CN110719837B - 互连的可偏转板件和节点及其制造方法 - Google Patents

互连的可偏转板件和节点及其制造方法 Download PDF

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CN110719837B
CN110719837B CN201880038277.XA CN201880038277A CN110719837B CN 110719837 B CN110719837 B CN 110719837B CN 201880038277 A CN201880038277 A CN 201880038277A CN 110719837 B CN110719837 B CN 110719837B
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约翰·拉塞尔·巴克内尔
亚哈·纳吉·艾尔·那加
安东尼奥·伯纳德·马丁内斯
斯图亚特·保罗·梅西
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Abstract

本公开的一些实施例涉及一种包括具有插槽的增材制造的节点的设备。该设备包括与节点互连的板件。该板件包括相对的表面层和表面层的至少一部分之间的芯部。插槽接合板件的端部部分，并使板件的端部部分上的表面层成形。

Description

互连的可偏转板件和节点及其制造方法
相关申请的交叉引用
本申请要求于2017年6月7日提交的题为“互连的可偏转板件和节点及其制造方法(AN INTERCONNECTED DEFLECTABLE PANEL AND NODE AND METHODS FOR PRODUCINGSAME)”的美国专利申请No.15/616,620号的权益，其明确地通过引用整体并入本文中。
技术领域
本公开总体上涉及用于将板件互连到节点的技术，更具体地涉及用于打印具有锥形插槽的节点以及通过使板件变形以与锥形节点的形状一致来互连板件的增材制造技术。
背景技术
增材制造(AM)过程包括一种或更多种材料的逐层堆积，以制造三维物体。AM技术能够通过多种材料制造复杂的部件。通常，独立式物体是由计算机辅助设计(CAD)模型制造的。使用CAD模型，AM过程可以通过使用激光束烧结或熔化粉末材料(然后将粉末颗粒结合在一起)来创建实体三维物体。在AM过程中，不同的材料或材料的组合，比如工程塑料、热塑性弹性体、金属和陶瓷，可以用于创建独特形状的三维物体。
存在若干不同的打印技术。一种这样的技术被称为选择性激光熔化。选择性激光熔化涉及在低于粉末材料的熔点的温度下熔融(凝聚)粉末的颗粒。更具体而言，激光扫描粉末床并在期望结构的位置使粉末熔化在一起，并避免扫描切片数据指示不打印任何东西的区域。该过程可以重复数千次，直到形成期望的结构，在此之后由制作者移除打印零件。
随着AM过程继续改进，更复杂的机械制造商开始研究在他们的设计中使用增材制造的零件的益处。这是因为，以低成本实现高效和有效的制造过程是许多行业制造部门的永恒目标。例如，汽车工业、飞机制造和涉及运输结构的组装的其它行业一直在致力于成本节约优化，并寻找改善制造过程的机会。将具有各种形状的部件结合在一起是这样一个被证明难以优化的领域。例如，常规的制造过程提供简单的内部几何形状，比如没有附加特征的矩形。这些简单的内部结构限制了可以被互连的部件的构造。因此，这种制造过程的实际范围有限，因为它们不能有效地用于生产具有提供新的和不同的特征及能力的潜力的复杂几何结构。
三维打印或AM过程的最新进展为以相对有竞争力的成本构建各种各样的简单到非常复杂的零件提供了新的机会。使用AM，可以打印具有独特内部结构的部件，这在结合部件时可以提供更多选择。然而，这些独特的形状对能够变形以适配更复杂内部结构的形状的结合部件提出了一系列新的独特挑战。例如，插槽连接需要内部适配，而这种内部适配对于常规制造厂的焊工而言在外部是看不到的。因此，难以将具有独特内部结构的插槽部件结合至可变形部件。
发明内容
下文将参考三维打印技术更全面地描述用于将增材制造的节点结合至部件的技术的若干方面。
该设备的一个方面包括具有插槽的增材制造的节点。该设备包括与节点互连的板件。该板件包括相对的表面层和表面层的至少一部分之间的芯部。插槽接合板件的端部部分，并使板件的端部部分上的表面层成形。
一种方法的一个方面包括通过增材制造打印具有插槽的节点。该方法将板件与节点互连。该板件包括相对的表面层和表面层的至少一部分之间的芯部。该方法使插槽与板件的端部部分接合。通过插槽，该方法使板件的端部部分上的表面层成形。
