupling method through various steps, according to exemplary7embodiments of the present invention.

[0028] Figure 6 is a flow chart of an example method for joining of metallic support structures and using the coupling method of Figures 5A, 5B, 5C, and 5D, according to exemplary embodiments of the present invention.

[0029] Figure 6A, 6A1, 6B, 6C, 6D, 6E, 6E1, 6F, and 6F1 are cross-sectional, top, and side views of various examples of the tool of Figures 5 A, 5B, 5C, and 5D forming at least one weld between a plurality7of support structures of Figure 3B, 3C, 3D, 3E, 3G, or 31, a frame, and / or the vehicle of Figure 1 A, according to exemplary embodiments of the present invention.

[0030] Figure 6G is a top view of a support structure including a pattern of welds and adhesive on a structure, according to exemplary embodiments of the present invention.

[0031] Figure 7A is an isometric view of a robot for bonding and / or welding metallic structures of Figure 3B, 3C. 3D, 3E, 3G. or 31. according to exemplary embodiments of the present invention.

[0032] Figure 7B is a simplified block diagram showing components of an example computing device, according to exemplary embodiments of the present invention.DETAILED DESCRIPTION

[0033] Disclosed herein are examples of systems, methods, and devices for coupling a support structure to a vehicle. In some embodiments, the vehicle may be a vertical take-off and landing (e.g., VTOL) or an electric VTOL (e.g., eVTOL), which may or may not use propellers to hover, takeoff, and / or land. It should be understood that in other embodiments, the vehicle may be any other type of vehicle that may be able to utilize the advantages of the present invention, such as a ground vehicle (e.g., an automobile), a sea vehicle (e.g., a boat), or a flying craft (e.g., an aerial, floating, soaring, hovering, airborne, aeronautical aircraft, airplane, plane, spacecraft, a helicopter, an airship, or an unmanned aerial vehicle, or a drone). In some embodiments, the support structure may be part of a vehicle, such as a fuselage, nacelle, doors, control surfaces, empennage, or wings.

[0034] The disclosed embodiments of the present invention may be used in any of these vehicles to obtain advantages such as strong localized bonding and / or welding of specific portions of support structures, providing load transfer between structures and / or between structures and the vehicle without the need to drill and install traditional fasteners (e.g., nuts, bolts, and / or rivets), and reducing the weight of the support structure(s) by minimizing the use of traditional fasteners.

[0035] Figure 1 A is an isometric view of a vehicle 10 having a vehicle body 12 with at least one support structure 100 of Figure IB, according to an exemplary embodiment of the present invention. In some examples, the vehicle 10 may be an aircraft, an automobile, a boat, or a spacecraft. The vehicle 10 may include at least one wing coupled to or extending from the vehicle body 12 and a propulsion unit coupled to the at least one wing and / or the vehicle body12. The body 12 may be fabricated of any suitable material, such as a metal (e.g., titanium, aluminum, magnesium, and / or a combination thereol) designed to withstand an outside or inside environment and var ing loads.

[0036] The structure 100 may be coupled to or be integrally formed with one or more components of the vehicle body 12, such as when the manufacturer of the vehicle 10 is building the (e.g., main) vehicle body 12. For example, the structure 100 may be coupled to a frame of the vehicle body 12, a skin 80 of the vehicle body 12, a panel of the vehicle body 12, and / or any other structural or non-structural component of the vehicle body 12. In some examples, as shown in Figure 1C, the skin 80 may include a planar portion 71 and / or a non-planar portion 72 (e.g., a curved portion) and may have an arcuate profde, and the structure 100 may be coupled to one or both portions 71, 72. The coupling of the structure 100 to (e.g., one or more components) of the vehicle 10, may use adhesive bonding and / or welding, such as refdl friction stir spot welding (RFSSW). In one example, the adhesive may be the primary bonding with the RFSSW as the secondary bonding.

[0037] In some examples, the structure 100 may be coupled to an exterior portion of the vehicle body 12, such as the (e.g., outer fuselage) skin 80, exposing the structure 100 to an outside environment or environmental elements. However, in other examples, the structure 100 may be coupled to an interior portion of the vehicle body 12, such as an inner surface 78 of the (e.g., outer fuselage) skin 80, a cabin floor (e.g., a deck), and / or interior paneling (e.g., storage compartments), which may prevent the structure 100 from being exposed to an outside environment. In further examples, one or more structures 100 may form an (e.g., inner waffle) skin or panel 120, with or without an interior frame 350, which may then be coupled to the (e.g., outer fuselage) skin 80. In a further example, one or more structures 100 may replace the skin 80. such that the one or more structures 100 may be coupled to other components of the vehicle 10. While Figures 1A and 1C illustrate the structure 100 coupled to the skin 80. in otherexamples the structure 100 may be coupled to another structural and / or non-structural component, such as another panel, a beam, a frame, a fairing, and / or a nacelle, of the vehicle 10. In one example, the structure 100 may form an angle between about 0 degrees and about 180 degrees with another structure 100 and / or with the vehicle body 12, such as an angle maybe formed between the structure 100 and the skin 80 of the vehicle body 12.

[0038] In order to couple one or more structures 100 together and / or to couple at least one structure 100 to the vehicle body 12, one or more coupling methods, as described herein, may be used. The coupling methods may include chemical bonding and / or mechanical bonding, such as adhesive bonding, and / or welding (e.g., friction welding, fusion welding, or solid state welding), brazing, fastening (e.g., with bolts, rivets, and / or staples), diffusion bonding, and / or a combination thereof.

[0039] One or more coupling methods may facilitate forming at least one metallurgical bond (e.g., a weld) between one or more structures 100 and / or between at least one structure 100 and the vehicle body 12. Metallurgical bonds (e.g., welds) may create (e.g., irreversible) atomic- scale joints between metals. In addition to the metallurgical bonds, the one or more structures 100, may be coupled together with a (e.g., non-metallic) bonding material, such as adhesive, as discussed herein, and / or the one or more structures 100 may be coupled to the vehicle body 12 with a (e.g., non-metallic) bonding material.

[0040] Moreover, any number of structures 100 may be coupled together and / or may be coupled (e.g., directly) to the vehicle body 12. Structures 100 may be provided in varying arrangements. For example, the structures 100 may be aligned with one another, may be adjacent to one another, and / or spaced a distance apart from one another. In one example, when the one or more structures 100 are aligned, one or more raised portions from one structure 100 may align with one or more raised portions of another structure 100. In one example, the raised portions are configured to provide structural support to the structure 100. Moreover, in oneexample, one or more structures 100 may be coupled (e.g., stacked or positioned) together such that at least one structure 100 is coupled above and / or below another structure 100. In such an example, one structure 100 may (e.g., fully or substantially) overlap with another structure 100, or one structure 100 may partially overlap with a portion of another structure 100, such as a flange or edge from a structure 100 may overlap with another flange or edge of another structure 100

[0041] Additionally, one or more structures 100 may be coupled together (e.g., aligned with one another) to create a (e.g., larger) panel 120 (shown in Figure 3D). The panel 120 may then be coupled to the vehicle body 12. As discussed herein, a frame 350 (also shown in Figure 3D) may facilitate coupling more than one structure 100 to other structures 100 and / or may facilitate securing a number of structures 100 together in a set or predetermined arrangement (e.g., to form a panel 120). When the frame 350 is used, the frame 350 may be coupled (e.g., directly) to the vehicle body 12. In other examples, the structures 100 of the panel 120 may be designed to couple to (e.g., directly) to a (e.g., fuselage) skin 80 of the body 12 of the vehicle 10 of Figure 1 A. In one example, the panel 120 may form an angle between about 0 degrees and about 180 degrees with the body 12 of the vehicle 10.

[0042] Moreover, in one example, the structure 100 is provided in the form of a metal, such as, but not limited to, magnesium, aluminum, titanium, and / or a combination thereof. The structure 100 is substantially planar (shown in Figure IB). In another example, the structure 100 may, similar, to an example skin 80 may include a planar portion and / or a non-planar portion (e.g., a curved portion) providing the structure 100 with an arcuate profile. The non-planar portion of the structure may be located along various portions of the structure 100, such as along one or more sides of the structure 100, along atop surface, and / or along a bottom surface of the structure 100. In some examples, the planar portion and / or the non-planar portion of the structure 100 may include one or more raised portions, described herein.

[0043] The curved portion of the structure 100 may be sized and shaped to mate with a corresponding part of (e.g., a structure or surface of) the vehicle body 12. For example, the planar portion and / or the curved portion of the structure 100 may be sized and shaped to mate with a curvature of the (e.g., outer fuselage or wing) skin 80. In some examples, the structure 100 may be sized and shaped to correspond to an entire surface of the skin 80, w hile in other examples the structure 100 may correspond to (e.g., only) a portion of a surface of the skin 80.

[0044] Similar to the structure 100, in one example, the panel 120 is substantially planar; however, in another example, the panel 120 may include a planar portion and / or a non-planar portion (e.g., a curved portion) providing the panel 120 with an arcuate profile.

[0045] Figure 2 illustrates an isometric view of a prior art structure 90. As shown, the structure 90 includes one or more stringers 92 coupled to a surface, such as a surface of a vehicle. The one or more stringers 92 are manufactured separately from the structure 90 and may be fabricated of metal and / or a composite material. During assembly, the one or more stringers 92 are coupled to the surface of the structure 90 by way of a (e.g., metal) fastener, such as one or more bolts or rivets, and the fastener extends through the structure 90. The fasteners add weight to the overall structure 90. Also, holes may be drilled into the structure 90 to facilitate installation of the fasteners. The drilling and / or holes may break the fibers of the structure 90, particularly if the structure is a composite laminate, which may adversely affect the mechanical properties of the structure 90. Further, load transfer from the fasteners to the structure may create high localized stresses around the fastener holes, which may result in various failure modes and / or damage to the composite laminate structure, such as delamination. Additionally, the fasteners inserted into holes in the structures 90 may deteriorate or corrode due to atmospheric humidity and operational environment contaminants (e.g., deicing fluids) and / or extreme thermal conditions, which may impact the strength of the fasteners and / or the strength of the structures held together by the metal fasteners.

[0046] Figure 3A is an isometric view of a mold 50 for the support structure 100, according to an exemplary7embodiment of the present invention. As shown in Figure 3A, a tool or mold 50 is provided, such that the mold 50 facilitates the formation of at least one structure 100, as discussed herein, having a geometric (e.g., waffle-like) design.

[0047] The mold 50 may include a plurality' of components (e.g., physical aspects), such as a first edge 122A, a second edge 122B, at least one first raised portion 124, at least one second raised portion 126, and at least one surface 128. The mold 50 may be provided in any suitable material, such as a (e.g., durable) plastic.

[0048] In some examples, the first edge 122A, the second edge 122B, the first raised portion 124, and / or the second raised portion 126 may be integrally formed with the surface 128 to form the mold 50. In other examples, the first edge 122A, the second edge 122B, the first raised portion 124, and / or the second raised portion 126 may7be coupled to the surface 128.

