Tongue-and-Groove Node Joints for Large 3D-Printed Assemblies
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in joining large components and complex geometries, particularly in transport structures, as traditional methods like welding and machining are labor-intensive and costly, and existing 3D printing capabilities are restricted by build plate size, necessitating the use of multiple subcomponents that require reliable and efficient bonding methods.
Innovation Solution
The use of tongue-and-groove connections in additively manufactured nodes and subcomponents, facilitated by adhesive application and vacuum infusion, allows for the efficient and durable joining of components without the need for additional processes like welding, enabling the creation of complex geometries and large structures from multiple subcomponents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding or riveting techniques are used to join components, then the components can be connected, but the process becomes labor-intensive and expensive
Solution Approach 1:
The patent replaces traditional mechanical joining methods (welding, riveting) with an adhesive bonding system. The adhesive is applied between the tongue and groove interfaces of additively manufactured components, eliminating the need for complex welding or riveting operations while reducing labor intensity and manufacturing costs.
Solution Approach 2:
The patent changes the joining mechanism from mechanical (welding/riveting) to chemical adhesive bonding. This parameter change allows for simpler, less labor-intensive assembly processes while maintaining joint integrity through the adhesive's bonding properties.
2Adaptability or versatility
If 3-D printing is used to create large components, then manufacturing flexibility increases, but the build plate size limits the maximum component dimensions
Solution Approach 1:
The patent divides large components that exceed single build plate dimensions into multiple smaller subcomponents that can be additively manufactured separately. These subcomponents are then joined using adhesive bonding at tongue-and-groove interfaces to form the complete large-scale component, effectively overcoming the build plate size limitation.
Solution Approach 2:
The patent uses tongue structures that extend into groove structures, creating a nested arrangement where one subcomponent fits within or alongside another. This nesting approach allows multiple additively manufactured subcomponents to be assembled into a larger integrated structure.
3Length of stationary object
If multiple subcomponents are 3-D printed and combined, then components of any size can be created, but the assembly process becomes complex
Solution Approach 1:
The patent employs asymmetric tongue and groove geometries that provide built-in alignment features. The tongue structure on one subcomponent is designed to fit precisely into the groove structure of another subcomponent, ensuring correct orientation and positioning during assembly. This asymmetric design simplifies the assembly process by eliminating the need for complex alignment procedures.
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
This method enables the cost-effective and flexible assembly of complex mechanical structures, such as gear cases and fluid pipe interfaces, by seamlessly integrating subcomponents with precise geometry and sealing, reducing material usage and preventing galvanic corrosion, while allowing for the integration of fluid transport within the component.
Implementation Method 1
techniques for joining nodes and subcomponents with adhesive
Implementation Method 2
facilitated by adhesive application and vacuum infusion
Data Source
AI summary
Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.