Additive Spoiler Cap with Segmented Solid Lattice Hollow Interior

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Solution Overview

Problem

Conventional casting and molding processes limit article design due to geometric constraints and manufacturability issues, requiring compromises between performance and manufacturability, which prevents optimization of either.

Innovation Solution

The design of an article featuring a solid shell enclosing an interior region with distinct solid, lattice, and hollow sub-regions, where main working load paths are supported by solid sub-regions, secondary load paths by lattice sub-regions, and non-load path areas as hollow sub-regions, fabricated using additive manufacturing to optimize material distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional casting or molding processes are used, then manufacturability is improved, but design flexibility and performance optimization are worsened due to geometric constraints

Engineering Contradiction:

ImprovemanufacturabilityVSAvoiddesign flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The interior region is segmented into multiple sub-regions (solid, lattice, hollow) with different structural characteristics, allowing each sub-region to be optimized for its specific functional requirements while maintaining overall manufacturability through additive manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sub-regions within the interior are assigned different material densities and structural properties (solid for high strength, lattice for moderate strength with weight reduction, hollow for maximum weight reduction) based on local load requirements, enabling performance optimization without sacrificing manufacturability

Inventive Principle:

Principle #3Local quality

2Strength

If solid material is used throughout the interior region, then structural integrity is improved, but weight is increased

Engineering Contradiction:

Improvestructural integrityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The interior region employs spatially varying material density with solid sub-regions placed along main working load paths for structural integrity, lattice sub-regions along secondary load paths for moderate strength with weight reduction, and hollow sub-regions in non-load path areas for maximum weight reduction

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The article utilizes a composite structure combining three different material configurations (solid, lattice, hollow) within a single component, allowing optimization of both strength and weight by placing each material type where it provides the most benefit

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If complex geometries are implemented, then performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical manufacturing processes (casting, molding) with additive manufacturing technology, enabling the fabrication of complex geometries including internal lattice and hollow structures that would be impossible or excessively complex to produce using traditional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10906236B2Article with solid, lattice, and hollow sub-regions

Publication Date: 2021.02.02 FORD GLOBAL TECH LLC

AI summary

An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.