[0049] The surface 128 may have a (e.g., substantially constant) thickness TO (see Figure 3 A). In one example, the thickness TO may be between about 0.063 inches (e.g., about 0. 16002 centimeters) and about 0.25 inches (e g., about 0.635 centimeters), or about 0.04556 inches (e.g., 0.1 157224 centimeters). In other examples, the thickness TO of the surface 128 may vary between the first edge 122A and the second edge 122B. Moreover, although the surface 128 is shown as substantially planar, the surface 128 may include one or more planar portions and / or one or more non-planar (e.g., curved or arcuate) portions.

[0050] Continuing with Figure 3 A, the plurality' of first raised portions 124 and the plurality of second raised portions 126 extend (e.g., protrude) outward from the surface 128. While the mold 50 in Figure 3A shows a set number of first and second raised portions 124 and 126, in other examples, the mold 50 may include any number of raised portions 124 and 126.

[0051] In one example, each of the first raised portions 124 may be substantially planar and / or parallel with respect to one another, and, similarly, each of the plurality of second raisedportions 126 may be planar and / or parallel with respect to one another. Additionally, one or more of the plurality of first raised portions 124 may intersect with one or more of the plurality of second raised portions 126 forming at least one (e.g., point of) intersection I.

[0052] Additionally, one or more raised portions 124 may intersect with one or more raised portions 126 to form a plurality of polygonal segments (e.g., SI and / or S2) and an optional cavity C therein. The segments SI and S2 may form a grid-like (e.g., an orthogrid or an isogrid) (e.g., waffle-like) structure with each segment SI and S2 having a geometric shape (e.g., a triangular shaped segment, a rectangular shaped segment, a pentagonal shaped segment, a hexagonal shaped segment, and / or an octagonal shaped segment). In one example, as shown in Figure 3 A, each segment SI and S2 has a substantially square shape, wherein each raised portion 124 and 126 forms an angle with respect to one another. In other examples, the segment SI may have a shape that is different than the shape of the segment S2. The segments SI and / or S2 may form a symmetrical geometric design or an asymmetrical geometric design throughout the mold 50.

[0053] The first segment S 1 may be at a first location on the mold 50 and the second segment S2 may be at a second location, different than (e.g., or separate from) the first location, on the mold 50. The first segment S 1 may have a first width W1 defined by a spacing between the one or more raised portions, such as between at least two second raised portions 126. In one example, the width W1 may be between about 0.5 inches (e.g., about 1.27 centimeters) and about 3 inches (e.g., about 7.62 centimeters), or between about 1 inch (e.g., about 2.54 centimeters) and about 2 inches (e.g., about 5.08 centimeters), or about 1.75 inches (e.g., 4.445 centimeters).

[0054] The second segment S2 may have a second width W2 defined by a spacing between the one or more raised portions, such as between at least two first raised portions 124. In one example, the width W2 may be between about 0.5 inches (e.g., about 1.27 centimeters) and about 3 inches (e.g., about 7.62 centimeters), or between about 1 inch (e.g., about 2.54centimeters) and about 2 inches (e.g., about 5.08 centimeters), or about 1.25 inches (e.g., 3.175 centimeters). In some examples, one or more dimensions of the first segment S 1 may be the same as one or more dimensions of the second segment S2, such that the first width W1 may be substantially the same width as the second width W2. However, in other examples, one or more dimensions of the first segment SI may be different than one or more dimensions of the second segment S2, such that the first width W1 may be different than the second width W2.

[0055] Additionally, the segment S 1 may have a first height H 1 provided between the surface 128 and a top surface, such as a top surface 126 A of the second raised portion 126. In one example, the height Hl may be between about 0.1 inches (e.g., about 0.254 centimeters) and about 0.5 inches (e.g., about 1.27 centimeters), or about 0.25 inches (e.g., 0.635 centimeters). The segment S2 may have a height H2 provided between the surface 128 and a top surface, such as a top surface 124A of the second raised portion 124. In one example, the height H2 may be between about 0.1 inches (e.g., about 0.254 centimeters) and about 0.5 inches (e.g., about 1.27 centimeters), or about 0.25 inches (e g., 0.635 centimeters). In one example, the first height Hl may be substantially the same as the height H2; however, in other examples, the first height Hl may be different than the height H2. The one or more dimensions of the first segment SI and the second segment S2 may be based on the design needs of the structure 100, such as determined load paths and / or spacing for hardware (e.g., a conduit).

[0056] In one example, the first raised portion 124 of the mold 50 may include at least the top surface 124 A, a bottom surface 124C, and at least two side surfaces 124B1 and 124B2 extending substantially between the top surface 124A and the bottom surface 124C. In one example, the first raised portion 124 is integrally formed with the surface 128. In such an example, the bottom surface 124C of the first raised portion 124 is integrally formed with the surface 128. The first raised portion 124 may extend outwardly (e.g., protrude) a distance (e.g., such as the first height H2) from the surface 128.

[0057] Additionally, at least one side surface 124B1 and / or 124B2 of the first raised portion124 may be integrally formed with the top surface 124A and / or the surface 128. In some examples, the side surfaces 124B1 and / or 124B2 may form an angle, such as between about a 0 degree angle and about 180 degree angle, with at least one of the top surface 124A and the surface 128. In one example, the side surfaces 124B1 and / or 124B2 may be substantially perpendicular to at least one of the top surface 124 A and the surface 128. However, in other examples the side surfaces 124B1 and / or 124B2 may form an acute angle with at least one of the surface 128 and the top surface 124A. In yet further examples, the side surfaces 124B1 and / or 124B2 may form an obtuse angle with at least one of the surface 128 and the top surface 124A. The angle may be chosen to prevent jamming material during use of the mold 50.

[0058] Moreover, the first raised portion 124 may have a thickness T1 (e.g., provided between a first side surface 124B1 and a second side 124B2). In one example, the thickness T1 may be between about 0.063 inches (e.g., about 0.16002 centimeters) and about 0.25 inches (e g., about 0.635 centimeters), or about 0.094444 inches (e.g., 0.23988776 centimeters). In such an example, the thickness T1 of the first raised portion 124 is substantially the same between the top surface 124 A and the bottom surface 124C. In another example, the thickness T1 may vary between the top surface 124A and the bottom surface 124C, such that the thickness T1 has a dimension that is larger near the bottom surface 124C and a smaller dimension near the top surface 124A.

[0059] Continuing with Figure 3 A, the second raised portion 126 may include a top surface 126 A, a bottom surface 126C, and at least two side surfaces 126B1 and 126B2 extending substantially between the top surface 126A and the bottom surface 126C. In one example, the bottom surface 126C is integrally formed with the surface 128. The second raised portion 126 may extend outwardly (e.g., protrude) a distance (e.g.. such as the height Hl) from the surface 128. The second raised portion 126 may include the same or different features as the first raisedportion 124.

[0060] In one example, at least one side surface 126B1 and / or 126B2 may be integrally formed with the top surface 126A and / or the surface 128. In some examples, the side surfaces 126B1 and / or 126B2 may form an angle, such as between about a 0 degree angle and about a 180 degree angle, with at least one of the top surface 126A and / or the surface 128. For example, the side surfaces 126B1 and / or 126B2 may be substantially perpendicular to at least one of the top surface 126A and the surface 128. However, in other examples the side surfaces 126B1 and / or 126B2 may form an acute angle with at least one of the surface 128 and the top surface 126 A. In yet further examples, the side surfaces 126B1 and / or 126B2 may form an obtuse angle with at least one of the surface 128 and the top surface 126A. The angle may be chosen to prevent jamming material during use of the mold 50.

[0061] Moreover, the second raised portion 126 may have a thickness T2 (e.g., provided between a first side surface 126B1 and a second side 126B2). In one example, the thickness T2 may be between about 0.063 inches (e.g., about 0.16002 centimeters) and about 0.25 inches (e.g., about 0.635 centimeters), or about 0.25 inches (e.g., 0.635 centimeters). In such an example, the thickness T2 of the first raised portion 126 is substantially the same betw een the top surface 126 A and the bottom surface 126C. In another example, the thickness T2 may vary between the top surface 126A and the bottom surface 126C, such that the thickness T2 has a dimension that is larger near the bottom surface 126C and a smaller dimension near the top surface 126 A.

[0062] Additionally, in some examples, the first thickness T1 of the first raised portion 124 may be the same as the second thickness T2 of the second raised portion 126. However, in other examples the first thickness T1 may be different than the second thickness T2.

[0063] Although the mold 50 (e.g.. with raised portions 124 and 126, segments SI and S2, and intersections I) is discussed herein with details, the mold 50 may be manufactured in varyingsizes, thicknesses, shapes, and with vary ing material properties to customize the design of the mold 50 and / or the (e.g., corresponding) structure 100 for specific uses and / or applications. Moreover, the mold 50 may not have sharp edges and may not have sharp angles to substantially prevent jamming during fabrication of the structure 100. For example, the mold 50 may have curved edges.

[0064] Figure 3B is an isometric view of a support structure 300 formed using the mold 50 (shown in Figure 3A), according to an exemplary embodiment of the present invention. In one example, the support structure 300 is the support structure 100. Similar to the support structure 100, a plurality7of support structures 300 may be coupled in an arrangement forming a panel, such as the panel 120 (shown best in Figure 3D).

[0065] Before discussing the details of the support structure 300, a method of fabricating the support structure 300 will be briefly discussed.

[0066] First in fabricating the support structure 300, in one example, at least one layer of material (e.g., metal, such as a layer of sheet metal) is provided, which may' have a rectangular shape, although in other examples the material may be provided in any suitable shape.

[0067] The material of the structure, such as the structure 300, is provided in the form of magnesium, aluminum, titanium, or a combination thereof. Because magnesium and aluminum have different thermal conductivities, one material may be a more suitable choice over the other depending on the intended use of the structure 300 and / or the intended use of the panel 120. Specifically, the thermal conductivity of aluminum is about 205 W / m-K (e.g.. Watts per meter- Kelvin), and the thermal conductivity of magnesium is about 156 W / m-K. In one example, if the structure 300 and / or panel 120 is planned for use in an environment with a higher thermal conductivity, then aluminum may be selected. In other examples, if the structure 300 and / or the panel 120 is planned for use in an environment with a lower thermal conductivity, then magnesium may be selected. Moreover, the structure 300 and / or the panel 120, in someexamples, may be recyclable, making it a sustainable design and reducing the impact on the environment. Further, in some examples, the panel 120 may be fire resistant.

[0068] Additionally, in one example, a (e.g., protective) coating, such as, but not limited to, anodizing, painting, or applying conversion coatings, may be applied to at least one surface of the structure 300 and / or the panel 120 to facilitate minimizing corrosion that may occur due to environmental factors, such as humidity, temperature, and / or electrolytes, increase durability, and in turn minimize maintenance. The coating may be applied to the structure 300 and / or the panel 120 at any time and / or may be applied one or more times. Moreover, the structure 300 and / or the panel 120 is highly durable and resistant to wear, extending the lifespan thereof and reducing potential maintenance costs.

