Deflectable Panel-to-Node Joint for Tapered Socket Bonding
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Solution Overview
Problem
Conventional manufacturing processes struggle to efficiently join components with complex internal geometries, particularly those requiring deformation to fit unique internal structures, such as tapered sockets, due to limited flexibility and configurational constraints.
Innovation Solution
Additive manufacturing techniques are used to print nodes with tapered sockets and deformable panels, where the panel's surface layers and core are designed to conform to the node's shape, allowing for a stronger and simpler bond through the use of fillers and adhesives that can be compressed or expanded to fit the socket's geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing processes are used to join components with complex internal geometries, then manufacturing simplicity is maintained, but the ability to create unique internal structures and configurational flexibility is limited
Solution Approach 1:
The patent applies local quality by creating nodes with non-uniform, location-specific internal geometries that are tailored to the exact deformation requirements of each panel. The additively manufactured nodes have varying wall thicknesses, curvature radii, and socket geometries at different locations, allowing each region of the node to be optimized for its specific function in shaping the panel during bonding.
Solution Approach 2:
The patent utilizes the third dimension by creating complex internal geometries within the nodes that cannot be achieved through conventional 2D machining or molding. The additively manufactured nodes feature multi-layered internal structures, varying cross-sections, and three-dimensional socket configurations that enable sophisticated panel deformation patterns.
2Adaptability or versatility
If additively manufactured nodes with unique internal structures are used, then configurational flexibility and customization are improved, but the difficulty of joining deformable panels to these nodes increases
Solution Approach 1:
The patent applies preliminary action by pre-designing the nodes with built-in deformation zones and tapered sockets that guide the panel deformation process. The nodes are manufactured with predetermined geometric features that automatically shape the panel as it is bonded, eliminating the need for complex post-manufacturing adjustments or specialized joining equipment.
Solution Approach 2:
The patent utilizes parameter changes by varying the geometric parameters of the node sockets and deformation zones to match the specific requirements of different panel types. The additively manufactured nodes can have adjustable curvature radii, wall thicknesses, and socket angles that are optimized for each application, making the joining process easier despite the complexity of the structures.
3Strength
If panels are deformed to fit complex node geometries, then interconnection strength is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the node manufacturing and panel deformation processes into a single additive manufacturing operation. The nodes are printed with integrated deformation zones that perform both structural support and panel shaping functions, eliminating the need for separate deformation equipment and reducing overall manufacturing process complexity despite the high interconnection strength achieved.
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 approach enables the creation of stronger and more customizable interconnections in complex mechanical structures by allowing panels to deform and fit seamlessly into additively manufactured nodes with unique internal shapes, enhancing the bonding process and reducing manufacturing costs.
Implementation Method 1
The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel
Data Source
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AI summary
Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.