Deflectable Panel and Tapered Node Socket for Complex Interconnections
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Solution Overview
Problem
Conventional manufacturing processes struggle to efficiently join components with complex internal structures, particularly additively manufactured parts, due to their limited ability to create unique internal shapes and deformable features, which complicates the interconnection of socket components.
Innovation Solution
Additive manufacturing techniques are used to print nodes with tapered sockets and deformable panels, allowing the panel to conform to the node's internal shape through the use of compressible or expandable filler materials and adhesives, enabling a strong and customizable bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional manufacturing processes are used to create simple internal geometric shapes, then manufacturing complexity is reduced, but the ability to create complex geometrical structures with unique internal structures is limited
Solution Approach 1:
The patent changes the manufacturing method from conventional subtractive or formative processes to additive manufacturing, enabling the creation of complex internal geometric shapes including tapered sockets that were previously difficult or impossible to manufacture. This parameter change in the manufacturing process allows unique internal structures to be created directly from digital models.
Solution Approach 2:
The patent uses composite panel structures with face sheets and cores, where the additive manufacturing process creates integrated node components with complex internal geometries that combine structural and joining functions. The tapered socket geometry within the node creates a composite joint system combining mechanical interference fit with adhesive bonding.
2Adaptability or versatility
If additively manufactured nodes with unique internal structures are created, then component interconnection options are expanded, but the difficulty of joining deformable panels to socket components increases
Solution Approach 1:
The patent applies preliminary action by pre-shaping the socket interior geometry during additive manufacturing to match the desired final panel configuration. The tapered socket geometry is created in advance, and the panel is then deformed to conform to this pre-established geometry, simplifying the actual joining operation.
Solution Approach 2:
The patent changes physical parameters of the panel (temperature, stress state) to enable deformation into the socket. Heating the panel above its glass transition temperature and applying mechanical stress transforms the rigid panel into a deformable state, allowing it to conform to the complex socket geometry, then cooling locks in the deformed shape.
3Strength
If panels are deformed to conform to complex socket shapes, then interconnection strength is improved, but the manufacturing precision required to achieve proper fit increases
Solution Approach 1:
The patent applies self-service by designing the socket geometry to guide and control the panel deformation process. The tapered walls and internal features of the socket act as molds that automatically shape the panel as it is inserted and deformed, eliminating the need for complex external tooling or multiple adjustment steps to achieve precise fit.
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 stronger, more efficient interconnections in complex mechanical structures by enabling panels to deform and fit seamlessly into additively manufactured nodes with unique internal shapes, enhancing the flexibility and cost-effectiveness of manufacturing processes.
Implementation Method 1
The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel
Data Source
AI summary
Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.