Patent Application
20190061835
The present disclosure relates generally to techniques for joining nodes to panels, and more specifically to joining nodes to panels using additively manufactured parts and techniques.
Recently three-dimensional (3D) printing, also referred to as additive manufacturing, has presented new opportunities to efficiently build parts for automobiles and other transport structures such as airplanes, boats, motorcycles, and the like. Applying additive manufacturing processes to industries that produce these products has proven to produce a structurally more efficient transport structure. An automobile produced using 3D printed components can be made stronger, lighter, and consequently, more fuel efficient. Advantageously, 3D printing, as compared to traditional manufacturing processes, does not significantly contribute to the burning of fossil fuels; therefore, the 3D printing of parts for automobiles can be more eco-friendly than conventional manufacturing techniques.
Automobiles and transport vehicles are constructed with panels and extrusions.
Conventional techniques for joining parts, such as welding, may not be a viable alternative for use with additively manufactured panels and extrusions. Accordingly, there is a need to discover and develop new ways to join panels to nodes and/or extrusions using additively manufactured parts and techniques.
Several aspects of techniques for joining panels to additively manufactured components, including nodes and/or extrusions, will be described more fully hereinafter with reference to three-dimensional (3D) printing techniques.
In one aspect an apparatus comprises a component, a panel, and an adhesive. The component has a socket; and the panel has an end portion positioned within the socket.
The adhesive is between the end portion of the panel and the socket to adhere the panel to the component.
The panel can be additively manufactured. The component can comprise a channel extending from an external surface of the component to the socket for adhesive injection. The component can further comprise a second channel. The second channel can extend from an external surface of the component to the socket for applying a vacuum during adhesive injection.
The apparatus can comprise a spacer between the end portion of the panel and the socket. The spacer can separate a surface of the panel from a surface of the socket. The surface of the panel can be separated from the surface of the socket so as to reduce galvanic corrosion.
The apparatus can also comprise a sealant between the end portion of the panel and the socket to seal the adhesive in the socket. The sealant can reduce galvanic corrosion by forming a gap. The panel can comprise a plurality of adhesive patches extending across an edge of the end portion of the panel. The adhesive can be between the end portion of the panel and the socket, and the adhesive can extend from the adhesive patches.
Additionally, the component can comprise an additively manufactured node having one or more co-printed heat conductors thermally coupled to the adhesive patches.
The apparatus can further comprise a node. The node can have a second socket at one end and a channel extending from the second socket to an opposite end of the node. The component can comprise an extrusion located in the second socket; and the panel can extend from the socket in the extrusion through the channel in the node.
A first portion of the adhesive can be in the channel between the node and the panel; and a second portion of the adhesive can be in the socket between the extrusion and the panel. Also, a third portion of the adhesive can be in the second socket between the extrusion and the node.
The apparatus can further comprise a plurality of sealants arranged to seal the first, second and third portions of the adhesive from one another. The component can also comprise two nodes adhered together to form the socket. The panel can comprise a hole, and the component can comprise a protrusion extending into the hole of the panel.
The component can comprise an additively manufactured node having one or more co-printed grooves in the socket. Also, the one or more grooves can comprise a first groove and a second groove. The first groove and the second groove can form a channel, and the channel can be configured to from a seal upon receiving an adhesive injection.
The component can comprise an additively manufactured node having a plurality of weep holes for visually monitoring adhesive flow. The component can also comprise an additively manufactured node having a plurality of ports for air expulsion during adhesive injection.
The panel can include one or more thermocouples.
The apparatus can further comprise an additively manufactured modular injector for adhesive injection in a selected region between the component and the panel. The modular injector can further comprise a portion that seals the adhesive between the component and panel in the selected region.
The apparatus can further comprise a punctured encapsulated adhesive tube located on an internal surface of the socket. The adhesive can extend from the punctured tube into the socket. The internal surface of the socket can include a notch; and the punctured encapsulated adhesive tube can be located in the notch.
The panel can comprise a hole; and the component can comprise an additively manufactured node having a co-printed pin extending through the hole.
Also, the apparatus can further comprise a cap having a hole. The distal end of the pin can extend through the hole to secure the panel between the node and the cap.
The component can further comprise an additively manufactured node having one or more grooves formed in the socket; and the adhesive can extend from the one or more grooves into the socket. Also, the end portion of the panel can comprise first and second surfaces. The first and second surfaces can comprise a core region between the first and second surfaces. The one or more grooves can include a groove positioned along the core at an edge of the end portion of the panel. The component can comprise an additively manufactured node having a hole extending from the surface of the node to the socket. The hole can be used to visually monitor adhesive flow. The component can also comprise an additively manufactured node having one or more cups formed in the socket for adhesive or sealant overflow.
