Adhesive Node-to-Tube Joints for Corrosion-Safe Vehicle Chassis
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Solution Overview
Problem
Conventional techniques for joining nodes to tubes in transport structures, such as automobiles, are inadequate for achieving robust, lightweight, and multi-material connections, particularly when using additively manufactured parts, as they often lead to galvanic corrosion and lack flexibility in connection methods.
Innovation Solution
The use of additively manufactured nodes with sealing interfaces and adhesive paths, which form a sealant chamber when coupled with tubes, allowing for adhesive injection and vacuum evacuation to create a strong bond while preventing physical contact between dissimilar materials, thereby reducing galvanic corrosion and enabling flexible connection techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining techniques (welding) are used to connect nodes to tubes, then strong connections are achieved, but galvanic corrosion occurs and material flexibility is reduced
Solution Approach 1:
The patent introduces an adhesive as an intermediary substance between dissimilar materials (e.g., aluminum node and steel tube) to join them without direct contact. This adhesive layer prevents galvanic corrosion by electrically isolating the dissimilar materials while still providing strong mechanical bonding, thus resolving the contradiction between connection strength and galvanic corrosion prevention
Solution Approach 2:
The patent replaces conventional mechanical joining methods (welding) with chemical bonding through adhesives. This substitution allows dissimilar materials to be joined without the harmful effects of welding-induced galvanic corrosion, while maintaining or even improving connection strength through properly engineered adhesive bonds
2Adaptability or versatility
If additive manufacturing is used to fabricate nodes, then manufacturing flexibility and multi-material connections are improved, but new joining techniques must be developed
Solution Approach 1:
The patent merges the node fabrication and joining functions into a single additive manufacturing process. The node is printed with integrated adhesive paths, sealing interfaces, and alignment features already incorporated into its geometry, eliminating the need for separate joining preparation steps and simplifying the overall manufacturing process
Solution Approach 2:
The additive manufacturing process performs preliminary actions by pre-forming the node with built-in adhesive channels, sealing surfaces, and alignment features before the actual joining operation. This preliminary structuring simplifies subsequent assembly and joining operations, making the overall process easier despite the complexity of the joining technique itself
3Object-affected harmful factors
If adhesive bonding is used to connect nodes to tubes, then galvanic corrosion is prevented, but robust connections require complex sealing and adhesive delivery systems
Solution Approach 1:
The patent combines multiple functions (adhesive delivery, sealing, and structural support) into the additively manufactured node itself. The adhesive paths are integrated directly into the node geometry, and sealing interfaces are built-in, eliminating the need for separate sealing components and simplifying the overall system
Solution Approach 2:
The additively manufactured node serves itself by incorporating all necessary features for adhesive bonding directly into its structure. The node provides its own adhesive delivery channels, sealing surfaces, and alignment features, eliminating the need for external sealing systems or complex adhesive delivery mechanisms
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 provides robust, lightweight connections between nodes and tubes, reduces tooling costs and lead times, and prevents galvanic corrosion by using sealants to contain the adhesive and isolate materials, resulting in a more efficient and environmentally friendly manufacturing process.
Implementation Method 1
The first sealing interface, the second sealing interface, and the node wall can form a first annular region... The first sealing interface, the second sealing interface, the node wall, and a wall of the tube can form a sealant chamber
Implementation Method 2
The node can further comprise a plurality of annular regions... A width for at least one of the plurality of annular regions can be based on an anticipated load of a connection between the node and a tube coupled to the node
Data Source
AI summary
Apparatus and methods for joining nodes to tubes with node to tube joints are presented herein. Joining techniques allow the connection of additively manufactured nodes to tubes. In an embodiment, at least one node may be joined to a tube and may be a part of a vehicle chassis. The node to tube joint connection incorporates adhesive bonding between the node to tube to realize the connection. Sealants may be used to provide sealed regions for adhesive injection, which are housed in sealing interfaces co-printed with the additively manufactured nodes. Additionally, seals may act as isolators and reduce galvanic corrosion.