Additive Node-Panel Joint Structure for Lightweight Corrosion Isolation
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Solution Overview
Problem
The design and manufacture of node-panel joint structures in transport structures are challenging due to the need for intricate substructures, high precision, and efficient, cost-effective methods, often resulting in bulkier and heavier components that are inefficient and prone to corrosion when connecting dissimilar materials.
Innovation Solution
The use of additive manufacturing to create nodes with recesses, ports, and adhesive regions, where sealants and adhesives are applied to form secure, lightweight connections, preventing galvanic corrosion and enabling complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes (machining, casting) are used to create node-panel joints, then high precision can be achieved through machining, but the manufacturing cost increases significantly and the structures become bulkier and heavier
Solution Approach 1:
The patent changes the manufacturing method from conventional subtractive (machining) or formative (casting) processes to additive manufacturing (3D printing). This parameter change enables complex geometries to be produced directly without tooling, reducing manufacturing cost while maintaining precision through digital control of the printing process
Solution Approach 2:
The patent introduces internal channels and adhesive regions that are impossible to create with conventional machining or casting. These three-dimensional internal structures are built layer-by-layer through additive manufacturing, enabling complex fluid transport paths and multi-functional integration without increasing external dimensions
2Ease of manufacture
If conventional manufacturing processes are used for node-panel joints, then manufacturing is simpler, but the resulting structures are bulkier and heavier
Solution Approach 1:
The node is divided into functional regions (adhesive regions, channels, ports) that are integrated into a single lightweight structure. The additive manufacturing process creates thin-walled structures with internal cavities, eliminating the need for bulk material while maintaining structural integrity and reducing weight
Solution Approach 2:
The patent nests multiple functions within the node structure itself - channels are embedded within the node body, adhesive regions are integrated into the geometry, and ports are formed as part of the external surface. This nesting eliminates separate components and reduces overall weight while maintaining manufacturing simplicity
3Adaptability or versatility
If dissimilar materials are connected using conventional processes, then material selection flexibility is achieved, but corrosion resistance deteriorates
Solution Approach 1:
The patent introduces an adhesive as an intermediary material between dissimilar node and panel materials. The adhesive is applied through channels within the node structure, creating a controlled bonding interface that prevents direct contact between dissimilar metals, thereby eliminating galvanic corrosion while maintaining material selection flexibility
Solution Approach 2:
The patent replaces conventional mechanical fastening systems (screws, rivets, welds) with an adhesive bonding system. This substitution eliminates the mechanical contact and potential galvanic cells between dissimilar metals, while the adhesive provides reliable bonding across different material types with inherent corrosion protection
4Reliability
If intricate substructures are added to achieve secure node-panel bonds, then connection reliability improves, but device complexity increases
Solution Approach 1:
The patent merges multiple functions (structural support, adhesive delivery, fluid transport, sealing) into a single integrated node structure. The additive manufacturing process creates this multi-functional component in one piece, reducing the number of separate parts and assembly steps while maintaining connection reliability through the integrated design
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 allows for the creation of sophisticated, lightweight node-panel joints with improved durability and corrosion resistance, enhancing the efficiency and performance of transport structures while reducing manufacturing costs.
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 and second ports and configured to fill the adhesive regions with an adhesive
Data Source
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.