应该明白的是，根据以下详细描述，具有增材制造的节点共同打印互连件的其它方面对于本领域技术人员来说将变得显而易见，其中仅通过图示示出并描述了几个实施例。如本领域技术人员将意识到的是，具有增材制造的节点的共同打印互连件能够具有其它和不同的实施例，并且其若干细节能够在各种其它方面进行修改，所有这些都不背离本发明。相应地，附图和详细描述本质上被认为是示例性的而不是限制性的。
附图说明
现在将在附图中通过示例而非限制的方式在详细描述中呈现具有增材制造的节点的共同打印互连件的各个方面，其中：
图1示出了包括节点和与该节点互连的板件的设备的示例性实施例。
图2A-2B示出了包括通过使锥形插槽变窄而接合的板件和节点的设备的示例性实施例。
图3A-3C示出了包括通过使锥形插槽加宽而接合的板件和节点的设备的示例性实施例。
图4示出了具有节点的设备的示例性实施例，该节点具有被设计成使板件在插入到节点中时成锥形的增材制造的特征。
图5概念性地示出了用于在将板件与节点结合时采用共同打印的内部特征的过程500。
具体实施方式
以下结合附图阐述的详细描述旨在提供用于共同打印的节点和互连件的增材制造的技术的各种示例性实施例的描述，而并不旨在表示可以实践本发明的仅有实施例。贯穿本公开使用的术语“示例性”意指“用作示例、实例或图示”，并且并不一定被解释为优选或优于本公开中提供的其它实施例。详细描述包括便于提供向本领域技术人员充分传达本发明的范围的详尽和完整的公开内容的具体细节。然而，可以在没有这些具体细节的情况下实践本发明。在一些情况下，公知的结构和部件可以以方框图形式示出，或者完全省略，以便避免模糊贯穿本公开提供的各种构思。
在结合两个或两个以上零件的背景下使用增材制造提供了显著的灵活性和成本节约益处，这允许机械结构和机械化组件的制造商以较低的成本给消费者制造具有复杂几何结构的零件。前面描述的结合技术涉及用于结合增材制造的零件和/或商用现货(COTS)部件(比如板件)的过程。增材制造的零件通过基于预编程设计将层添加到材料的层上来三维打印。前面描述的零件可以是用于组装机动交通工具(比如汽车)的零件。然而，本领域的技术人员应理解的是，所制造的零件可以用于组装其它复杂的机械产品，比如交通工具、卡车、火车、摩托车、船、飞机等，而不背离本发明的范围。
这些行业中遇到的一个重要问题是如何使各种不同的零件或结构更有效地互连。这里公开的一种这样的技术包括使用增材制造。更具体而言，通过采用增材制造技术来打印独特的零件，使得在制造过程中结合不同的零件和/或部件变得更简单。这种技术可以包括使一个零件的一部分变形以与另一零件的内部形状一致。增材制造提供了创建复杂内部形状的能力，在以前使用常规制造技术来创建复杂内部形状是不可能的。例如，具有在其间带有凹口的端部部分的可变形板件可以插入到具有独特锥形形状的节点中。在结合过程中，板件的端部部分可以变形为节点的内部形状，这在现在的互连的部件之间产生了更强和更简单的结合。
如这里将要讨论的，节点是增材制造的零件的示例。节点可以是任何3-D打印零件，其包括用于接收诸如板件的部件的插槽。该节点可以具有被构造成接收特定类型部件的内部特征。这些特征可以与节点一起被共同打印。替代地或联合地，节点可以成形为接收特定类型的部件。例如，节点的内部形状可以成锥形或扩张，以使可偏转板件根据节点的内部插槽的形状而变形，然后接收粘合剂以将部件粘附到节点。然而，如本领域普通技术人员将理解的，节点可以成形为接收任何类型的部件，并且采用任何内部设计或形状，并且接收任何种类的部件，而不背离本公开的范围。
图1示出了包括节点和与该节点互连的板件的设备100的示例性实施例。在设备的一些实施例中，板件可以包括可偏转板件。如图所示，设备100包括节点105、板件110和注入端口155、插槽115和插槽开口190。板件110包括表面层140、芯部145和端部部分150。端部部分150包括填充材料125。填充材料可以是可交联聚合物，比如环氧树脂或液体粘合剂。在该设备的一些方面，端部部分150还可以包括填充材料125中的微球囊120。在该设备的一些方面，相对的表面层140可以是碳纤维片。芯部145的至少一部分可以从表面层140之间移除。在该设备的一些方面，端部部分150可以没有芯部145。因此，填充材料125可以被注入到表面层140之间的端部部分150附近的可用区域。填充材料125可以通过注入端口155注入。微球囊120可以用于使填充材料125较不致密，而不损害结构完整性，从而其可以如图1中所示被压缩。例如，微球囊可以结合到诸如环氧树脂的材料中，以形成较不致密的浆料，该浆料可以根据需要变形或压缩。然而，液体粘合剂或任何合适的可固化和可延展的物质可以被用作图1中所示的填充材料125。
