Additively Built Metallic Doubler Joints for Fastener-Free Attachment
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Solution Overview
Problem
Existing metallic sandwich structures face challenges in efficiently integrating metallic articles due to the use of mechanical fasteners, which increase weight, complexity, and cycle time, and are limited by the thinness of the face sheets.
Innovation Solution
A metallic structure comprising a metallic sheet with a doubler extending from its surface, where a metallic article is additively manufactured on the sheet's surface, utilizing junctions with defined boundaries to ensure structural integrity and heat dissipation while minimizing weight and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners are used to couple metallic articles to face sheets, then the metallic articles can be securely attached, but the weight, complexity, and part count of the metallic sandwich structure increase
Solution Approach 1:
The patent merges the metallic article and the face sheet into a single integrated component by additively manufacturing the article directly onto the face sheet surface. This eliminates the need for separate fasteners and reduces part count, thereby reducing weight while maintaining attachment strength through direct metallurgical bonding.
Solution Approach 2:
The patent replaces the mechanical fastening system with an additive manufacturing process that creates direct metallurgical bonds. Instead of using mechanical fasteners that require holes, threads, and clamping forces, the additive process melts and fuses material to create an integral connection, eliminating the mechanical system entirely.
2Strength
If mechanical fasteners are used to couple metallic articles to face sheets, then the metallic articles can be securely attached, but the device complexity and part count increase
Solution Approach 1:
The patent combines multiple components (face sheet, metallic article, and fastening function) into a single integrated structure. By additively manufacturing the article directly on the face sheet, the design eliminates separate fasteners, joints, and assembly procedures, thereby reducing device complexity while maintaining secure attachment.
3Strength
If mechanical fasteners are used to couple metallic articles to face sheets, then the metallic articles can be attached, but the cycle time increases
Solution Approach 1:
The patent performs the attachment action during the additive manufacturing process itself. As the metallic article is being built layer by layer, the material is simultaneously fused to the face sheet, creating the attachment as an inherent part of the manufacturing process rather than a subsequent step. This eliminates separate fastening operations and reduces cycle time.
4Weight of moving object
If other coupling techniques are used to attach metallic articles, then weight and complexity may be reduced, but the techniques are limited by the relative thinness of the face sheet
Solution Approach 1:
The patent applies local reinforcement by additively manufacturing material that extends from the face sheet surface to form the metallic article. This localized material deposition creates a thicker, reinforced region at the attachment zone while maintaining the overall thinness of the face sheet. The additive process allows precise control of material placement, providing structural integrity exactly where needed without adding unnecessary weight or limiting coupling technique options.
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
The proposed solution enhances the structural rigidity and heat dissipation of the metallic structure, reduces weight and complexity, and allows for efficient integration of metallic articles without the need for mechanical fasteners.
Implementation Method 1
a metallic article, extending from a portion of the metallic-sheet second surface... additively manufacturing a metallic article onto a portion of a metallic-sheet second surface
Implementation Method 2
The metallic doubler has at least a first doubler thickness and a second doubler thickness... enhances the structural rigidity and heat dissipation
Data Source
AI summary
A metallic structure includes a metallic sheet, including a metallic-sheet first surface and a metallic-sheet second surface. The metallic structure includes a metallic doubler, extending from the metallic-sheet first surface, and a first junction between the metallic-sheet first surface and the metallic doubler. The metallic structure includes a metallic article, extending from the metallic-sheet second surface, and a second junction between the metallic-sheet second surface and the metallic article. The first junction has a first-junction boundary. The second junction has a second-junction boundary. When viewed at any point along the second-junction boundary in a direction, perpendicular to the metallic-sheet first surface, the second-junction boundary does not extend outside of the first-junction boundary. In a plane, intersecting the metallic doubler and perpendicular to the metallic-sheet first surface, the metallic doubler has at least a first doubler thickness and a second doubler thickness, which is less than the first doubler thickness.