Additively Manufactured Node-Panel Joints for Corrosion-Safe Bonding
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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, especially 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 traditional manufacturing processes (machining, casting) are used to create node-panel joints, then manufacturing precision can be achieved, but the components become bulkier and heavier
Solution Approach 1:
The patent changes the manufacturing method from traditional machining and casting to additive manufacturing (3D printing). This parameter change enables the creation of complex, lightweight node geometries with optimized internal structures that would be impossible to achieve with conventional processes, directly reducing weight while maintaining or improving precision
Solution Approach 2:
Additive manufacturing introduces a new dimensional capability by building nodes layer-by-layer in three dimensions, allowing for complex internal geometries, lattice structures, and optimized material distribution that reduce weight while maintaining structural integrity and manufacturing precision
2Ease of manufacture
If conventional joint structures are used, then manufacturing simplicity is maintained, but the joints become bulkier and less efficient
Solution Approach 1:
The patent changes the manufacturing approach to additive manufacturing, which simplifies the production of complex geometries by eliminating the need for complex tooling, multiple assembly steps, and specialized fixtures required by conventional methods, thereby reducing weight without compromising manufacturability
3Adaptability or versatility
If dissimilar materials are connected using conventional processes, then material versatility is achieved, but corrosion resistance deteriorates
Solution Approach 1:
The patent introduces an adhesive bonding system as an intermediary between dissimilar materials (e.g., aluminum nodes and steel panels). This adhesive layer acts as a protective barrier that prevents galvanic corrosion while enabling the connection of different materials, thus maintaining material versatility while improving corrosion resistance
4Reliability
If intricate substructures are designed for secure panel bonds, then joint reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the manufacturing process to additive manufacturing, which can directly produce intricate substructures and complex geometries in a single operation. This eliminates the need for multiple assembly steps and complex tooling, thereby maintaining joint reliability through optimized structures while reducing manufacturing complexity
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 that are durable, efficient, and cost-effective, while preventing corrosion and enhancing structural performance 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 and second ports and configured to fill the adhesive regions with an adhesive, the adhesive being cured to form a node-panel joint
Implementation Method 2
preventing galvanic corrosion and enabling complex geometries
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.