AM Node Fluid Injection Channels for Strong Structural Joints
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Solution Overview
Problem
Traditional methods for connecting space frame and monocoque structures result in high manufacturing costs and design inflexibility due to complex tooling requirements and limitations in accommodating varied structural geometries, particularly in applications like automotive and marine industries.
Innovation Solution
The use of additively manufactured nodes with integrated fluid injection systems that create tortuous paths for fluid flow, allowing for the precise distribution of sealants and adhesives through a network of channels to facilitate efficient connection and sealing between nodes and structures, reducing the need for complex tooling and enhancing design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional welding or mechanical connection methods are used for space frame structures, then structural strength can be achieved, but manufacturing costs increase and design flexibility is reduced
Solution Approach 1:
The connection system is segmented into modular components: nodes with integrated fluid injection channels, separate tube structures, and distinct sealing/adhesive components. This segmentation allows each component to be manufactured independently using cost-effective processes while maintaining strong connections through the fluid distribution system that injects sealants and adhesives into predefined channels at connection interfaces.
Solution Approach 2:
A fluid intermediary system is introduced as the connecting medium between structural components. The fluid injection system delivers sealants and adhesives through internal channels to connection interfaces, acting as an intermediary that bonds dissimilar materials (metal tubes to composite panels) without requiring direct mechanical fastening or welding, thereby reducing manufacturing complexity and cost.
2Manufacturing precision
If complex tooling is used for traditional connection methods, then precise alignment can be achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
Alignment features and fluid channels are pre-formed during node manufacturing using additive manufacturing techniques. The nodes are produced with integrated alignment geometries and internal fluid channels already in place, eliminating the need for complex alignment tooling during assembly. The preliminary formation of these features ensures precise alignment while reducing on-site tooling requirements.
Solution Approach 2:
The patent replaces complex mechanical alignment and connection tooling with a fluid-based system. Instead of using mechanical fixtures, jigs, and alignment devices, the invention uses fluid injection through pre-formed channels to achieve precise distribution of bonding materials and ensure proper alignment, substituting mechanical complexity with a simpler fluid distribution approach.
3Adaptability or versatility
If planar elements are used in monocoque design, then manufacturing is simpler, but design flexibility is reduced
Solution Approach 1:
The node structures serve multiple functions: they provide structural connection points, contain integrated fluid distribution channels, incorporate alignment features, and facilitate sealing and bonding operations. This multi-functionality allows the same basic node geometry to adapt to various connection configurations and structural designs, enhancing design flexibility without requiring complex manufacturing processes for each variation.
Solution Approach 2:
The invention enables design flexibility by allowing parameter variations in the fluid channels, outlet positions, and node geometries while maintaining the same basic manufacturing approach. The additive manufacturing process allows easy modification of channel dimensions, outlet locations, and node shapes to accommodate different design requirements, providing versatility without sacrificing manufacturing simplicity.
4Reliability
If dissimilar materials are brought into direct contact for structural connections, then assembly is simpler, but corrosion resistance is reduced
Solution Approach 1:
The fluid injection system delivers sealants and adhesives as intermediary materials between dissimilar structural components (such as metal tubes and composite panels). These fluid-applied materials create a protective barrier that prevents direct contact between dissimilar materials, eliminating galvanic corrosion while maintaining simple assembly procedures. The intermediary bonding materials protect the interface without adding significant complexity to the connection system.
Data Source
AI summary
An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a receptacle, etc., for accepting another structure, e.g., a tube, a panel, etc. An additively manufactured node can include a surface with an opening to a feed channel through the node. A second surface of the node can include with a plurality of openings to an array of outlet channels. Each of the outlet channels can extend through the node and can connect to the feed channel. Tortuous paths can be used between channels created by the node surface and adjacent structures as well as node interior surfaces. These tortuous paths can be tuned to allow for optimal fluid flow processes.