[0069] Second in fabricating the support structure 300, after the material has been provided, the optional step of preparing the material follows. In one example, the material may be prepared for pressing by treating the one or more surfaces of the material with a (e.g., chemical) cleaning and / or a mechanical cleaning to clean the surfaces of the material.

[0070] Third in fabricating the support structure 300, the material is pressed against the mold 50 (e g., avoiding the need for hot pressing) (e g., with a substantially constant pressure). The mold 50 is a mirrored (e.g., negative) geometric design of the structure 300. As such, when the material is pressed against the mold 50, the structure 300 having a (e.g., corresponding) geometric shape of the mold 50 is formed.

[0071] The temperature for molding and the pressure applied to the material to form the support structure 300 may vary depending on the forming process, selected alloy, and final depth (e.g., thickness) of the mold 50. In an example, the material may be an aluminum alloy or a magnesium alloy.

[0072] In an example, the material may be pressed into the mold 50 via hot stamping with a temperature of about 200 degrees Celsius to about 500 degrees Celsius and a pressure of about300 MPa to about 500 MPa.

[0073] In another example, the material may be pressed into the mold 50 via superplastic forming with a temperature of about 450 degrees Celsius to about 550 degrees Celsius and a pressure of about 350 MPa to about 450 MPa, although a higher pressure may be applied.

[0074] In a further example, the material may be pressed into the mold 50 via cold forming with a temperature range of about room temperature to about 100 degrees Celsius and a pressure of about 60 MPa to about 350 MPa.

[0075] In one example, as shown in Figure 3B, the (e.g., unitary ) structure 300 is provided with a (e.g., positive) geometric shape of the mold 50 having a surface 303, a plurality' of raised portions (e.g., elevated portions) 304, and at least one recessed portion (e.g., channel) 306 between each of the raised portions 304 such that the structure 300 has a (e.g., symmetrical) grid-like (e.g., ortho-grid) pattern. Moreover, the dimensions of the mold 50 provide the (e.g., corresponding) dimensions for the structure 300. For example, since the segment SI is the part of the mold that forms the raised portion 304, the size of the segment SI corresponds to the size of the raised portion 304.

[0076] Additionally, in some examples, the structure 300 may include one or more (e.g., small) depressions integrally formed within the structure 300. The depressions may serve as a coupling location 140. The coupling location 140 may be a location where the structure 300 is coupled to another structure 300, or where the structure 300 is coupled to the body 12 of the vehicle 10. For example, the coupling location 140 may be a (e.g., predetermined or identified) location indicating where adhesive may be applied and / or where a weld may be applied to the structure 300 to facilitate coupling the structure 300 to another structure(s) 300, a frame, and / or to the vehicle body 12.

[0077] As shown in Figure 3B. in one example, each raised portion 304 has a substantially square shape; however, in other examples, each raised portion 304 may have any other suitablegeometric shape (e.g., a triangle, a rectangle, and / or a quadrilateral). Further, in one example, each raised portion 304 has an (upper) surface 309 to provide at least one coupling location 140.

[0078] Moreover, in another example, at least one recessed portion 306 may intersect with another recessed portion 306 to form an intersection II. In one example, the intersection II may also be a coupling location 140. In a further example, the recessed portion 306 may provide a coupling location 140.

[0079] As discussed herein below, the coupling locations 140 may be provided in a pattern, such as a checkered pattern, other patterns, and / or may be sporadic. In one example, the coupling locations 140 may be provided in locations of traditional fasteners. The traditional fasteners may be replaced by other coupling methods, such as adhesive and / or welding, as discussed herein. In another example, the coupling locations 140 may be determined based on where the stresses on the structure 300 are greatest during operation of the vehicle 10.

[0080] Continuing with Figure 3B, the structure 300 may also include a flange 310 formed around one or more edges. The flange 310 may facilitate coupling the structure 300 to other structures 300, may provide a lip and / or surface to engage at least a portion of a frame 350 (shown in Figure 3D), or may facilitate coupling the structure 300 to the body 12 of the vehicle 10. Moreover, the flange 310 may also provide one or more coupling locations 140.

[0081] Although the structure 300 is discussed and fabricated herein with certain dimensions, based on the dimensions of the mold 50, the structure 300 may be manufactured in varying sizes, thicknesses, shapes, and with varying material properties to customize the design for specific uses and / or applications.

[0082] In one example, stress software, such as HyperMesh or similar, may provide a respective profile of the structure 300 and / or the mold 50. The software provided profile may facilitate providing an optimized structure 300 and / or modifying the structure 300 and / or the coupling locations 140 for optimization to improve the efficiency of the load transfer from thevehicle 10. Tools may be fabricated to transfer the profile onto the respective structure 300.

[0083] As shown in Figure 3C, the structure 300 also may include one or more optional apertures 308, according to an exemplary embodiment of the present invention. The apertures 308 may be openings extending through or formed within the structure 300, and the apertures 308 may be provided in a circular shape or any suitable shape to facilitate (e.g., air) flow through the structure 300. In some examples, the apertures 308 may only extend partially through the structure 300.

[0084] While the apertures 308 are shown on the (e.g., top) surface 309 of the structure 300, in other examples the apertures 308 may be formed elsewhere on or within the structure 300. In some examples, the apertures 308 may be acoustic ports as a Helmholtz resonator. The acoustic ports may facilitate re-direction of noise (e.g., mitigate noise) from the vehicle 10 that the structure 300 is attached to or noise coming from external sources outside of the vehicle 10. In other examples, the structure 300 may provide other utility and may not be limited to sound redirection or dampening.

[0085] For example, at least one of the apertures 308 may be used as a pressure tap. The pressure tap may be used in combination with other pressure gauging hardware (e g., a pitot tube) to help determine pressure. In some examples, the apertures 308 may function as a lightening hole to reduce panel weight and / or overall vehicle weight. The apertures 308 may also provide access points to a portion of the structure 300. In one example, electrical conduit, wires, and other materials may be routed through at least one aperture 308 and placed within the structure 300.

[0086] Turning to Figure 3D, the at least one structure 300 may be coupled to one or more (e.g.. additional) structures 300 to form the panel 120. wherein the panel 120 may form a (e.g., inner) waffle skin, according to an example of the present invention. In one example, full or partial structures 300 may be coupled to one another to form the panel 120. Further, at least onestructure 300 may be aligned with another structure 300 or stacked on top of another structure300 to form the panel 120.

[0087] In one example, at least one (e.g., race-way) channel 312 is formed between one or more coupled structures 300 of the panel 120. For example, the flanges 310 of the structures 300 may (e.g., align to) form the channel 312. In other examples, the recessed portion 306 between each of the raised portions 304 of the structures 300 may also form at least a portion of the channel 312. The channel 312 may be sized to receive an optional (e.g., interior) frame 350. The frame 350 facilitates holding the structures 300 together and / or securing the position of each structure 300. In other examples, the structures 300 may be coupled and / or secured together without the use of the frame 350 to form the panel 120.

[0088] Once the structures 300 are coupled together to form the panel 120, the panel 120 may be coupled to one or more components of the body 12 of the vehicle 10, such as the skin 80. The panel 120 may be coupled to the body 12 with or without the frame 350. Similar to coupling the structures 300 together, the panel 120 may be coupled to the body 12 using one or more coupling methods.

[0089] Here, coupling methods used to couple the structures 300 together, and / or to couple the structure 300 and / or the panel 120 to the vehicle body 12 will be discussed in greater detail below.

[0090] As show n in Figure 3E, one or more panels 352 may be coupled to a surface of the structure 300 to prevent debris from entering or effecting the structure 300, according to an exemplary embodiment of the present invention. The panel 352 may be a sheet of material, such as a sheet of metallic material.

[0091] Figure 3F illustrates an isometric view of a portion of another mold 52. according to an exemplars’ embodiment of the present invention. In one example, the mold 52 has similar properties to the mold 50, although the mold 52 has a different shape, as discussed herein.

[0092] As shown, the mold 52 may include a first raised portion 224, a second raised portion226, a third raised portion 230, and a surface 228. In one example, the first raised portion 224 may be or may include the same and / or similar features as the first raised portion 124, and the second raised portion 226 may be or may include the same and / or similar features as the second raised portion 126. Moreover, in one example, the surface 228 may be the same or include similar features to the surface 128.

[0093] As shown in Figure 3F, the mold 52 may include a plurality of the first, second, and / or third raised portions 224, 226, and 230 integrally formed with the surface 228 to form the mold 52; however in other examples the raised portions 224, 226, and / or 230 may be coupled to the surface 228.

[0094] Moreover, each of the plurality of raised portions 224 may be substantially parallel to other raised portions 224, each of the plurality of raised portions 226 may be substantially parallel to other raised portions 226, and each of the plurality of raised portions 230 may be substantially parallel to other raised portions 230. One or more of the first raised portions 224, the second raised portions 226, and the third raised portions 230 may intersect with one another.

[0095] In one example, the raised portions 224, 226, and / or 230 of the mold 52 may intersect to form one or more points of intersection 12 (e.g., in a similar manner as the points of intersection I of the mold 50), and the intersection 12 may be a coupling location 140.

[0096] The formation, positioning, and / or intersection of the raised portions 224, 226, and / or 230 may form one or more grid-like structures (e.g., such as an isogrid) provided in the form of geometnc shapes, such as a triangular shape, as shown in Figure 3G. It is noted that the raised portions 224, 226, and / or 230 may create other geometric shapes. In one example, the one or more raised portions 224. 226, and / or 230 form polygonal segments, such as a polygonal segment S3 (e.g., a triangle) and a polygonal segment S4 (e.g., a triangle) or S5, of the surface 228. In one example, the polygonal segment S3 and the polygonal segment S4 may havedifferent sizes. Moreover, in one example, each raised portion 224, 226, and / or 230 may form an angle (e.g., an acute angle) with respect to another raised portion 224, 226, and / or 230.

[0097] Continuing with the raised portions 224, 226, and 230, the first raised portion 224 may include a top surface 224A and at least one side surface 224B, the second raised portion 226 may include a top surface 226A and at least one side surface 226B, and the third raised portion 230 may include a top surface 230A and a side surface 230B. Each of the first, second, and third raised portions 224, 226, and 230 may include a height. For example, the first raised portion 224 may have a defined height H3, measured between a first surface 228 and the top surface 224A. The second raised portion 226 may include a defined height H4, measured from the first surface 228 and top surface 226 A. The third raised portion 230 may include a defined height H5, measured from the first surface 228 and the top surface 230A. In one example, the heights H3, H4, and H5 may be substantially the same or may be different from one another. Varying heights H3, H4, and H5 may make the raised portions 224, 226, and 230 of the mold 52 create different heights within the structure 400 (shown in Figure 3G).

