Additively Manufactured Sealing Nodes for Adhesive Panel Joints
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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, leading to inefficiencies in manufacturing, bulkier and heavier components, and difficulties in connecting dissimilar materials, resulting in potential corrosion and performance issues.
Innovation Solution
Additively manufacturing nodes with integrated sealant features and adhesive channels to enable secure, lightweight, and sophisticated connections between components, including the use of sealants to isolate and hermetically seal adhesive bonds, preventing contamination and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes (machining, casting) are used to manufacture node-panel joint structures, then manufacturing precision can be achieved, but manufacturing cost increases significantly and production efficiency decreases
Solution Approach 1:
The patent changes the manufacturing method from traditional subtractive (machining) or formative (casting) processes to additive manufacturing (3D printing). This parameter change enables complex joint structures to be manufactured directly layer-by-layer, achieving high precision for intricate geometries while dramatically improving production efficiency and reducing manufacturing costs compared to traditional methods
Solution Approach 2:
The patent employs composite materials, specifically carbon fiber reinforced polymers (CFRP), in the additive manufacturing process. This allows the joint structures to achieve high strength-to-weight ratios and complex internal geometries that would be difficult or impossible to obtain with traditional manufacturing, while maintaining precision and improving productivity
2Ease of manufacture
If traditional manufacturing processes are used for node-panel joints, then manufacturing capability is maintained, but component weight increases and sophistication decreases
Solution Approach 1:
The transition to additive manufacturing enables the production of optimized, lightweight structures with complex internal geometries such as lattices and honeycombs. These structures maintain full manufacturing capability while significantly reducing component weight compared to traditional solid or semi-solid joint designs
Solution Approach 2:
The use of carbon fiber reinforced polymer composites in additive manufacturing provides high strength and stiffness with reduced weight. The composite material structure, combined with additive manufacturing capabilities, allows for sophisticated lightweight joint designs that maintain ease of manufacture while reducing overall component weight
3Ease of manufacture
If conventional joint structures are used to connect dissimilar materials, then connection is achieved, but corrosion resistance decreases and reliability worsens
Solution Approach 1:
The patent introduces adhesive bonding as an intermediary connection method between dissimilar materials (e.g., aluminum nodes and CFRP components). This adhesive intermediary prevents direct galvanic contact between incompatible materials, eliminating galvanic corrosion while maintaining strong connections. The additive manufacturing process integrates adhesive application features directly into the joint structure
Solution Approach 2:
The patent changes the connection parameter from direct mechanical or welded contact to adhesive-bonded contact. This parameter change eliminates the galvanic corrosion mechanism that occurs with direct contact between dissimilar metals, thereby improving reliability and corrosion resistance while maintaining ease of manufacture for connecting different materials
4Strength
If intricate substructures are designed for secure panel connections, then connection strength improves, but device complexity increases and manufacturing difficulty increases
Solution Approach 1:
The patent changes the manufacturing parameter from traditional subtractive or formative processes to additive manufacturing. This enables intricate substructures with complex internal geometries to be manufactured as single integrated components rather than assemblies of multiple parts, maintaining high connection strength while reducing overall device complexity and assembly requirements
Solution Approach 2:
The patent merges multiple joint components and functions into a single additively manufactured node structure. Features such as mounting points, sealing channels, adhesive injection pathways, and structural elements are integrated into one monolithic component, reducing device complexity while maintaining or improving connection strength through optimized geometry
Data Source
AI summary
A node may be additively manufactured. The node may include a first surface and a second surface, and the second surface may bound a recess of the node. A structure may be inserted into the recess. A sealing member extend away from the second surface and contact the structure, such that a sealed space may be created between the node and the structure. An adhesive may be applied in the sealed space to at least partially attach the structure to the node.