表面层140可以夹置有芯部材料145，比如蜂窝状材料或泡沫。芯部145可以保持在表面层140的至少一部分之间，至少直到板件110结合到节点105。为了结合节点105和板件110，板件110的表面层140的端部部分150可以被压缩和变形，以在其滑动通过插槽开口190时适配到插槽115中。如图所示，随着与插槽开口190的距离增加，插槽115内的锥度增加，或插槽变窄。变窄的插槽致使板件110压缩。因此，板件110的端部部分125可以抵靠节点105压缩，使得板件110适配到插槽115中。在该设备的一些方面，密封剂和/或粘合剂可以随后注入到插槽115中，以将板件110以变形构造固定到节点105。沿插槽115的凹口可以为密封剂和/或粘合剂提供路径，但是对于有效地结合板件110和节点105不是必需的。
图2A示出了包括通过变窄的锥形插槽接合的板件210和节点205的设备200的示例性实施例。类似于图1的板件110，板件210可以是能够通过扩张或压缩而变形的可偏转板件。如图所示，板件210包括凹口215、表面层240和芯部245。节点205包括具有粘合剂层220的插槽295和插槽开口290。图2B示出了包括与节点205互连的板件210的设备200。在该设备的一些方面，板件210可以通过插槽开口290插入到节点205的插槽295中。如图所示，类似于图1，插槽295包括锥形部分，该锥形部分随着与插槽开口290的距离增加而变窄。当板件210被插入时，凹口215可以被锥形部分压缩，使得板件210的包围凹口215的端部部分与节点205的形状一致。另外，如本领域技术人员将理解的，节点和板件之间的接口可以类似于图1中所示的插槽130接口，而不背离本公开的范围。
表面层240可以包括轻质坚固材料，比如复合材料。这种复合材料可以包括碳纤维。复合材料可以具有比芯部材料更大的柔性，这可以通过降低芯部245的刚度来实现。表面板件240的柔性能够使得板件210的插入到节点205中的端部部分变得可延展并与节点插槽295的形状一致，以形成牢固结合。如前所述，节点可以被构造成使表面板件符合许多不同的形状和布置。
此外，粘合剂层220然后可以包围板件210的被封闭在节点205内的部分。在该设备的一些方面，粘合剂层220是薄膜泡沫粘合剂。在这些方面，薄膜泡沫粘合剂比液体粘合剂更硬，比液体粘合剂固化更快，并且提供比液体粘合剂更牢固的结合。粘合剂层220可以固化以将互连板件210与节点205固定在一起。外部热源，比如烤箱，可以向板件/节点连接施加热量，并使粘合剂层220固化。如将在下面论述的，在将板件210插入节点205之前，可以将粘合剂施加到板件210。
图3A-3C示出了包括通过加宽的锥形插槽接合的板件310和节点305的设备300的示例性实施例。图3A示出了结合之前的节点和互连板件，而图3B和3C示出了结合节点和板件的以下步骤。图3A-3C包括设备300。设备300包括节点305和板件310。类似于板件110和210，板件310包括表面层340和芯部345。板件310还包括可变形边缘335和凹口315。芯部的一部分可以被切除以形成凹口。凹口内部是预先施加的粘合剂325，其在被加热时可以发泡和/或分散。节点305进一步包括插槽330和插槽开口390。
如图3A中所示，凹口315可以形成在芯部345中。在该设备的一些实施例中，芯部345的至少一部分被移除。在该设备的一些方面，粘合剂325可以使用外部源加热。当粘合剂325的温度达到特定点时，粘合剂可以开始发泡并扩张到插槽330中。粘合剂325可以在将板件310插入节点305之前被施加到板件310。
如图3B中所示，随着粘合剂325开始发泡，它开始填充节点305的插槽330。随着粘合剂325继续发泡，它可能致使板件310扩张，如图3C中所示。因此，与图2的设备200相比，插槽330可以包括锥形部分，该锥形部分随着与插槽开口390的距离而加宽。因此，可变形边缘和凹口335可以扩张，从而导致凹口315加宽。在这些方面，板件310的可变形边缘335可以由于粘合剂325的作用而扩张，以与节点305的插槽330的几何结构一致。如上所述，可变形端部335的表面层340可以比芯部345具有更大的柔性或可压缩性，这是因为芯部的刚度被凹口315降低了。因此，插槽330根据插槽330的形状使凹口315扩张，这与具有适配图2中的锥形插槽的柔性的板件形成对比。
在以上示例中，粘合剂可以是薄膜泡沫粘合剂。然而，在该设备的一些方面，粘合剂325可以是液体粘合剂。使用液体粘合剂可能需要额外的材料和制造时间。例如，当使用液体粘合剂时，可以在芯部345中的凹口315和预施加的粘合剂325之间施加衬里。衬里用于防止粘合剂移动到芯部345中。例如，因为芯部345通常由具有蜂窝状结构的材料制成，因此在没有衬里的情况下，液体粘合剂可能渗入到芯部的蜂窝状结构的孔中。