[0098] Although the mold 52 (e.g., with raised portions 224 and 226, segments S3 and S4, and intersection(s) 12) is discussed herein with certain dimensions, the mold 52 may be manufactured in varying sizes, thicknesses, shapes, and with varying material properties to customize the design for specific uses and / or applications.

[0099] Similar to forming the structure 300 using the mold 50, to form a structure 400, the material is pressed against the mold 52 (e.g., avoiding the need for hot pressing), which is a mirrored (e.g., negative) geometric design of the structure 400. As such, when the material is pressed against the mold 52, the structure 400 having a (e.g., corresponding) geometric shape is formed. A (e.g., unitary) structure 400 is provided with a (e.g.. positive) geometric shape of the mold 52 having a surface 403. a plurality of raised portions (e.g., elevated portion) 404, and at least one recessed portion (e.g., channel) 406 between each of the raised portions 404 such thatthe structure 400 has a grid-like (e.g., iso-grid) pattern. Moreover, the dimensions of the mold52 provide the (e.g., corresponding) dimensions of the structure 400. For example, since the segment S3 or S4 is the part of the mold that forms the raised portion 404, the size of the segment53 or S4 corresponds to the size of the raised portion 404.

[0100] Although the structure 400 is discussed herein with certain dimensions, based on the dimensions of the mold 52, the structure 400 may be manufactured in varying sizes, thicknesses, shapes, and with varying material properties to customize the design for specific uses and / or applications.

[0101] As shown in Figure 3G, each raised portion 404 has a substantially triangular shape. Further, each raised portion 404 has an (upper) surface 409 to provide a coupling location 140. The coupling location 140 may be a location where the structure 400 is coupled to the body 12 of the vehicle 10 or where the structure 400 is coupled to another structure, such as the structure 300 and / or 400.

[0102] Further, at least one recessed portion 406 may intersect another recessed portion 406 forming an intersection 13, and the intersection 13 may also be a coupling location 140. In one example, the recessed portion 406 may provide a coupling location 140.

[0103] A flange 410 may be formed around one or more edges of the structure 400. The flange 410 may facilitate coupling the structure 400 to other structures 300 and / or 400 or may provide a lip and / or surface to engage at least a portion of a frame, such as the frame 350. Further, the flange 410 may also provide one or more coupling locations 140.

[0104] Figure 3H is an isometric view of a portion of another mold 54, according to an exemplary embodiment of the present invention. In some examples, the mold 54 may include the same and / or similar features and / or functions as the mold 50 and / or the mold 52. although the mold 54 has a different shape.

[0105] As shown in Figure 3H, the mold 54 may include a first raised portion 324. a secondraised portion 326, a third raised portion 330, and a surface 328. In one example, the first raised portion 324, the second raised portion 326, and / or the third raised portion 330 may be integrally formed with the surface 328 to form the mold 54. In another example, the first raised portion 324, the second raised portion 326, and / or the third raised portion 330 may be coupled to the surface 328. The first raised portion 324 may include a top surface 324A and at least two side surfaces 324B1 and 324B2, the second raised portion 326 may include a top surface 326 A, a first side surface 326B1, and a second side surface 326B2, and the third raised portion 330 may include atop surface 330A and a side surface 330B.

[0106] The surface 328 may have a thickness 328A. In one example, the thickness 328 A may be between about 0.063 inches (e.g., about 0.16002 centimeters) and about 0.25 inches (e.g., about 0.635 centimeters), or about 0.04 inches (e.g., 0.1016 centimeters). The thickness 328A of the surface 328 may be constant throughout the mold 54 in some examples, while in other examples the thickness 328A may vary throughout the mold 54 at one or more cross-sections of the surface 328. For example, the thickness 328A of the surface 328 at a first cross-sectional location may be different than the thickness 328A at a second cross-sectional location. In some examples, the thickness 328A at a particular cross-sectional location may be based on a determined design need, such as a determined load carrying capability of the particular location.

[0107] One or more of the first, second, and third raised portions 324, 326, and 330 may intersect to form a polygonal segment. The formation, positioning, and / or intersection of the raised portions 324, 326, and / or 330 may form one or more grid-like structures (e.g., such as an isogrid) provided in the form of geometric shapes, such triangular shapes. For example, as shown, the first, second, and third raised portions 324, 326, and 330 may intersect to form one or more triangular segments S5 and / or S6. In such an example, the second raised portion 326 and the third raised portion 330 may form an angle 0 within the segment S5 and / or the segment S6. such that the angle 0 is an acute angle. In one example, as shown in Figure 3H. bothtriangular segments S5 and / or S6 may have a height 332 between about 0.5 inches (e.g., about1.27 centimeters) and about 4 inches (e.g., about 10.16 centimeters), or about 3 inches (e.g., 7.62 centimeters). It is understood that the triangular segments S5 and / or S6 may be the same size or may be different sizes with respect to one another.

[0108] In one example, the triangular segments S5 and S6, together, form a rectangular segment S7. In such an example, the first and second raised portions 324 and 326 intersect to form the rectangular segment S6. The shape of the particular polygonal segment formed may be based on one or more design needs, such as a determined stress level, load path, and / or buckling stress at a respective location. In some examples, one or more components of the mold 54 may include the same or similar features and / or functionality as the mold 50 and / or mold 52.

[0109] Additionally, the first raised portion 324, the second raised portion 326, and the raised third portion 330 may have varying dimensions, such as varying heights and thicknesses, as compared to one another. In one example, both the first raised portion 324 and the second raised portion 326 may have a (e.g., substantially uniform) thickness T3 between about 0.063 inches (e.g., about 0.16002 centimeters) and about 0.25 inches (e.g., about 0.635 centimeters), or about 0.2056 inches (e.g., 0.522224 centimeters), and may have a height H6 between about 0. 1 inches (e.g., about 0.254 centimeters) and about 3 inches (e.g., about 7.62 centimeters), or about 0.25 inches (e.g., 0.635 centimeters).

[0110] Although the mold 54 (e.g., with raised portions 324 and 326, segments S5, and S6 and S7, and intersection(s) 14) is discussed herein with certain dimensions, the mold 54 may be manufactured in varying sizes, thicknesses, shapes, and with varying material properties to customize the design for specific uses and / or applications.

[0111] Similar to forming the structure 300 using the mold 50 and similar to forming the structure 400 using the mold 52, to form a structure 500, the material is pressed against the mold 54 (e.g., avoiding the need for hot pressing), which is a mirrored (e.g.. negative) geometricdesign of the structure 500. As such, when the material is pressed against the mold 54, the structure 500 having a (e.g., corresponding) geometric shape is formed.

[0112] A (e.g., unitary) structure 500 is provided with a (e.g., positive) geometric shape of the mold 54 having a surface 503, a plurality of raised portions (e.g., elevated portion) 505, and at least one recessed portion (e.g., channel) 506 between each of the raised portions 404 such that the structure 500 has a grid-like (e.g., iso-grid) pattern. Moreover, the dimensions of the mold 54 provide the (e.g., corresponding) dimensions of the structure 500. For example, since the segment S5 or S6 is the part of the mold that forms the raised portion 505, the size of the segment S5 or S6 corresponds to the size of the raised portion 505.

[0113] Although the structure 500 is discussed herein with certain dimensions, based on the dimensions of the mold 54, the structure 500 may be manufactured in varying sizes, thicknesses, shapes, and with varying material properties to customize the design for specific uses and / or applications.

[0114] As shown in Figure 31, each raised portion 504 has a substantially triangular shape, according to an exemplar}’ embodiment of the present invention. Further, each raised portion 504 has an (upper) surface 507 to provide a coupling location 140. The coupling location 140 may be a location where the structure 500 is coupled to the body 12 of the vehicle 10 or where the structure 500 is coupled to another structure, such as the structure 300 and / or 400 and / or 500.

[0115] Further, the more than one recessed portion 51 1 may intersect forming an intersection 14 that may also be a coupling location 140. In one example, the recessed portion 511 may provide a coupling location 140.

[0116] A flange 510 may be formed around one or more edges of the structure 500. The flange 510 may facilitate coupling the structure 500 to other structures 300 and / or 400 and / or 500 or may provide a lip and / or surface to engage at least a portion of a frame, such as the frame350. Further, the flange 510 may also provide one or more coupling locations 140.

[0117] Turning to Figure 4, during fabrication, the support structure 100 and / or the panel 120 may be formed and coupled to additional structures 100 and / or panels 120 and / or may be coupled to the vehicle body 12 using a method 550. The method 550 provides for coupling structures 100 together and / or coupling the structure 100 and / or the panel 120 to the vehicle body 12, according to an exemplary embodiment of the present invention.

[0118] The method 550 may begin with a step 501 of forming (e.g., fabricating) the at least one structure 100 having a geometric shape. For purposes of the method 550, the structure will be referred to as the structure 100; however, the structure 100 may be a plurality of structures 100 and / or the structure 100 may be the structure 300, 400, and / or 500 formed having a geometric shape using at least one mold, such as the mold 50, 52, and / or 54, as discussed herein.

[0119] Once the structure 100 has been formed, the method 550 continues to a step 502 of arranging the one or more structures 100 for coupling. Although the method 550 refers to arranging one or more structures 100, it may also apply to arranging one or more structures 100 with one or more panel 120 and / or with one or more components of the vehicle body 12.

[0120] Arranging the structures 100 with respect to one another may be done manually or automatically, via a machine such as a robot (shown in Figure 7A) or the like. Similarly, arranging one or more structures 100 with the vehicle body 12 may be done manually or with a robot.

[0121] In one example, the structures 100 may be aligned (e.g. horizontally) with one another, using one or more features of the individual structures 100 as guides. In such an example, the structures 100 may be aligned such that the raised portions 304 may be aligned (e.g.. horizontally or vertically with one another) so that the surfaces 303 of the structure 100 may be substantially planar to one another. Further, the structures 100 may be aligned such that a coupling location 140 on one structure 100 is aligned or arranged to be in contact with anothercoupling location 140 of another structure 100. Additionally, the structures 100 may be aligned such that a depression on one structure 100 is aligned or arranged to be in contact with another depression of another structure 100. Moreover, the structures 100 may be aligned using one or more of the intersections I, II, 12, 13, and / or 14 as a guide. Yet further, the structures 100 maybe aligned using the one or more frames 350. In other examples, the structures 100 may be aligned based on the intended use of the structure 100.

[0122] Similarly, the structures 100 may be aligned with the vehicle body 12 using one or more features of the individual structures 100 as guides and / or using one or more frames 350 as a guide.

[0123] Any number of the structures 100 may be coupled together, such that the structures 100 may either be positioned next to one another, stacked on top / below one another, may partially overlap w ith one another, and / or may substantially (or fully) overlap with one another.

[0124] Although specific alignment and / or arrangement examples are provided herein, it is understood that any method of alignment and / or arrangement may be used to arrange one or more structures 100 with another structure 100 and / or arrange one or more structures 100 with the vehicle body 12.

