Patent Application
20190063476
The present disclosure relates generally to techniques for joining tubes to parts in transport structures, and more specifically to joining tubes to parts using additively manufactured parts and techniques.
Recently three-dimensional (3D) printing, also referred to as additive manufacturing, has presented new opportunities to efficiently build 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 classified as a green technology.
Transport vehicles may require a chassis or frame including tubes, extrusions, panels, and the like; additionally, some of the parts may not have been previously available in traditional manufacturing processes. Thus, for this and a variety of reasons, conventional techniques for joining parts, such as welding, may not be a viable alternative for use with some of the new parts. Accordingly, there is a need to discover and develop new ways to join tubes in transport structures using additively manufactured parts and techniques.
Several aspects of techniques for joining tubes to parts will be described more fully hereinafter with reference to three-dimensional (3D) printing techniques.
In one aspect an apparatus comprises a part, a node, and first and second tubes. The node comprises a first portion attached to the part and a second portion having a socket; and the first and second tubes extend from the socket along non-parallel axes.
The part can be additively manufactured. The node can be additively manufactured; and at least one of the first and second tubes can be additively manufactured. Additionally, the part can be an extrusion, and the extrusion can be hollow.
The apparatus can further comprise a wedge. The wedge can be between the first and second tubes to secure the first and second tubes to the socket. The wedge can be removable. The wedge can be additively manufactured. Also, the wedge can be tapered. At least one spacer can be inserted between the first and second tubes and the socket. The at least one spacer can separate a surface of the first and second tubes and a surface of the socket. The surface of the first and second tubes can be separated from the surface of the socket so as to reduce galvanic corrosion.
The wedge can comprise opposing concave surfaces. Each of the concave surfaces can be engaged with a different one of the first and second tubes. The wedge can be attached to the socket via an adhesive. The apparatus can comprise at least one seal, and the at least one seal can be configured to reduce galvanic corrosion. Additionally, the wedge can be attached to the socket via a fastener; and the fastener can be a blind fastener.
In another aspect a method of securing tubes to a part using a node having a socket comprises attaching the node to the part and inserting first and second tubes into the socket along nonparallel axis.
The part can be additively manufactured. Also, the part can be an extrusion, and the extrusion can be hollow.
At least one of the first and second tubes can be additively manufactured. Also, the node can be additively manufactured to extend from a surface of the part. Additionally, the surface can be flat.
The method can further comprise inserting a wedge between the first and second tubes to secure the first and second tubes to the socket. The wedge can be removable. The wedge can be additively manufactured. Also, the wedge can be tapered.
The method can comprise inserting at least one spacer between the first and second tubes and the socket. The at least one spacer can form a gap between a surface of the first and second tubes and a surface of the socket. The at least one spacer can form the gap between the surface of the first and second tubes and the surface of the socket so as to reduce galvanic corrosion.
Additionally, the wedge can comprise concave surfaces; and the step of inserting the first and second tubes into socket can comprise inserting the first tube between one of the concave surfaces and the socket. Also, the step of inserting the first and second tubes into the socket can comprise inserting the second tube between the other one of the concave surfaces and the socket.
The step of inserting the wedge can comprise securing the first and second tubes to the socket using an adhesive. Securing the first and second tubes to the socket using an adhesive can comprise forming at least one seal, and the at least one seal can reduce galvanic corrosion. The step of inserting the wedge can also comprise securing the first and second tubes to the socket using a fastener. Also, the fastener can be a blind fastener.
Different parts may be used that were not previously available for constructing frames and chassis in traditional manufacturing processes. It will be understood that other aspects of joining tubes to parts 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 tubes and parts using additively manufactured nodes, components, and/or parts 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 tubes to extrusions 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 tubes to parts 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 (AM) parts and/or commercial off the shelf (COTS) components. Additively manufactured (AM) parts are printed three-dimensional (3D) parts that are printed by adding layer upon layer of a material based on a preprogrammed design; and COTS components may include aluminum manufactured extrusions and tubes. In the foregoing both COTS components and AM parts may be referred to simply as parts.
