Lightweight Vehicle Body Node via Laser Additive Manufacturing
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Solution Overview
Problem
Existing vehicle body node structures lack optimal lightweight design and stability, particularly in space frame constructions, where conventional manufacturing methods restrict geometric freedom and material distribution for enhanced mechanical performance.
Innovation Solution
A body node with connecting flanges and a topologically optimized structure manufactured using laser additive manufacturing, allowing for the distribution of material only where needed for anticipated loads, combined with a connecting structure that includes bars or struts similar to those found in nature, such as bird bones, to enhance torsional and flexural stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods are used for vehicle body nodes, then manufacturing simplicity is maintained, but geometric freedom and material distribution are restricted, leading to suboptimal lightweight design and mechanical performance
Solution Approach 1:
The patent applies laser additive manufacturing to fundamentally change the manufacturing parameters and process capabilities, enabling complex geometric structures and optimized material distributions that cannot be achieved with conventional manufacturing methods, thus resolving the contradiction between manufacturing simplicity and mechanical performance
Solution Approach 2:
The patent utilizes topologically optimized structures that can be viewed as composite designs combining different structural elements (bars, struts, hollow sections) within a single integrated node, achieving superior mechanical performance through optimized material arrangement rather than traditional composite materials
2Strength
If material is distributed throughout the entire body node structure, then strength is improved, but weight increases, contradicting lightweight design goals
Solution Approach 1:
The patent implements topological optimization that distributes material locally only where structurally necessary based on stress patterns and load paths, creating a non-uniform material distribution that maintains strength while minimizing weight by removing material from low-stress regions
Solution Approach 2:
The optimized body node structure segments the material distribution into distinct functional zones with bars and struts positioned specifically to handle different load types, rather than using uniform material distribution throughout the entire structure
3Stability of the object's composition
If the body node structure is made more rigid to improve stability, then torsional and flexural stiffness increase, but weight and material usage increase
Solution Approach 1:
The patent incorporates curved and optimized geometric forms in the body node structure, including hollow sections and rounded transitions that provide enhanced torsional and flexural stiffness compared to straight linear elements, achieving improved stability without proportional weight increase
Solution Approach 2:
The structure applies localized reinforcement through strategically positioned bars and struts only in regions requiring enhanced stiffness, rather than uniformly thickening the entire structure, thus achieving improved stability with minimal weight penalty
4Adaptability or versatility
If conventional manufacturing methods are used, then production simplicity is maintained, but adaptability to varying load conditions and lifecycle changes is reduced
Solution Approach 1:
The patent leverages the flexibility of laser additive manufacturing to easily modify design parameters, geometric configurations, and material distributions to adapt to varying load conditions and lifecycle requirements, demonstrating superior adaptability compared to conventional manufacturing methods
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 solution achieves a high-strength, lightweight vehicle body node with improved stability and flexibility, enabling efficient production of vehicle components that can adapt to varying load conditions and lifecycle changes with reduced material usage.
Implementation Method 1
manufactured using laser additive manufacturing
Implementation Method 2
laser additive manufacturing methods (LAM), in particular selective laser melting (SLM)
Implementation Method 3
selective laser melting (SLM)
Data Source
AI summary
A body node for connecting shell-shaped body structures, of a vehicle, the body node having: a first connecting flange for connection to a first shell-shaped body structure, a second connecting flange for connection to a second shell-shaped body structure, a third connecting flange for connection to a third shell-shaped body structure, and a connecting structure rigidly connecting the connecting flanges with each other and, for example, forming a monolithic body with the connecting flanges.