Additively Manufactured Node-Panel Joint With Injected Adhesive Channels
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Solution Overview
Problem
The design and manufacture of node-panel joints in transport structures are challenging due to the need for intricate substructures, which are difficult to produce efficiently and cost-effectively using traditional methods, often resulting in bulkier, heavier components prone to corrosion and geometrical design limitations.
Innovation Solution
The use of additive manufacturing to create nodes with recesses, ports, and adhesive regions, where channels are used to fill adhesive areas, allowing for secure and durable connections between panels while preventing galvanic corrosion through sealants and isolators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes (machining, casting) are used to create node-panel joints, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple joint functions into a single integrated node structure. The node includes a base, sides, recesses, adhesive regions, and channels all as one unified component that performs attachment, sealing, and adhesive distribution functions simultaneously, eliminating the need for separate sub-components
Solution Approach 2:
The node structure serves multiple functions: it provides structural attachment points, contains recesses for panel reception, includes adhesive regions for bonding, incorporates channels for adhesive distribution, and integrates ports for material injection. This multi-functionality reduces the overall system complexity while maintaining manufacturing precision
2Strength
If conventional joint designs are used, then structural strength is maintained, but weight increases due to bulkier components
Solution Approach 1:
The node is divided into distinct functional segments: a base for structural support, sides for panel engagement, recesses for positioning, adhesive regions for bonding, and channels for adhesive flow. This segmentation allows each part to be optimized for its specific function while reducing overall material usage
Solution Approach 2:
The node structure applies material and structural properties locally where needed: adhesive regions are positioned specifically at bonding interfaces, channels are created only where adhesive distribution is required, and recesses are formed only at panel contact points. This localized approach reduces weight by eliminating unnecessary material in non-critical areas
3Reliability
If intricate substructures are created for secure bonds, then connection reliability improves, but manufacturing efficiency decreases
Solution Approach 1:
The node structure is pre-configured with integrated channels and adhesive regions during manufacturing. The channels are formed as part of the node's basic structure, and adhesive regions are positioned in advance, allowing for rapid assembly and bonding operations without requiring complex real-time adjustments or multiple manufacturing steps
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 lightweight, sophisticated node designs with improved performance capabilities at manageable costs, providing efficient and reliable connections between panels in transport structures.
Implementation Method 1
one or more adhesive regions disposed on an inner surface of each side adjacent the panel; and at least one channel coupled between the first port and the second port and configured to fill the adhesive regions with an adhesive
Data Source
Figure 1
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Figure 3A
AI summary
A node to panel interface structure for use in a transport structure such as a vehicle is disclosed. In an aspect, the node includes a base, first and second sides protruding from the base to form a recess for receiving a panel, ports for adhesive injection and/or vacuum generation, one or more adhesive regions disposed on a surface of each side adjacent the panel, and at least one channel coupled between the first and second ports and configured to fill the adhesive regions with an adhesive, the adhesive being cured to form a node-panel interface. The node may be additively manufactured. In an exemplary embodiment, the node may use sealant features for including sealants that border and define the adhesive regions, and that may hermetically seal the region before and after adhesive injection. In another embodiment, the node may include isolation features for including isolators for inhibiting galvanic corrosion. In another aspect, adhesive may be filled serially on the adhesive regions on the first side and then on the adhesive regions on the second side. Adhesive may alternatively may be filled in parallel, or concurrently, on the adhesive regions of both sides.