[0125] Once the structures 100 are arranged (e.g., for coupling), the method 550 proceeds to step 504. The step 504 may include preparing the structures 100 for coupling to other structures 100, one or more panels 120, the frame 350, and / or the body 12 of the vehicle 10.

[0126] Preparing the structures 100 may include chemical cleaning and / or mechanical cleaning, such as cleaning and / or degreasing. Cleaning includes removing all contaminants, including grease, from one or more of the surfaces of the structure 100. The cleaning may include applying a solvent to and / or wiping the surface of the structure 100. After cleaning the surfaces of the structure 100, the surfaces of the structure 100 may be exposed or treated with an abrasive material to increase the surface area to which an adhesive or bonding material or thelike will be applied.

[0127] In one example, preparing the structures 100 may include laser ablation, which may be prior to applying adhesive, such that a robot (e.g., the robot 690) is vertical.

[0128] In a further example, preparing the structures 100 may include solvent washing the structures 100 in a closed environment.

[0129] In another example, preparing the structures 100 may include plasma cleaning with a solvent to wipe at least one of the structures 100.

[0130] In a further example, the structure 100 or structures 100 may be provided (e.g., previously) prepped and primed, such that the cleaning step 504 of preparing the structures 100 for coupling may be omitted from the method 550.

[0131] When the structures 100 are prepared (e.g., step 504 ofthe method 550), the structures 100 may undergo process verification, such as stress relief verification, weld procedure qualification (PQR / WPS), water break, or a contact angle test for cleanliness. For example, the process verification may include a water break test to detect and / or determine whether a (e.g., continuous) film of water is present, and / or a contact angle test to measure and / or determine a static, advancing, and / or receding contact angle to quantify wettability.

[0132] Once the structures 100 are arranged and prepared, the method 550 continues to a step 506 of applying a (e.g., non-metallic) adhesive (e.g., bonding material), such as an adhesive 102, to at least one surface of at least one (e.g., metallic) structure 100 to facilitate bonding of the structures 100 and / or bonding of the structure 100 and the vehicle body 12. For example, the adhesive may be applied to at least one surface of one or more structures 100. The adhesive (e.g., bonding material) may include one or more of an epoxy, phenolic, acrylic, a combination thereof, and / or other adhesives. The adhesives are intended to carry structural loads and facilitate dispersing the load throughout the structure 100. In one example, the tensile lap shear strength of the adhesive, may be between about 6500 psi (pounds per square inch) and about4000 psi at room temperature, whereas the tensile lap shear strength may be between about 4600psi and 1900psi at about 250 degrees Fahrenheit.

[0133] Moreover, the adhesive (e.g., bonding material) may be chosen based on the stiffness of the material (e.g., of the structure 100) and / or the environmental conditions (e.g., temperatures, humidity, and / or chemicals). The adhesive also may facilitate preventing corrosion and / or loosening at or near the at least one coupling location 140.

[0134] In one example, the adhesive is applied to at least one surface of one structure 100 such that the adhesive has a substantially uniform thickness; however, in other examples, the adhesive is applied to any number of surfaces of the structures 100 and / or may have a non- uniform thickness. The adhesive may be positioned between at least two structures 100 and / or positioned between the structure 100 and the body 12.

[0135] In one example, the adhesive is applied to the entire surface of the structure 100. In other examples, the adhesive is applied to a portion of the surface, such as at or near at least one coupling location 140. In further examples, the adhesive may be applied to at least a portion of the surface, where the adhesive is not at or near at least one coupling location 140 or where the adhesive is a distance from the coupling location 140.

[0136] Also, the adhesive may be applied in a pattern or may be applied in sections or may be applied in a shape, such as a rectangle, a line, a circle, or a curve. Further, in one example, the adhesive is applied as a film adhesive or a paste adhesive; however, other applications are possible, and the application may impact the shape of the adhesive.

[0137] The amount of adhesive may vary depending on factors such as the size, weight, and / or material of the structures 100 being coupled together or being coupled to the vehicle body 12, and consideration of the conditions under which the structures 100 will be used after the coupling is complete.

[0138] Once the adhesive is applied, at least a portion of a joint 150 may be formed betweenone or more structures 100 and / or between the structure 100 and the vehicle body 12, such as between the structure 100 and the skin 80. In the example when the frame 350 is used, the adhesive may be positioned between one or more structures 100 and the frame 350, and / or between the vehicle body 12 and the frame 350.

[0139] Also, once the adhesive is applied, the method 550 continues to an optional step 508 of curing the (e.g., partially or fully formed) joint 150. A first predetermined period of time provides a time frame for how long to wait after the adhesive is applied to start the optional step of curing. Curing may include heating the adhesive to strengthen the joint 150. When the adhesive is heated, a chemical reaction occurs, which results in a stronger joint 150. The curing may also be done manually or automatically, for example, with the use of a robot (such as the robot shown in Figure 7A) or machinery. For example, an induction heater (e.g., targeted heating) may be used to heat the adhesive of the entire panel and thejoint 150. The heat may be applied to the joint 150 for a second predetermined time to ensure that thejoint 150 is cured. During or after the curing of thejoint 150, pressure may be applied to the adhesive via applying pressure to the least one of the structures 100 (e.g., manually or automatically) for a third predetermined period of time.

[0140] The first, second, and / or third predetermined time may be dependent on formulation of the adhesive, and may be the same amount of time or different amounts of time. Many adhesives may be cured at varying times and temperatures. In one example, the third predetermined time may be about 24 hours at room temperature (e.g., with pressure applied to the joint 150 for the 24 hours) or the time may be about one hour at about 300 degrees Fahrenheit (e.g., with pressure applied to thejoint 150 for one hour).

[0141] Bonding, via an adhesive, allows for fastening (e.g., coupling) to occur (e.g., using an adhesive or bonding material) without generating (e.g., metallic) fastener holes in the (e.g., metallic buildup) and through the vehicle body 12, as fastener holes may cause damage to thevehicle structure and potentially weaken the mechanical properties while showing an unsightly fastener. Additionally, using bonding methods saves time, as bonding removes and / or prevents the steps of fitting the structure 100, drilling holes, disassembling the structure 100, deburring and cleaning the holes, refitting the structure, and installing a fastener to the hole formed in the structure.

[0142] Moreover, adhesive may be applied to a structure 100 (e.g., substantially simultaneously) to form one or more joints 150 at substantially the same time. Additionally, adhesive may be applied at substantially the same time on a plurality of different structures 100. Both avenues of bonding more than one joint 150 at substantially the same time decrease cost and production time and increase assembly efficiency.

[0143] Once the joint 150 is (e.g., fully) formed through the coupling method of (e.g., adhesive) bonding, an additional (e.g., a secondary or supplemental) coupling method is applied. In one example, the additional coupling method may applied at or near the joint 150 and / or may be applied at or near at least one coupling location 140. In other examples, the additional coupling method may be applied a distance from the joint 150 and / or a distance from the coupling location 140.

[0144] In one example, once the joint 150 is (e.g., fully) formed between the plurality of metallic structures 100 or the joint 150 is formed between the structure 100 and / or the vehicle body 12 and / or between the frame 350 and structure 100 and / or the vehicle body 12, such as with adhesive, a step 509 of a (e.g., second) coupling method of welding, such as refill friction stir spot welding (RFSSW), may be applied to one or more structures 100, with or without the frame 350, and / or vehicle body 12 at any location. In one example, the RFSSW may be applied at or near a coupling location 140. In another example, the step 509 of welding may be applied prior to the joint 150 being (e.g., fully) formed, such that the adhesive is cured after the welding is provided.

[0145] During RFSSW, the friction creates heat, which diffuses the (e.g., two) metals together and creates a metallurgical bond (e.g., which is different than the chemical bonds created by adhesion) or a weld 801 (show n in at least Figures 5A-5D). The diffusion is aided by the intense pressure and mechanical mixing (e.g., plastic deformation). RFSSW will be discussed in further detail hereinbelow.

[0146] Moreover, other additional coupling methods may be used to couple structures 100 together. In one example, an adhesive can be applied, and optionally (e.g., thermally) cured, then welds may be formed through the (e.g., cured) adhesive. In other examples, an adhesive can be applied and (e.g., not fully) cured, then at least one weld can be formed (e.g., a distance from, next to, or near) the adhesive to couple structures 100 together. In another example, an (e.g., uncured) adhesive may be present as welds are formed, and a (e.g., single) thermal cycle can cure the adhesive, control distortion on the structure 100 and / or the vehicle body 12, and potentially age-harden the weld. In a further example, adhesive may be selectively applied to leave (e.g., clean) spots for metallurgical joints and improve weld quality. In yet a further example, (e g., post-cured) adhesive can be selectively removed, such as through abrasive, machining, chemical, and / or laser ablative methods to create a (e.g., clean) spot for welds (e.g., metallurgical joints). Moreover, in yet an even further example, the coupling method may include stress relief welding.

[0147] In other examples, it is possible to remove steps 506 and 508 from the method 550, such that the method 550 proceeds from step 504 (e.g., directly) to step 509 of joining the structures 100 with the weld 801.

[0148] The method 550 is complete (e.g., step 510) when the one or more structures 100, with or without the frame 350, are coupled together and / or one or more structures 100 are coupled to the vehicle body 12, with or without the frame 350.

[0149] The structure 100. the panel 120, and / or the frame 350 may facilitate transferring theloads of the vehicle 10. The structures 100 improve the durability of the vehicle 10 and facilitate efficient load weight transfer across the vehicle 10. As described herein, the structure 100 is provided to be strong yet lightweight (e.g., when using a material such as aluminum or magnesium or titanium), which may be useful for applications where minimizing weight is helpful.

[0150] Figures 5A, 5B, 5C, and 5D are cross-sectional views of atool 601 used to implement an additional coupling method 600, such as RFSSW, through various steps 604, 606, 608, 610, 611, 613 of a method 600, to strengthen the adhesive coupling and / or strengthen the joint 150 and form the weld 801, and Figure 6 is a flow chart of the example method 600 for the joining of structures 100 and strengthening the joint 150 via RFSSW. Although method 600 is discussed herein as coupling structures 100 together, the method 600 may also be applied to coupling structures 100 with the vehicle body 12, with or without the frame 350. The method 600 also is useful as RFSSW may be used in narrow spaces and hard to reach areas. Moreover, in one example, the temperature may rise as the method continues from steps 604 through 613.

[0151] RFSSW is a solid-state joining process that may create (e.g., localized spot) welds 801 (e g., at or near the coupling locations 140), to optionally strengthen at least one joint 150, by using at least friction and material (e.g., metal) deformation to join the structure 100 to at least one additional structure 100 or to join the structure 100 to at least one component of the vehicle body 12 (e.g., creating a metallurgical bond), a frame, and / or the like. RFSSW may be applied directly to or a distance from the joint 150, while thejoint 150 is still curing (e.g., during the first predetermined period of time) or after the joint 150 has cured or solidified (e.g., after the first, second, and / or third predetermined period of time). With RFSSW, tool wear may impact cost and weld quality; thus, the tool used for RFSSW should be replaced routinely.

