Additive Manufacturing Connection Node for Weight Reduction
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Solution Overview
Problem
Current connection nodes in vehicles are heavy, material-intensive, and inefficiently designed for space constraints, failing to achieve optimal weight reduction and stability while fitting within limited installation spaces.
Innovation Solution
A connection node system comprising a one-part or multi-part central body manufactured via additive processes like 3D printing or casting, with integrated features such as cable guides and connection elements, allowing for modular assembly and reduced material usage, and utilizing adhesive bonding with optimized structural designs for weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional manufacturing processes are used for connection nodes, then structural strength and stability are ensured, but weight and material consumption increase significantly
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the connection node central body according to local load requirements. The additive manufacturing process enables different wall thicknesses in different regions, allowing material to be concentrated where structurally necessary and reduced where loads are lower, thus achieving weight reduction while maintaining structural strength.
Solution Approach 2:
The patent utilizes the third dimension by creating complex three-dimensional internal structures and optimized wall thickness distributions that cannot be achieved with conventional manufacturing. The additive process allows building structures in all three dimensions with varying densities and thicknesses, optimizing the strength-to-weight ratio.
2Volume of moving object
If connection node dimensions are reduced to fit limited installation space, then space utilization improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the connection node into a central body and multiple connection elements that can be manufactured separately using additive processes and then assembled. This segmentation allows each component to be optimized independently for its specific function and load requirements, simplifying the manufacturing of complex geometries while maintaining compact overall dimensions.
Solution Approach 2:
The patent incorporates cable guides and other functional features directly into the central body design during the additive manufacturing process. This preliminary integration of auxiliary functions eliminates the need for separate manufacturing steps and assembly operations for these features, reducing manufacturing complexity despite the compact size.
3Adaptability or versatility
If integrated functions are added to connection node, then system efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the connection node central body by integrating cable guides, mounting features, and structural elements into a single additively manufactured component. This consolidation reduces the total number of parts and assembly steps, thereby reducing device complexity while improving system efficiency through integrated functionality.
Solution Approach 2:
The connection node central body is designed as a multi-functional component that simultaneously provides structural support, cable routing, and mounting functions. The additive manufacturing process enables this universality by allowing complex geometries to be created in a single operation, making the component adaptable to multiple functions without proportionally increasing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves a weight reduction of up to 50% while maintaining stability and durability, enabling precise fitment within limited spaces and reducing manufacturing time and costs.
Implementation Method 1
at least a part of the connection node central body (5) and/or the first connection element (6, 7, 8) and/or the second connection element (6, 7, 8) is/are manufactured by means of an additive process, for example 3D printing
Implementation Method 2
utilizing adhesive bonding with optimized structural designs for weight reduction
Data Source
AI summary
The present invention relates to a system consisting of a connection node and at least one first connection body, wherein: the connection node comprises a connection node central body, a first connection element for joining with the connection body, and at least one second connection element for joining with a second connection body; the first connection element and the second connection element are connected or may be connected to the connection node central body; and at least one portion of the connection node central body and/or of the first connection element and/or of the second connection element is manufactured by means of an additive process, for example 3D printing, or by means of a casting process.