Additively Manufactured Interconnects for Joining Composite Panels
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Solution Overview
Problem
Conventional joining techniques, such as welding, are not viable for some composite materials used in additive manufacturing, necessitating the development of new methods to connect panels efficiently.
Innovation Solution
The use of additively manufactured interconnects with notches and projections, or inserts like triangular prisms with internal ribbing, along with fluid transport tubing for adhesive injection, to join panels, allowing for flexible and strong connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding techniques are used to join panels, then strong connections can be achieved, but the technique is not viable for some composite materials used in additive manufacturing
Solution Approach 1:
The patent introduces an interconnect component as an intermediary element between panels that cannot be directly welded. This interconnect serves as a mediator that mechanically joins panels through notches and projections, enabling connection of composite materials that are incompatible with conventional welding techniques while maintaining strong structural bonds
2Ease of manufacture
If traditional manufacturing processes are used to join panels, then established techniques are available, but these processes do not efficiently handle additively manufactured parts with complex geometries
Solution Approach 1:
The patent segments the joining process into discrete components: panels with integrated notches, separate interconnect elements with projections, and adhesive application points. This segmentation allows each component to be manufactured independently using additive manufacturing, enabling efficient production of complex geometries that would be difficult or impossible to achieve with traditional manufacturing processes
Solution Approach 2:
The notches are pre-formed in the panels during additive manufacturing before the joining process. This preliminary action eliminates the need for post-manufacturing modifications and allows for precise alignment and efficient assembly of panels with complex geometries using the interconnect elements
3Strength
If panels with complex geometries are joined using conventional methods, then connections can be made, but material usage increases and structural integrity decreases
Solution Approach 1:
The interconnect design concentrates bonding material and structural reinforcement only at critical locations where panels join, rather than applying material uniformly across entire panel surfaces. The notches and projections are strategically positioned to maximize structural integrity at connection points while minimizing overall material consumption
Solution Approach 2:
The patent employs composite construction combining rigid panel materials with adhesive bonding materials in the interconnect assembly. This composite approach optimizes the structural properties of each material in its appropriate location, achieving high structural integrity with reduced total material usage compared to conventional solid filler methods
Data Source
AI summary
Apparatus and methods for joining panels are presented. Panels may be commercial off the shelf (COTS) panels and/or additively manufactured panels; and panels can be joined using an additively manufactured interconnect unit. Notches and protrusions can be formed in the panels and in the interconnect unit to facilitate the connection of the panels with the interconnect unit. In another approach a ribbed triangular prism can be manufactured using three dimensional (3D) printing. The panels can then be joined by inserting the ribbed triangular prism between the panels and by using an adhesive for bonding.