3D-Printed Tube Frame Joints for Flexible Chassis Assembly
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Solution Overview
Problem
Traditional methods for fabricating joints in space frame construction, such as welded tube frame chassis, incur high equipment and manufacturing costs due to the need for various connection angles and geometries, limiting design flexibility and efficiency.
Innovation Solution
A 3-D printing method is employed to create joints that accommodate different tube geometries and stress directions by determining relative tube angles, sizes, and shapes, and printing centering features and internal routing features to support stress and facilitate adhesive application, using a computer system to design and communicate with a 3-D printer for precise joint fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding methods are used to fabricate joint members for tube frame chassis, then the structural strength and reliability are maintained, but the equipment costs and manufacturing costs increase significantly
Solution Approach 1:
The patent replaces traditional welding (a thermal/mechanical process requiring expensive equipment) with adhesive bonding (a chemical process). The joint member design includes specific features like bonding surfaces and positioning structures that enable reliable adhesive attachment, substituting the welding mechanism with an adhesive bonding mechanism while maintaining structural integrity
Solution Approach 2:
The patent changes the fundamental bonding parameter from mechanical/thermal welding to chemical adhesive bonding. This parameter change allows for lower equipment requirements and reduced manufacturing costs while maintaining joint reliability through proper adhesive selection and application protocols
2Adaptability or versatility
If traditional fabrication methods are used to create joints with various connection angles and tube geometries, then the structural requirements are met, but the design flexibility and efficiency are limited
Solution Approach 1:
The patent segments the joint fabrication process into modular components: standardized joint members with predefined bonding surfaces, and configurable tube connections. This segmentation allows for easier adaptation to different designs while keeping the basic joint member fabrication process simple and repeatable
Solution Approach 2:
The joint members are designed with universal bonding surfaces and attachment features that can accommodate various tube geometries and connection angles. A single joint member design can serve multiple connection configurations, increasing design flexibility without requiring complex custom fabrication for each variant
3Manufacturing precision
If precise joint fabrication is required to accommodate various tube geometries and angles, then the assembly accuracy is improved, but the manufacturing time and costs increase
Solution Approach 1:
The joint members are pre-fabricated with integrated positioning features, bonding surfaces, and alignment structures. This preliminary action ensures that when tubes are assembled, the precise alignment is achieved automatically through the built-in features rather than requiring complex real-time adjustment during assembly
Solution Approach 2:
The joint members incorporate self-aligning features such as positioning protrusions, recesses, and bonding surface geometries that automatically guide tube placement and ensure precise alignment. The structure itself provides the alignment function without requiring external tooling or complex fabrication processes
Data Source
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AI summary
A method for fabricating a joint designed to connect tubes for a space frame, where a space frame may be a vehicle chassis, is provided. The method may generate joints with variable geometry and fine features which may reduce production costs, reduce production time, and generate joints configured for highly specific applications. The joint may include centering features which may create a space between a surface of the tube and a surface of the joint through which adhesive may flow.