[0152] As shown in Figure 6, the method 600 may include steps 602, 604, 606, 608. 610, 611, 613. and as the steps proceed from 602 to 611, the temperature may increase.

[0153] Turning to the method 600, the method 600 includes a step 602 of providing a tool601 having at least a clamping ring 612 including an upper portion 614 and a lower portion 616, a radial sleeve 618 radially inward of the clamping ring 612, and a pin 620 radially inward of the clamping ring 612. In one example, each of the clamping ring 612, the radial sleeve 618, and / or the pin 620 may be provided in the form of a cylindrical member with or without a central opening extending through the middle thereof.

[0154] Once the step 602 the tool 601 is provided, the method continues to a step 604 of positioning the tool 601. The tool 601 may be positioned at or near at least one coupling location 140. During the step 604, the lower portion 616 (e.g., is positioned underneath or below the structures 100 and / or the vehicle body 12) and the upper portion 614 of the clamping ring 612 (e.g., is positioned above or on top of the structures 100 and / or the vehicle body 12 and / or the joint 150) so that the upper portion 614 and the lower portion 616 may clamp or apply pressure at or near one or more coupling locations 140 and / or the joint 150 of the structures 100. Moreover, the clamping ring 612, while in contact with at least one surface of the structures 100 and / or the vehicle body 12, may apply (e g., a downward) pressure throughout the steps of the method 600.

[0155] The method 600 then continues to a step 606 of rotating the tool 601 in either a clockwise or counterclockwise direction. For example, in step 606, the sleeve 618 and the pin 620 are rotated in the same direction (e.g., in a counterclockwise direction), while the clamping ring 612 remains substantially stationary and applies pressure to the structures 100. In one example, the steps 602 and 604 may be performed substantially simultaneously (e.g., the clamping and rotating of the tool 601 happen substantially simultaneously). In another example, the step 604 may be performed after the step 602.

[0156] The method 600 then continues to a step 608 where pressure may be applied (e.g., in a downward motion to the sleeve 618 to force (e.g., plunge) the sleeve 618 into at least a portionof the plurality of structures 100 and / or the vehicle body 12. As shown, in one example, there may be two structures 100; however, in other examples, there may be less than or more than two structures 100. In another example, there may be at least one structure 100, the vehicle body 12, and / or the frame. In step 608, the sleeve 618 and pin 620 continue to spin (e.g., in a counterclockwise direction) at a predetermined (e.g., rotational) speed. As the sleeve 618 is inserted into and through (e.g., at least a portion of) the (e.g., at least two) structures 100 and / or the vehicle body 12, the sleeve 618 is moved (e.g., downward) from a first position to a second position, wherein a top of the sleeve 618 may be substantially coplanar with the top of the clamping ring 612 in the second position. Moreover, as the sleeve 618 is inserted into at least a portion of the structures 100 and / or the vehicle body 12, the pin 620 is (e.g., substantially simultaneously) moved (e.g., in an upward direction (away from the joint 150) or opposite the direction of the sleeve 618) from a first position to a (e.g., higher) second position. As the components of the tool 601 are moved in step 608, the material of the structures 100 and / or the vehicle body 12 is displaced and / or heated.

[0157] The method 600 then continues to a step 610 of retracting the sleeve 618 and plunging the pin 620 to form at least a portion of the weld 801 . In one example, the sleeve 618 is moved in an upward motion (e.g., away from the joint 150) to the first position (e.g., the top surface of the sleeve 618 is higher than the top surface of the clamping ring 612). In one example, removing the sleeve 618 creates a cavity for displaced material. The pin 620 is also moved (e.g., in a downward motion) into at least a portion of the cavity and / or structures 100 and / or the vehicle body 12. As the sleeve 618 is retracted, the pin 620 is moved (e.g., downward) to push material into the cavity (e.g., refilling the cavity created by removing the sleeve 618). The (e.g., refill) weld 801 has been substantially formed, strengthening the joint 150 of structures 100 and coupling the (e.g., at least two) structures 100 together and / or coupling at least one structure 100 to the vehicle body 12.

[0158] The method 600 then continues to a step 611 of returning the tool 601 to its starting position.

[0159] The method 600 may end with a step 613 where the tool 601 is removed from contacting the structures 100.

[0160] The method 600 of (e.g., additional) coupling may provide strengthened joints and an improved finish (e.g., smooth) on the structures 100. Moreover, the method 600 also allows for scalability and is quicker than coupling (e.g., metallic) fasteners between or through structures 100.

[0161] Figures 6A, 6A1, 6B, 6C, 6D, 6E, 6E1, 6F, 6F1, and 6G show vary ing arrangements of support structures, frame(s), and / or the vehicle of Figure 1 A coupled together by at least one weld, such as by RFSSW, according to exemplary embodiments of the present invention. Specifically, each Figure 6A, 6A1, 6B, 6C, 6D, 6E, and 6E1 includes at least one weld 801 formed by RFSSW to facilitate coupling one or more structures 100 and / or a frame and / or a portion of the vehicle body 12, such as outer skin 80, together at varying locations. In one example, the weld 801 may overlap the adhesive 102 applied in step 506 of the method 550.

[0162] Additionally, in one example, as shown in Figure 6G, the adhesive and the weld 801 may not be combined (e.g., may be positioned a distance apart), such that the adhesive and the weld 801 are not in the same weld nugget (e.g., the adhesive and the weld 801 do not overlap). In one example, the adhesive may act as the primary structure with varying strength, and the weld 801 (e.g., RFSSW) may act as the secondary structure to support and / or reinforce the adhesive (e.g., bonding). The weld 801 may act as a “chicken fastener” (e.g., a fastener that may be mechanical, such as a rivet or bolt, to provide a failsafe mechanism and protect against joint failure) if the adhesive were to fail and / or peel.

[0163] Moreover, in one example, the weld 801 may replace some or all conventional (e.g., mechanical) fasteners used when coupling structures, such as when coupling the structure 100to one or more components of the vehicle 10. Using the weld 801 (e.g., RFSSW) in place of some or all conventional fasteners reduces weight on the vehicle 10 and reduces manufacturing time.

[0164] Further, in one example, a conventional fastener may have a tensile load range greater than the tensile load of the weld 801 (e.g., RFSSW). For example, the weld 801 may have an (e.g., ultimate) tensile load range between about 5500N (N is Newtons) and about 10,000N, when the weld 801 is a spot weld having a diameter of 7mm or a diameter of 9mm and / or when provided in aluminum alloys). Thus, in one example, one or more conventional fasteners may be used in combination with the adhesive and / or the weld 801 depending on predetermined (e.g., manufacturing) specifications.

[0165] Turning to Figure 6A, Figure 6A is a cross-sectional view of a RFSSW (e.g., metallic) nugget or weld (e.g., providing a lap splice joint) 801, formed by RFSSW using the tool 601, to couple a plurality of (e.g. metallic) layers (e.g., at least four) together, wherein the layers, for example, are (e g., the outer skin 80 of) the vehicle body 10, a first structure 802, a second structure 804, and a frame 806. In one example, the first structure 802 is a structure 100, the second structure 804 is another structure 100, and the frame 806 is the frame 350. In other examples, the frame 806 may be any frame or any other (e.g., metallic) structure. In another example, the layers include the first structure 802 (e.g., structure 100), the second structure is a panel (e.g., the panel 352 or the panel 120), the frame 806 (e.g., frame 350), and the vehicle body 100 (e.g., outer skin 80). Figure 6A1 is a side view of Figure 6A, wherein Figure 6A1 shows the location of the weld 801 formed and adjoining the plurality of layers. Although RFSSW is provided as a method to facilitate forming the weld 801, other welding methods may be used in conjunction with or in place of RFSSW to facilitate coupling the plurality of layers together. Moreover, the weld 801 may be provided at least one coupling location 140, as discussed hereinabove.

[0166] Additionally, in one example, the weld 801 may strengthen the coupling of one or more joints 150 (e.g., formed from chemical bonding, such as adhesive bonding) formed between a plurality of layers, such as between the outer skin 80 and the second structure 804, between the first structure 802 and the second structure 804, and between the first structure 802 and the frame 806. As shown, (e.g., only) a portion (e.g., the edges or flanges) of the first structure 802 overlaps with a portion (e.g., the edges or flanges) of the second structure 804, and at least one gap 807 may be formed between (e.g., the edges or flanges of) the first structure 802 and the second structure 804. Turning briefly to Figure 6F, the layers of Figure 6A and the layers of 6F are the same; however, in Figure 6F, the layers are coupled via weld 801 without the gap 807.

[0167] Continuing with Figures 6A and 6A1, a plurality of welds 801 may be provided. In an example, when the structure 802 is a waffle-like structure, such as structure 300, at least one weld 801 may be positioned within at least one recessed portion 809. In an example, the at least one recessed portion 809 of the structure 802 may be the same as the recessed portion 306 of the structure 300. In other examples, when the structure 802 is the structure 300, the at least one weld 801 may be positioned at or near intersections II, or the at least one weld 801 may be positioned at or near an upper surface or a raised portion of the structure 802. Further, at least one weld 801 may be positioned along a flange of the structure 802.

[0168] Figure 6B is a cross-sectional view of a RFSSW (e.g., metallic) weld (e.g., providing a lap splice joint) 801, formed by RFSSW using the tool 601, to couple a plurality of (e.g., metallic) layers (e.g., at least three) together, wfierein the layers are, for example, the outer skin 80, the first structure 802, and the frame 806. Figure 6B is similar to Figure 6A; however, the difference is that the weld 801 couples three layers together, rather than four layers. For example, the weld 801 in Figure 6B couples the first structure 802. (e.g.. the outer skin 80) of the vehicle body 12, and the frame 806.

[0169] Figure 6C is a cross-sectional view of the RFSSW (e.g., metallic) weld (e.g., providing a lap splice joint) 801, and Figure 6D is the top view of Figure 6C, also showing the RFSSW (e.g., metallic) weld (e.g., lap splice joint) 801, formed by RFSSW using the tool 601, to couple a plurality' of (e.g., metallic) layers (e.g., at least three) together, such as the outer skin 80, the first structure 802, and the second structure 804. In one example, a plurality' of welds 801 are linearly positioned (as shown in Figure 6D) and the welds may be formed between two protrusions 808 of the first structure 802. In one example, when the structure 802 is the structure 300, the protrusions 808 may be the raised portions 304, and the weld 801 may be positioned between the raised portions 304 (e.g., such as in the recessed portion 306). Moreover, more than one weld 801 may be provided between the raised portions 304, and, as show n in Figure 6D, the welds 801 may' be linearly provided.

[0170] In another example, rather than the protrusions 808, a depression or dimples in the first structure 802 could be formed at the location of the protrusions 808. Further, the depression in the first structure 802 may serve as an index point for the robot (shown in Figure 7A) to locally minimize adhesive interaction with the (e.g., RFSSW) weld operation.

