Single-Port Additively Manufactured Node for Transport Structures
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Solution Overview
Problem
Traditional manufacturing processes for nodes in transport structures are inefficient and costly, often resulting in bulky, heavy components with geometrical limitations and corrosion issues due to multi-material connections, while existing two-port designs are complex and time-consuming.
Innovation Solution
A single-port node design with an inwardly extending port and integrated inlet and outlet apertures for fluid injection and removal, utilizing additive manufacturing to create complex geometries and reduce material usage, along with a nozzle system for efficient adhesive application and encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes (machining, casting) are used to produce nodes with intricate sub-substructures, then manufacturing precision can be achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent changes the manufacturing parameter from traditional subtractive (machining) or formative (casting) methods to additive manufacturing (3D printing). This parameter change enables the production of complex node geometries with intricate sub-substructures without the cost and time penalties of traditional methods, as additive manufacturing builds structures layer-by-layer directly from digital models.
Solution Approach 2:
The patent applies local quality by using additive manufacturing to create nodes with spatially varying material properties and geometries. The node includes intricate sub-substructures at specific locations where they are needed for connection functions, while other regions can be optimized for weight reduction. This localized approach allows high precision where required while maintaining overall manufacturing efficiency.
2Reliability
If conventional joints are designed to ensure secure connections, then connection reliability is improved, but the nodes become bulkier and heavier
Solution Approach 1:
The patent segments the node into multiple functional regions with distinct purposes: connection interfaces for securing panels, intricate sub-substructures for specific connection functions, and optimized core structures for strength-to-weight ratio. This segmentation allows each region to be optimized independently, ensuring connection reliability where needed while reducing overall weight through optimized material distribution.
Solution Approach 2:
The patent employs composite material strategies by combining different materials in the node structure, particularly at connection interfaces. The node can incorporate multi-material constructions that provide enhanced bonding capabilities and corrosion resistance at critical connection points while using lighter materials in non-critical regions, thus maintaining connection security while reducing overall weight.
3Weight of stationary object
If multi-material connections are used to optimize vehicle performance, then lightweighting is achieved, but corrosion resistance deteriorates
Solution Approach 1:
The patent converts the potential harm of multi-material corrosion into a benefit by designing the node with integrated corrosion protection features. The additive manufacturing process allows for built-in sealing structures, protective coatings, and drainage paths that prevent moisture accumulation at material interfaces. This approach maintains the weight advantages of multi-material construction while actively preventing corrosion rather than merely tolerating it.
Solution Approach 2:
The patent uses composite material strategies with careful selection of material combinations that have compatible thermal expansion coefficients and galvanic series positions. The node incorporates corrosion-resistant material pairings and protective barrier layers at material interfaces, allowing multi-material construction for lightweighting while systematically addressing corrosion risks through material science principles.
4Ease of operation
If two-port node design is used for adhesive injection, then adhesive application capability is improved, but system complexity and assembly time increase
Solution Approach 1:
The patent merges the inlet and outlet functions into a single port structure. The single port includes an inwardly extending portion that creates internal flow paths, allowing adhesive to be injected through one opening while excess adhesive and air can escape through the same port. This merging eliminates the need for separate inlet and outlet ports, reducing the number of components and simplifying the assembly system while maintaining effective adhesive application capability.
Solution Approach 2:
The single port is designed with multi-functionality, serving as both the injection point for adhesive and the exit path for excess adhesive and air bubbles. The inwardly extending portion of the port creates internal channels that guide fluid flow, enabling one structural feature to perform multiple functions that would traditionally require separate components, thus reducing system 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
The single-port node design enhances manufacturing efficiency, reduces material usage, and minimizes corrosion risks, enabling lightweight, high-performance connections with simplified assembly processes and reduced complexity in adhesive application systems.
Implementation Method 1
applying vacuum to an outlet aperture disposed inside the port through a second channel of the nozzle
Implementation Method 2
adhesive may be introduced to the bond regions between the components through an adhesive inlet port
Data Source
AI summary
A node including a single port for bonding to various components in a transport structure is disclosed. In an aspect, the node includes an inlet aperture disposed inside the port. The inlet aperture is configured to inject a fluid into at least one region to be filled by the fluid. For example, the fluid can be an adhesive. In another aspect of the disclosure, a nozzle to be interfaced with a single port node is provided. The nozzle includes a first channel to inject the adhesive. The nozzle may further include a second channel and a third channel. In another aspect of the disclosure, a method of using a single port node is provided.