Metallic Doubler Structure for Thin-Sheet Additive Attachment
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Solution Overview
Problem
Metallic sandwich structures face challenges in coupling metallic articles to face sheets due to the thinness of the face sheets, leading to increased weight, complexity, and cycle time, with existing techniques being limited in effectively managing heat dissipation and structural rigidity.
Innovation Solution
A metallic structure is fabricated by attaching a metallic doubler to a face sheet and additively manufacturing articles on the opposing surface, using a doubler with varying thickness to provide structural backup and efficient heat transfer, while minimizing overall thickness and weight.
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 face sheet into a single integrated structure by additively manufacturing the metallic article directly on the face sheet surface. This eliminates the need for separate fasteners and reduces part count, thereby reducing weight while maintaining attachment strength through direct material bonding.
Solution Approach 2:
The patent extracts and removes the fasteners from the assembly, eliminating the harmful element (extra weight and complexity) while preserving the essential function of attachment through the additive manufacturing process that directly bonds the article to the face sheet.
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 fasteners) into a single integrated structure through additive manufacturing. This reduces device complexity by eliminating the need for separate fasteners and assembly steps, while maintaining secure attachment through direct material bonding.
3Weight of moving object
If face sheets are made thinner to reduce weight, then the overall structure weight decreases, but the ability to couple metallic articles effectively is limited
Solution Approach 1:
The patent applies local quality by adding material only where needed - the metallic article is additively manufactured directly on the face sheet surface at specific locations requiring attachment. This allows the face sheet to remain thin overall for weight reduction, while providing localized reinforcement and attachment capability at critical points through the deposited metal.
4Strength
If traditional coupling methods are used on thin face sheets, then attachment can be achieved, but heat dissipation and structural rigidity are compromised
Solution Approach 1:
The patent merges the thermal management function with the structural attachment function by additively manufacturing the metallic article directly on the face sheet. This creates a continuous metal pathway that simultaneously provides mechanical attachment strength and thermal conduction, allowing heat to dissipate through the metal bond without requiring separate thermal management components.
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 configuration enhances structural rigidity, reduces weight, and improves heat dissipation, enabling efficient formation and joining of articles while minimizing the thickness and weight of the metallic structure.
Implementation Method 1
using a doubler with varying thickness to provide structural backup and efficient heat transfer
Data Source
Figure 1~2
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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.