[0171] Figure 6E is a cross-sectional view of two RFSSW (e.g., metallic) welds (e.g., providing a butt splice joint) 801, formed by RFSSW using the tool 601, to couple a plurality of (e.g., metallic) layers (e.g., at least three) together. As shown, the layers include the outer skin 80, the first structure 802 aligned with (e.g., abuts) the second structure 804 such that the first structure 802 and the second structure 804 are substantially planar, and the frame 806. In one example, the first structure 802 is a structure 100, the second structure 804 is another structure 100, and the frame 806 is the frame 350. In other examples, the frame 806 may be any frame or other (e.g., metallic) structure. Moreover, Figure 6E1 is aside view of Figure 6E. wherein Figure 6E1 shows the location of at least one weld 801 through both structure 802 and structure 804, the frame 806, and the outer skin 80.

[0172] As shown, the (e.g., edge or end) of the structure 802 abuts the (e.g., edge or end) of the structure 804. Moreover, as shown in Figure 6E, based on the position of the abutting structures, the welds 801 are spaced a distance 810 apart such that one (e.g., first) weld 801 facilitates coupling the frame 806, the first structure 802, and the outer skin 80 together, whereas another (e.g., second) w eld 801 facilitates coupling the frame 806, the second structure 804, and the outer skin 80 together. The welds 801 may strengthen the coupling of one or more joints 150 (e.g., formed from chemical bonding, such as adhesive bonding) formed between the layers (e.g., between the frame 806, the structures 802 or 804, and the outer skin 80). The wields 801 may overlap the adhesive or may be positioned a distance from the adhesive (e.g., the wields 801 do not overlap the adhesive).

[0173] Figure 6F is a top view of a structure coupled to another structure, showing an example of the position of wields and at least one layer of adhesive. The structure provided may be the structure 802. In Figure 6F, for example, the structure 802 may be coupled to the vehicle body 12. In other examples, the structure 802 may be coupled to other structures, the vehicle body 12, a frame, and / or other components.

[0174] As shown, in one example, the frame 806 is coupled (e.g., stacked) to a top layer of the structure 802, the structure 802 is coupled to a top surface of the structure 804, the structure 804 is coupled to the top layer of the skin 80 of the vehicle body 12. Thus, the weld 801 extends from the frame 806 through the structures 802, 804 and into the skin 80.

[0175] As shown in Figure 6F, the welds 801 may be positioned (e.g., located) or applied across the top surface of the structure 802. The welds 801 may act as secondary support.

[0176] In one example, as shown in Figure 6G, the welds 801 are a secondary support to the adhesive 102. The adhesive may not have a continuous application, such that the adhesive may be distributed across a surface of the structure 802. such that the adhesive may be applied in patches. In one example, the adhesive is applied in patches that are linearly placed orsporadically placed in one or more predetermined locations.

[0177] A weld 801 may be provided as additional reinforcement for coupling the structure 802 to the vehicle body 12, another structure, a frame, and / or the like together. For example, the weld 801 may be applied to the structure 802 where there is no adhesive 101 on the structure 802. In another example, the weld 801 may be applied to the structure 802 where adhesive 102 has been applied. In one example, the weld 801 (e.g., RFSSW) may have a tensile load range between about 5500N (N is Newtons) and about 10,000N, when the weld 801 is a spot weld having a diameter of 7mm or a diameter of 9mm and / or when provided in aluminum alloys.

[0178] The number of welds 801 is based on the size of the structure 802 and may also be determined based on the intended use of the structure 802.

[0179] In an example, each weld 801 may have a substantially circular shape with a diameter between about 1mm and about 20mm, or between about 3mm and about 15 mm, or between about 5mm and about 9mm. In a further example, the diameter of each weld 801 is 5mm, 7mm, or 9mm. Although an example is provided for the size of each w eld 801 , each w eld 801 may be any suitable size to facilitate coupling and / or reinforcing the coupling of the structure 802 to the vehicle body 12, another structure, a frame, and / or the like.

[0180] Further, although the weld 801 has been provided in a substantially circular shape, the weld may be applied in another shape. For example, the weld 801 may be provided as a linear weld.

[0181] Although the welds 801 are shown in a checkered pattern in Figure 6F, such that the welds 801 do not overlap the adhesive 102 on the structure 802, in other examples, the welds 801 may be positioned in another pattern and / or may overlap with the (e.g., previously applied) adhesive. For example, the welds 801 may be provided in a linear pattern, a circular pattern, an oval pattern, an arc pattern, a zig-zag pattern, and / or the like.

[0182] Moreover, in one example, the size (e.g., diameter) or surface area of each weld 801may be smaller than the size and / or surface area of at least one application or section of the adhesive 102. For example, the surface area of the at least one application or section of the adhesive 102 may be between about 50 times and about 1000 times, or may be about 100 times, greater than the surface area of at least one weld 801.

[0183] Turning to Figure 7A, when combining coupling methods, such as adhesive bonding and / or welding (e.g., RFSSW), one or more coupling methods may be accomplished through the use of a robot 690 (see Figure 7A) or an automated system. The adhesive and RFSSW act as a safe system designed to work together to minimize damage from occurring during flight. Thus, the body 12 does not need to be transported around a warehouse, but rather a robot, or the like, may be transported to the body 12 to increase automation and decrease manufacturing time for the vehicle 10.

[0184] Figure 7A is a perspective view of a robot 690 to assist in bonding and / or welding a plurality of structures 100 together, according to examples of the present invention. For example, the robot 690 may assist in bonding and / or welding at least one structure 100 to a frame and / or the vehicle body 12.

[0185] In some examples, the robot 690 may include a base 691, an optional controller 692, an arm 694 having joints 696 movable in six degrees of freedom, and an attachment head 698. The arm 694, together with the joint 696, may allow the robot 690 to position the attachment head 698 over a work area (e.g., a coupling location 140 and / or a joint 150), such as a work area including one or more structures 100. The robot 690 may be brought to the vehicle body 12 to facilitate joining one or more structures 100, frames, and / or vehicle components via adhesive bonding and / or w elding (e.g., RFSSW). For example, the base 691 may be on rails such that the robot 690 may travel along the rails to the bonding and / or welding location on the vehicle body 12 while the vehicle body 12 remains substantially stationary.

[0186] While the example illustrated in Figure 7A has a single arm 694. the robot 690 mayhave more than one arm. For example, the robot 690 may have two arms, with each arm having joints and / or the attachment head 698. Multiple arms may allow the robot 690 to join the structures 100 having a dimension outside of a predetermined tolerance. Moreover, in one example, the robot 690 may join structures 100 at substantially the same time as joining other structures 100 or may join one structure 100 at a first time and may join another structure 100 at a second time, which is after (e.g., subsequent to) the first time.

[0187] In some examples, the robot 690 may be coupled to a controller 692 configured to control operations of the robot 690. For example, the controller 692 may cause the attachment head 698 to perform all or only some of the bonding and / or welding steps, as described herein, to join the structures 100 together.

[0188] In bonding or welding, the controller 692 may cause the robot 690 to apply a load (e.g., using an actuator) and / or to heat a portion of the structures 100 and / or the one or more joints 150 to a set temperature. The heating may be performed using an induction heating unit or another suitable mechanism.

[0189] Additionally, a second robot 690 may be used in conjunction with a first robot 690 for efficiency. In one example, the second robot 690 could hold an anvil for the welding process, RFSSW, to work in conjunction with the first robot 690, such as when the structure 100 is coupled (e.g., in an upright position) to the vehicle body 12. In another example, the structure 100 could be cradled by a tool (e.g., with integral anvils) and the welding head (e.g., end effector) could be mounted on at least a part of the robot 690 (e.g., on a robot gantry system).

[0190] Figure 7B is a simplified block diagram showing some of the components of an example computing device 700, according to examples of the present invention. In some examples, a controller (e.g., the controller 692 shown and described with reference to Figure 7B) may include the computing device 700 or may be in electronic communication with the computing device 700. The computing device 700 may correspond to a computing deviceconfigured to perform additional functions (e.g., in communication with one or more other computing devices using a web browser and / or an application). In various examples, the computing device 700 may be a mobile computing device (e.g., a smartphone), a desktop computing device, a laptop computing device, a tablet computing device, or a wearable computing device (e.g., a smartwatch or a smart wristband). As illustrated in Figure 7B, the computing device 700 may include a network interface 702, a user interface 704, a processor 706, and data storage 708 (e.g., memory). The network interface 702, the user interface 704, the processor 706, and / or the data storage 708 may be communicatively linked together by a bus 710 (e.g., an electrical interconnect defined on one or more printed circuit boards).

[0191] The network interface 702 may be used by the computing device 700 to communicate with other computing devices over one or more networks (e.g., the public Internet). In some examples, the netw ork interface 702 may include a wired interface (e.g., Ethernet). Additionally or alternatively, the network interface 702 may include a wireless interface, such as WIFI. Other interfaces may be included in the netw ork interface 702 and are contemplated herein.

[0192] The user interface 704 may function to allow computing device 700 to receive input from and / or provide output to a user. As such, the user interface 704 may include inputs (e.g., a keypad, a keyboard, a touch-screen, a computer mouse, a microphone, a microphone jack, etc.) and / or outputs (e.g., a cathode-ray tube (CRT) display, a liquid-crystal display (LCD), a lightemitting diode (LED) display, a speaker, a speaker jack, headphones, a headphone jack, etc.).

[0193] The processor 706 may include one or more general purpose processors (e.g., microprocessors) and / or one or more special -purpose processors (e.g., graphics processing units (GPUs) or application-specific integrated circuits (ASICs)). In some examples, for example, the processor 706 may include special-purpose processors capable of generating a machine-learned model and / or using a machine-learned model to perform analyses as described herein.

[0194] The data storage 708 may include one or more volatile and / or non-volatile memories.For example, the data storage may include a RAM. a ROM, a hard drive, a solid state drive, etc.In some examples, the data storage 708 may be partially or wholly integrated with the processor 706 (e.g., a level 1 (LI) cache or a level 2 (L2) cache within a central processing unit). The data storage 708 may include removable components (e.g., a flash drive) and / or non-removable components (e.g., a ROM integrated with a motherboard).

[0195] The processor 706 may be configured to execute instructions 718 (e.g., compiled or non-compiled program logic and / or machine code) stored in the data storage 708 to cany7out the methods described herein. Hence, the data storage 708 may include a non-transitory computer-readable medium, having stored thereon program instructions that, when executed by the processor 706, cause the processor 706 to cany7out any of the methods, processes, or operations disclosed in this specification and / or the accompanying drawings. In some examples, the processor 706 may use the application data 712 while executing the instructions 718.

[0196] In some examples, the instructions 718 may include an operating system 722 (e.g., an operating system kernel, device driver(s), and / or other modules) and one or more applications 720 (e.g., mobile applications, sometimes referred to as '‘apps’’). As described above, the processor 706 may access the application data 712 when executing the applications 720.