In another aspect a method of joining a panel of a transport vehicle comprises obtaining a joining component and adhering the panel to the joining component. The joining component can comprise a node.
Adhering the panel to the joining component can comprise applying a film foam adhesive to an interface of the panel and the joining component. It can also comprise fixturing a joint between the panel and the joining component and increasing the temperature of the adhesive. The temperature can be increased so as to create an adhesive bond.
The joining component can further comprise an extrusion. Also, the panel can be additively manufactured; and the node can be additively manufactured.
Adhering the panel to the joining component can further comprise inserting a spacer between the panel and the joining component. The spacer can form a gap between a surface of the panel and a surface of the joining component. The gap can be formed so as to reduce galvanic corrosion.
Adhering the panel to the joining component can further comprise first applying a sealant so as to secure the panel with the joining component. The sealant can reduce galvanic corrosion by forming a gap. Adhering the panel to the joining component can also comprise injecting an adhesive into an interface of the panel and the joining component.
Injecting the adhesive into an interface of the panel and the joining component can comprise applying an adhesive via an adhesive port; and providing a vacuum via a vacuum port.
The method of joining a panel of a transport vehicle can further comprise monitoring a pressure of the vacuum and withdrawing the vacuum. The pressure can be indicative of the amount of adhesive drawn into the interface; and the vacuum can be withdrawn after the vacuum pressure indicates the adhesive substantially fills the interface.
Applying an adhesive via an adhesive port can occur after providing a vacuum via a vacuum port. Also, applying an adhesive via an adhesive port can occur before providing a vacuum via a vacuum port.
Different complex geometries may be used that were not previously available in traditional manufacturing processes. It will be understood that other aspects ofjoining panels to nodes and/or extrusions will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only several embodiments by way of illustration. As will be appreciated by those skilled in the art, the joining of panels and nodes and/or extrusions using additively manufactured nodes, components, and/or panels can be realized with other embodiments without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
Various aspects of apparatus and methods for joining nodes, extrusions, and panels will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein:
The detailed description set forth below in connection with the drawings is intended to provide a description of exemplary embodiments of joining nodes, extrusions, and panels using additively manufacturing techniques, and it is not intended to represent the only embodiments in which the invention may be practiced. The term “exemplary” used throughout this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.
The use of additive manufacturing in the context of joining two or more parts provides significant flexibility and cost saving benefits that enable manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries at a lower cost to the consumer. The joining techniques described in the foregoing relate to a process for connecting additively manufactured parts and/or commercial off the shelf (COTS) components. Additively manufactured parts are printed three-dimensional (3D) parts that are printed by adding layer upon layer of a material based on a preprogramed design. The parts described in the foregoing may be parts used to assemble a transport structure such as an automobile. However, those skilled in the art will appreciate that the manufactured parts may be used to assemble other complex mechanical products such as vehicles, trucks, trains, motorcycles, boats, aircraft, and the like without departing from the scope of the invention.
Additive manufacturing provides the ability to create complex structures within a part. For example, a part such as a node may be printed with a port that enables the ability to secure two parts by injecting an adhesive rather than welding two parts together, as is traditionally done in manufacturing complex products. Alternatively, some components may be connected using a brazing slurry, a thermoplastic, or a thermoset, any of which can be used interchangeably in place of an adhesive. Thus, while welding techniques may be suitable with respect to certain additive manufacturing embodiments, additive manufacturing provides significant flexibility in enabling the use of alternative or additional connection techniques.
As described above, these are non-traditional approaches to connecting additively manufactured components, such as nodes, extrusions, and/or panels, and it can be advantageous to develop new ways to join components together during the manufacturing process. Joining panels to nodes and/or extrusions may incorporate one or more factors such as materials, structure, design, and/or connecting features.
As discussed above, panels can be COTS parts. Alternatively, panels can be additively manufactured.
Panels may be formed by sheets which in turn may be made of carbon fiber to reduce chassis weight. The sheets may alternatively or additionally be made from metals, such as aluminum, steel, iron, nickel, titanium, copper, brass, silver, or any combination or alloy thereof. Advantages of using metal materials may include improving puncture resistance. Panels may have various structures, such as plain sheets, honeycomb, sandwiched sheets, and the like. The panels may further include internal structures such as honeycomb structures, lattice structures, foam cores, and/or any other suitable 2D or 3D structures as discussed herein. Various structures can avail various advantageous. For instance, panels formed with honeycomb structures can have enhanced strength while using fewer materials. Advantageously, this can reduce weight and cost.
Alternatively, or additionally, panels can be formed as sandwich honeycomb structures. These can be referred to as “sandwich panels.” Also, panels may be formed to contain any suitable internal structures, such as lattice structure described further herein. Panels may include a combination of various internal structures such as honeycomb, foam, or lattice structures. The variety of internal structures may be fabricated using 3D printing (additive manufacturing). In some instances, a panel may be pre-drilled to accelerate riveting to shear panels. Alternatively, adhesives may be applied to the interface of the extrusion and the panel skin to form a connection.
