Single-Shear Node Joint With Adhesive Injection for 3D Bonding
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Solution Overview
Problem
Existing node-to-node connection techniques in 3-D printing struggle to achieve strong and reliable bonding between additively manufactured components, particularly in complex geometries and mechanical structures like vehicles, boats, and aircraft, where traditional methods fail to provide consistent mechanical properties and resistance to galvanic corrosion.
Innovation Solution
The implementation of a single shear adhesive bond joint using nodes with specifically designed bonding surfaces and features for adhesive injection, including vacuum evacuation and adhesive filling through configured channels, ensures robust coupling between nodes, enhancing mechanical properties and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional node-to-node connection techniques are used in 3-D printing, then the manufacturing process is simpler, but the bonding strength and reliability between additively manufactured components deteriorates
Solution Approach 1:
The bonding interface is segmented into distinct functional zones: a bonding surface for adhesive application, a bonding region for adhesive placement, and a shear joint for mechanical coupling. This segmentation allows each zone to be optimized for its specific function, achieving strong bonding without excessive overall complexity
Solution Approach 2:
The connection design transitions from traditional planar bonding to a three-dimensional configuration involving bonding surfaces, bonding regions, and shear joints that operate in multiple spatial dimensions. This enables robust mechanical coupling while maintaining manufacturing feasibility through controlled geometric complexity
2Reliability
If traditional bonding methods are used, then the manufacturing process is easier, but the resistance to galvanic corrosion deteriorates
Solution Approach 1:
An adhesive intermediary is introduced between the bonding surfaces to prevent direct galvanic contact between dissimilar metals. The adhesive layer acts as a protective barrier that eliminates galvanic corrosion pathways while the shear joint provides mechanical coupling, achieving both corrosion resistance and manufacturing feasibility
Solution Approach 2:
The bonding design incorporates self-aligning features and standardized interfaces that enable automated assembly processes. The shear joint geometry and bonding surface configurations are designed to facilitate precise alignment and consistent adhesive application, reducing manual intervention and improving manufacturing ease
3Manufacturing precision
If complex geometries are bonded using traditional methods, then manufacturing flexibility is maintained, but bonding consistency and mechanical properties deteriorate
Solution Approach 1:
The bonding structure incorporates locally optimized features tailored to specific geometric requirements. Bonding surfaces are designed with appropriate roughness and area for each application, bonding regions are sized and positioned according to local load requirements, and shear joints are configured to match the specific geometry being joined. This local optimization ensures consistent bonding quality across complex geometries without requiring excessive overall structural 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 method provides a flexible and reliable bonding solution for complex geometries, ensuring strong mechanical connections and preventing galvanic corrosion, thereby improving the structural integrity of 3-D printed components in mechanical assemblies.
Implementation Method 1
an adhesive couples the first bonding surface to the second bonding surface through the feature that is configured to accept the adhesive
Implementation Method 2
drawing vacuum to evacuate a bonding region
Data Source
AI summary
One aspect is an apparatus including a first node including a first bonding surface and a second node including a second bonding surface. The apparatus includes a feature configured to accept an adhesive and an adhesive channel coupled to the feature configured to accept the adhesive. The apparatus includes a shear joint coupling the first node and the second node, the shear joint configured to receive the adhesive in an adhesive region formed by the first bonding surface and the second bonding surface, the adhesive for coupling the first bonding surface to the second bonding surface through the feature configured to accept the adhesive.