[0197] The applications 720 may communicate with the operating system 722 through one or more application programming interfaces (APIs). These APIs may facilitate, for instance, the applications 720 reading and / or writing the application data 712, transmitting or receiving information via the network interface 702, receiving and / or displaying information on the user interface 704, etc.

[0198] Additionally, the applications 720 may be downloadable to the computing device 700 through one or more online application stores or application markets (e.g.. using the network interface 702). However, application programs may also be installed on the computing device 700 in other ways, such as via a web browser or through a physical interface (e.g., a universalserial bus (USB) port) on the computing device 700.

[0199] While many of the techniques and functions described herein may be performed by the processor 706 executing one of the applications 720, other ways for the computing device 700 to perform such techniques and functions are also possible and are contemplated herein. For example, some or all of the calculations may be performed remotely (e.g., on a server computing device). Such an example may be referred to as a “browser-based app” when the computing device 700 provides data (e.g., application data 712) to a different computing device for analysis using a web browser. Additionally or alternatively, such an interaction between the computing device 700 and another computing device may be performed using an API or a browser-based language (e.g., JavaScript).

[0200] Implementations of the present disclosure can thus relate to at least one of the enumerated examples (EE) listed below.

[0201] EE 1 is a support structure for a vehicle. The support structure includes a metallic panel. The metallic panel includes a raised portion with a geometric shape integrally formed with and protruding from a surface, and a recessed portion adjacent the raised portion. A non- metallic adhesive is applied to a surface of at least one of the raised portion or the recessed portion. A weld is applied a predetermined distance from the adhesive at a coupling location to facilitate coupling the metallic panel to the vehicle.

[0202] EE 2 is the support structure of EE1, the metallic panel is provided in the form of magnesium, aluminum, or titanium.

[0203] EE 3 is the support structure of any of EE1 to EE2, the geometric shape is provided by stress design software.

[0204] EE 4 is the support structure of any of EE1 to EE3, the geometric shape is at least one of a square, a rectangular, and a triangle.

[0205] EE 5 is the support structure of any of EE1 to EE4, the metallic panel is press formed using a mold.

[0206] EE 6 is the support structure of any of EE1 to EE5, the weld is formed using refill friction stir spot welding (RFSSW) via at least one robot.

[0207] EE 7 is the support structure of any of EE1 to EE6, the weld is applied to the recessed portion, and additional welds may be applied to the recessed portion, where the additional welds are co-linearly formed along a surface of the recessed portion.

[0208] EE 8 is the support structure of any of EE1 to EE7, the adhesive is applied prior to the weld.

[0209] EE 9 is the support structure of any of EE1 to EE8, the vehicle includes a panel. The metallic panel is a first metallic panel, and the support structure further may include a second metallic panel and a frame. The frame is configured to couple to at least one of the first metallic panel or the second metallic panel.

[0210] EE 10 is the support structure of any of EE1 to EE9, the frame is positioned on top of the first metallic panel, the first metallic panel is positioned on top of the second metallic panel, and the second metallic panel is positioned on top of the panel of the vehicle. The weld extends through the frame, the first metallic panel, the second metallic panel, and the panel of the vehicle to facilitate coupling of the frame, the first metallic panel, the second metallic panel, and the panel of the vehicle.

[0211] EE 11 is the support structure of any of EE1 to EE9, the frame is positioned on top of the first metallic panel and the second metallic panel. The first metallic panel is adjacent the second metallic panel. The first metallic panel and the second metallic panel are configured to be coupled to the panel of the vehicle. The weld extends through the frame, through at least one of the first metallic panel or the second metallic panel, and through at least a portion of thepanel of the vehicle to facilitate coupling of the frame, the first metallic panel or the second metallic panel, and the panel of the vehicle.

[0212] EE 12 is the support structure of any of EE1 to EE8, the metallic panel is a first metallic panel and a frame is positioned on top of the first metallic panel. The first metallic panel is positioned on top of the panel of the vehicle. The weld extends through the frame, the first metallic panel, and the panel of the vehicle to facilitate coupling of the frame, the first metallic panel, and the panel of the vehicle.

[0213] EE 13 is the support structure of any of EE1 to EE8, the metallic panel is a first metallic panel and the support structure further may include a second metallic panel. The weld is configured to couple a frame to a first flange of the first metallic panel and a second flange of the second metallic panel forming a composite metallic panel.

[0214] EE 14 is the support structure of any of EE1 to EE8, the metallic panel is a first metallic panel and the support structure further may include a second metallic panel. The first metallic panel includes a plurality of protrusions and the weld is configured to be positioned between a first protrusion of the plurality' of protrusions and a second protrusion of the plurality of protrusions. The weld is configured to couple the first metallic panel, the second metallic panel, and the panel of the vehicle.

[0215] EE 15 is the support structure of EE14, the first protrusion is the raised portion.

[0216] EE 16 is the support structure of any of EE1 to EE8, the panel of the vehicle is an outer skin, and the metallic panel is configured to couple to an interior surface of the outer skin.

[0217] EE 17 is the support structure of any of EE1 to EE8, the vehicle is VTOL or an eVTOL.

[0218] EE 18 is a vehicle. The vehicle includes a body including a panel. The vehicle also includes a metallic support structure. The metallic support structure includes a raised portion integrally formed with and protruding from a surface, and a recessed portion adjacent the raisedportion. A refill friction stir spot weld is applied to the recessed portion to facilitate coupling the metallic support structure to a frame and the panel.

[0219] EE 19 is a method for joining a plurality7of metallic structures for a vehicle. The method includes arranging the plurality of metallic structures. The method also includes bonding the plurality7of metallic structures, where the bonding includes preparing a surface of a first metallic structure of the plurality' of metallic structures for bonding, applying a non- metallic adhesive to the surface of the first metallic structure, and applying pressure to the surface of the first metallic structure and a second metallic structure of the plurality7of metallic structures to form a joint between the first metallic structure and the second metallic structure. The method also includes welding the first metallic structure and the second metallic structure to form a metallic weld to reinforce the joint and to secure the first metallic structure and the second metallic structure together.

[0220] EE 20 is the method of EE 19, the refill friction stir spot welding (RFSSW) forms the metallic weld.

[0221] The above detailed description describes various features and functions of the disclosed systems, apparatus, and methods with reference to the accompanying figures. In the figures, similar symbols typically identify similar components, unless context dictates otherwise. The example embodiments described herein and in the figures are not meant to be limiting. Other embodiments can be utilized, and other changes can be made, without departing from the scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

Claims

1. What is claimed is:

1. A support structure for a vehicle, the support structure comprising: a metallic panel having a raised portion with a geometric shape integrally formed with and protruding from a surface, and a recessed portion adjacent the raised portion, wherein a non-metallic adhesive is applied to a surface of at least one of the raised portion or the recessed portion, and wherein a weld is applied a predetermined distance from the adhesive at a coupling location to facilitate coupling the metallic panel to the vehicle.

2. The support structure of claim 1, wherein the metallic panel is provided in the form of Magnesium, Aluminum, or Titanium.

3. The support structure of claim 1, wherein the geometric shape is provided by stress design software.

4. The support structure of claim 1 , wherein the geometric shape is at least one of a square, a rectangular, and a triangle.

5. The support structure of claim 1, wherein the metallic panel is press formed using a mold.

6. The support structure of claim 1, wherein the weld is formed using refill friction stir spot welding (RFSSW) via at least one robot.

7. The support structure of claim 1, wherein the weld is applied to the recessed portion, and additional welds may be applied to the recessed portion, wherein the additional welds are co-linearly formed along a surface of the recessed portion.

8. The support structure of claim 1, wherein the adhesive is applied prior to the weld.

9. The support structure of claim 1, wherein the vehicle includes a panel, wherein the metallic panel is a first metallic panel and the support structure further comprises a second metallic panel, and wherein a frame is configured to couple to at least one of the first metallic panel or the second metallic panel.

10. The support structure of claim 9, wherein the frame is positioned on top of the first metallic panel, the first metallic panel is positioned on top of the second metallic panel, and the second metallic panel is positioned on top of the panel of the vehicle, such that the weld extends through the frame, the first metallic panel, the second metallic panel, and the panel of the vehicle to facilitate coupling of the frame, the first metallic panel, the second metallic panel, and the panel of the vehicle.

11. The support structure of claim 9, wherein the frame is positioned on top of the first metallic panel and the second metallic panel, wherein the first metallic panel is adjacent the second metallic panel, and the first metallic panel and the second metallic panel are configured to be coupled to the panel of the vehicle, such that the weld extends through the frame, through at least one of the first metallic panel or the second metallic panel, and through at least a portion of the panel of the vehicle to facilitate coupling of theframe, the first metallic panel or the second metallic panel, and the panel of the vehicle.

12. The support structure of claim 1, wherein the metallic panel is a first metallic panel and a frame is positioned on top of the first metallic panel, and the first metallic panel is positioned on top of the panel of the vehicle, such that the weld extends through the frame, the first metallic panel, and the panel of the vehicle to facilitate coupling of the frame, the first metallic panel, and the panel of the vehicle.

13. The support structure of claim 1 , wherein the metallic panel is a first metallic panel and the support structure further comprises a second metallic panel, wherein the weld is configured to couple a frame to a first flange of the first metallic panel and a second flange of the second metallic panel forming a composite metallic panel.

14. The support structure of claim 1 , wherein the metallic panel is a first metallic panel and the support structure further comprises a second metallic panel, wherein the first metallic panel includes a plurality of protrusions and wherein the weld is configured to be positioned between a first protrusion of the plurality of protrusions and a second protrusion of the plurality of protrusions, and wherein the weld is configured to couple the first metallic panel, the second metallic panel, and the panel of the vehicle.

15. The support structure of claim 14, wherein the first protrusion is the raised portion.

16. The support structure of claim 1. wherein the panel of the vehicle is an outer skin, and wherein the metallic panel is configured to couple to an interior surface of the outer skin.

17. The support structure of claim 1, wherein the vehicle is VTOL or an eVTOL.

18. A vehicle comprising: a body including a panel; and a metallic support structure including a raised portion integrally formed with and protruding from a surface and a recessed portion adjacent the raised portion, wherein a refill friction stir spot weld is applied to the recessed portion to facilitate coupling the metallic support structure to a frame and the panel.

19. A method for joining a plurality of metallic structures for a vehicle, the method comprising: arranging the plurality of metallic structures; bonding the plurality of metallic structures, wherein the bonding includes preparing a surface of a first metallic structure of the plurality of metallic structures for bonding, applying a non-metallic adhesive to the surface of the first metallic structure, and applying pressure to the surface of the first metallic structure and a second metallic structure of the plurality of metallic structures to form a joint between the first metallic structure and the second metallic structure; and welding the first metallic structure and the second metallic structure to form a metallic weld to reinforce the joint and to secure the first metallic structure and the second metallic structure together.

20. The method of claim 19. wherein refill friction stir spot welding (RFSSW) forms the metallic weld.

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