Additionally, additive manufacturing lends itself to node based architectures where components are fixed and/or floating. Floating can refer to being able to move in position for ease of positioning. For instance, a node based architecture enables a panel to be fixed while nodes float during assembly; or enables nodes to be fixed while a panel floats during assembly. When nodes are fixed, the nodes may be tailored to have features which allow a panel to float or move in position so as to facilitate connections to fixtures. Alternatively, when a panels is fixed, the panel may have features that would be connected to a fixture; the nodes would thereby float so as to facilitate assembly with the fixed panel. Following the assembly process of attaching floating/fixed nodes and panels, an adhesive can be injected or added to secure the nodes and panel.
Apparatuses and methods for joining nodes, extrusions, and panels are presented herein. Nodes, extrusions, and panels can be printed and joined together. Adhesive joining techniques can be applied to additively manufactured nodes, extrusions, and sandwich panels. There can be more than one type of a joint formed by the joining techniques. Exemplary types of joints can use a liquid adhesive in conjunction with a vacuum and/or a film foam adhesive.
Although
A sealant may also be applied to the panel node joint 200 to seal the interface. For instance, as shown in
In addition to improving the vacuum created within the interface, the sealant can advantageously reduce corrosion between parts by maintaining a gap or space between the parts. For instance, the sealant at interface 201 and locations 203 and 205 can prevent surfaces of the panel 202 from making contact with surfaces of the node 204. Having a separation between parts can reduce or eliminate different types of corrosion including galvanic corrosion which occurs between dissimilar materials. Additionally, sealants can prevent contamination from environmental factors. For instance, the sealants can serve as a physical barrier and block corrosive substances from entering regions between the panel 202 and node 204. Examples of environmental corrosive substances can include road salt, chemicals, and detergents.
After applying sealant to the panel node joint 200, a vacuum can be connected to a port such as port 206 or 208; and an adhesive, applied at another port such as port 206 or 208 can be drawn into the interface by the vacuum. In some embodiments the vacuum may be created before the adhesive is applied, while in other embodiments the adhesive may be applied prior to creating the vacuum. The vacuum pressure can be monitored to determine when the adhesive flow has completely or almost completely filled the interface. Additionally, as one of ordinary skill in the art can appreciate, adhesive volume and mass can be measured to determine if a complete fill has occurred. On completion of the adhesive application, the adhesive can be cured, thereby forming a joint between the two surfaces.
However, unlike the panel node joints 100 and 200 of
Under elevated temperatures, the adhesive, or adhesive patches, can foam up and cure, forming an adhesive bond at the interface 301. Bonds formed through such processes are typically stronger than liquid adhesive bonds, and less cumbersome. Additionally, the cure time for such adhesives is much lower in comparison with liquid adhesives.
The panel 402 and the component 404 can have different or dissimilar thermal properties, including thermal expansion properties. A measure of thermal expansion in materials is a coefficient of thermal expansion (CTE) which can have units of inverse temperature. When a coefficient of thermal expansion (CTE) of the panel 402 is different or mismatched from a CTE of the component 404, there can be a thermal stress or loading between the panel 402 and the component 404 during a heating or curing cycle.
A way to mitigate the thermal stresses during the heating cycle is to use temperature groups as illustrated in
Although,
In other embodiments, thermal heat conductors can be placed on a component, such as component 404 of
In some embodiments, copper (Cu) wires can be co-printed with a component, node, and/or extrusion. Additionally, a heat pad made of iron can be co-printed for transferring heat. This can enable Cu wires to locally transfer heat to a film foam adhesive or adhesive patch directly; and in this way the effects of CTE mismatch between metal nodes and composite panels can be mitigated when the entire assembly is heated.
In the embodiment of
Steps 517, 519 or other recessed areas can be provided at the end of the node segments 504 and 505 where the extrusion 506 can be inserted. Similarly, the extrusion 506 can have an internal socket 521 or channel to enable fitment of the panel 502. The panel 502 can then be attached to the node segments 504 and 505 via a step-down feature to enable the node-panel attachment at interface locations 514 and 515.
As discussed above with respect to
Prior to assembly, a hole can be drilled on the panel 802. A clamping feature, clamp 806, can be printed with the node, such that it goes through the hole (not shown in
The modular injector 1112 advantageously allows for adhesive to be selectively injected into different regions and/or certain pockets along the node 1102 and panel 1104 interface. The modular injector 1112 can also be configured to provide a seal at the location of liquid adhesive flow.
Although
The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other techniques for printing and joining panels, nodes, and/or extrusions with various interconnects (interconnect units). Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