Parts described in the foregoing may include extrusions. Extrusions find use in many applications including automotive manufacturing applications. For instance, extrusions may be used in an automobile frame, roofing, and sunroof. A way to join additional parts, such as tubes, with an extrusion can include attaching, via an additively manufacturing technique, a node to the extrusion and then using a node socket for connecting the additional parts.
Additive manufacturing techniques can advantageously simplify the joining of different parts and/or components. Additive manufacturing also provides the ability to create complex structures within a part and to secure the part. For example, a node may be printed with a port or socket that enables the ability to secure two or more parts using non-traditional methods. Additionally, parts may be secured by injecting an adhesive rather than by welding them together, as is traditionally done in manufacturing complex products. Alternatively, and additionally, 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.
Accordingly, there is a need to develop non-traditional alternatives and additional connection techniques for both AM parts and COTS components, including tubes, nodes, and/or extrusions. It can be advantageous to develop new ways to join parts together during the manufacturing process; and joining tubes to parts may incorporate one or more factors such as materials, structure, design, and/or connecting features.
Apparatus and methods for joining tubes in transport structures are presented herein. A part having an attached node with a socket can be joined with tubes. The tubes can be placed along nonparallel axes within the socket; and a wedge can be used to secure the tubes to the socket. The wedge can be secured between the tubes by using a fastener, such as a blind fastener; alternatively, or additionally, the wedge can be secured between the tubes using an adhesive.
Although the side perspective view 100a shows part 140 as having a flat surface, other surface geometries are possible. For instance, the node 102 may extend from a non-flat and/or non-uniform surface of a part; thus, the concept of joining nodes to parts can apply to any part where a node and/or a node socket may be attached.
Additionally, the wedge 108 can be attached to the node 102 and/or to the part 140 via a fastener (see
Additionally, some or all of the parts including the tubes 104 and 106, the extrusion 150, the node 102, and the wedge 108 can be additively manufactured (AM) parts. For instance, in one embodiment the node 102, the wedge 108, and the extrusion 150 can be AM parts while the tubes 104 and 106 can be COTS components.
In addition to having a collet feature, the wedge 108 is shown to have a top recessed feature 209. Within the recessed feature 209 there is an opening 223 which can accept a fastener 222. The fastener 222 may be used to fasten the wedge 108 to the node 102 so as to secure and/or clamp the tubes 104 and 106 within a socket of the node 102. An example of a fastener 222 can be a blind rivet which may be inserted through the opening 223 and secured to a lower portion of the node 102 (not shown). Alternatively, the fastener 222 can be a screw-type nut and bolt fastener which allows for easy removal. Having a removable fastener 222 can advantageously allow one to make repairs without having to replace or remanufacture parts.
As shown in the cross sectional view 300, a tube 304 and tube 306 are inserted within the node socket so that each has a surface in contact with an edge of the node socket. For instance, as shown in
A fastener 310 may be used to fasten the wedge 308 to the node 302. The fastener 310 is shown to have a top 322, a bottom 324 and a bolt feature 320. Also, as shown the bottom 324 extends through the node socket into a solid portion of the node 302 so as to fasten the wedge 308 to the node 302. Additional fastener features are possible. For instance, the fastener can have rivet and clamping features. The fastener 310 can be a blind fastener and/or the fastener 310 can be a removable fastener.
Seals can advantageously improve a vacuum and enhance quality. For instance, a seal formed by sealants placed in seal grooves 441, 443, and 452 can be connected to a vacuum and evacuated; this in turn can enhance the drawing and injection of the adhesive when the adhesive is connected to an adhesive injector. The seals additionally can prevent galvanic corrosion between dissimilar materials by preventing surface to surface contact.
As shown in
In the embodiment of
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 tubes, 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.”
