Additive Node-Tube Joints for Flexible Space Frame Assembly
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Solution Overview
Problem
Traditional methods for connecting nodes and tubes in space frame and monocoque constructions are costly and inflexible, leading to high equipment and manufacturing costs, and design limitations, especially when accommodating varied tube geometries and materials.
Innovation Solution
The use of additively manufactured nodes with sockets and interconnects that include spacer structures and seals to create efficient, adaptable joints, allowing for the connection of tubes with different materials and geometries, reducing galvanic corrosion and simplifying the assembly process through 3-D printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or mechanical connection methods are used for node-tube joints, then structural strength can be achieved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent combines the node and tube into a single additively manufactured component, eliminating the need for separate joining operations. The node is printed as an integrated structure with tubes extending directly from it, merging what were traditionally separate parts requiring welding or mechanical fastening into one monolithic component, thereby reducing manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The patent replaces traditional mechanical joining systems (welding equipment, fasteners, bolts) with additive manufacturing technology. The joint is created through the layer-by-layer deposition process itself, substituting complex mechanical assembly and joining operations with a single fabrication process that builds the jointed structure directly
2Reliability
If traditional fabrication methods are used for node connections, then structural integrity can be maintained, but manufacturing time and cost increase
Solution Approach 1:
The patent performs preliminary action by designing and manufacturing the entire node-tube assembly in a single additive manufacturing process before any assembly or joining operations would be required. The node is printed with precise geometric features and material properties built-in during fabrication, eliminating subsequent joining steps and reducing overall manufacturing time while ensuring structural integrity through controlled layer-by-layer construction
Solution Approach 2:
The patent utilizes parameter changes inherent to additive manufacturing, such as controlling layer height, infill density, and printing temperature, to optimize both the structural integrity and manufacturing efficiency of the node-tube joint. By adjusting these parameters during the printing process, the system achieves reliable joints without requiring post-assembly operations
3Ease of manufacture
If standardized connection nodes are used, then manufacturing cost is reduced, but adaptability to different tube geometries and materials is limited
Solution Approach 1:
The patent creates a universal node design through additive manufacturing that can accommodate multiple tube geometries, materials, and connection configurations. The node is designed with standardized interface features that can adapt to various tube types, making a single node design applicable to diverse applications without requiring custom tooling or expensive specialized components for each configuration
Solution Approach 2:
The patent introduces dynamics to the node design by creating parametric models that can be easily modified through software to adapt to different tube geometries and materials. The additive manufacturing process allows the node geometry to be dynamically adjusted and reprinted for different applications, providing versatility without the high tooling costs associated with traditional custom fabrication
Data Source
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AI summary
Connections between nodes and tubes are provided. An apparatus can include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes. An apparatus can include a node having an end portion with inner and outer concentric portions forming an annular gap therebetween, and a tube having an end portion extending into the gap.