另外，密封剂可能是将粘合剂325密封到节点305所必需的。因此，当将节点305与板件310互连时，密封剂可以预先施加到节点插槽330的至少一个内侧上。没有密封剂的情况下，在粘合剂325固化后，插槽330和板件310之间可能不会形成适当的密封。
然后，类似于上面的示例，热量可以被施加到该设备。当温度通过热量而升高时，密封剂可能首先开始发泡，以便在插槽330的边缘周围形成密封。粘合剂325可能随后发泡，以填充板件310和密封剂之间的腔体。在该设备的一些方面，密封剂可以在比粘合剂330更低的温度下发泡。在这些方面，在互连过程期间，热量可以施加到节点305和板件310。随着温度升高，密封剂会首先发泡。可以施加热量，使得密封剂在温度达到粘合剂325的发泡点之前有足够的时间部分或全部固化。在粘合剂325填充插槽330内的密封剂与板件310之间的腔体之后，温度可以保持在允许粘合剂325固化并将节点305和板件310结合在一起的点处，同时还密封节点305和板件310之间的接口。热量可以从外部热源施加到设备300。
替代地，当使用薄膜泡沫粘合剂时，如以上论述的，施加密封剂对于在节点305和粘合剂325之间形成密封可能是不必要的，因为薄膜泡沫粘合剂能够自身形成密封。因此，结合时间减少。因此，当需要更快的结合时间时，使用薄膜泡沫粘合剂可能是重要的，以便绕过施加密封剂的步骤，从而可以实现更快的结合时间。另外，在该设备的一些方面，增材制造的特征可以在节点305中打印，其中节点305用作锥形机构，使得板件310可以在粘合剂325流动穿过节点插槽之前偏转。下图示出了具有这种打印特征的节点。
图4示出了具有节点的设备400的示例性实施例，该节点具有被构造成使板件在插入到节点中时成锥形的增材制造的特征。如图所示，设备400包括节点405、板件410和粘合剂425。节点405包括锥形特征455、插槽495和插槽开口490。板件410包括芯部445和表面层440。如图所示，板件410表面层440的一部分415没有芯部。
如以上讨论的，锥形特征455随着距插槽开口490的距离而扩张。锥形特征455被构造成当板件410被插入节点405中时并且在粘合剂流动穿过插槽495之前，使得表面层440的一部分415(其间没有芯部445的情况下)变形或成锥形。如图所示，表面层440可以与锥形特征455的形状一致。不同于常规制造技术，比如焊接，增材制造技术允许锥形特征在节点内部被共同打印。用常规制造技术在结构内部添加这类特征通常是困难的。另外，图4中示出的锥形特征455仅是可以与节点共同打印的特征的示例性图示，以根据锥形特征的几何结构使板件或其它部件成形。事实上，在不背离本公开的范围的情况下，可以采用被构造成接收部件或部件的一部分(例如，板件的表面层)的任何共同打印的特征来增加可定制性。
因此，增材制造技术允许在将板件固连到节点之前使比如板件等部件先于共同打印特征变形或偏转。偏转允许更强和更可定制的互连，这是以前无法实现的。更强的互连有利于可能处于很大的应力的高度复杂的制造结构，比如陆地、海洋和空中交通工具。然而，本领域普通技术人员将会理解，上述技术可适用于需要强粘附力和/或更快结合时间的任何结构或制造过程。
图5概念性地示出了在将板件与节点结合时采用共同打印的内部特征的过程500。板件可以是可偏转板件，其被构造成通过降低板件的表面层之间的芯部材料的刚度而具有更大的柔性。过程500可以由机械装置来执行。当提供了增材制造零件的指令时，过程500开始。过程500可以结合上面参照图1-4讨论的设备100、200、300和400来执行。
在505处，过程500通过增材制造打印具有插槽的节点。过程500将板件与节点互连(在510处)。板件可以包括相对的表面层和表面层的至少一部分之间的芯部。如以上讨论的，该芯部的至少一部分可以在结合过程中被移除。过程500使插槽与板件的端部部分接合(在515处)。在使插槽与端部部分接合之后，过程500基于插槽的形状使板件的端部部分上的表面层成形(在520处)。例如，如图1和2中所示，板件的可偏转的端部部分可以具有足够的柔性来压缩并适配到锥形节点插槽中。这可以通过降低芯部的刚度来实现。相反，如图3和4中所示，例如，可偏转端部可以具有柔性以扩张并适配到更宽的插槽中。类似地，这可以通过从扩张的端部移除芯部的至少一部分来实现，这降低了芯部的刚度。
增材制造节点的能力创造了使部件(比如板件)成形以提供更强互连的机会。通过使板件的端部成锥形或扩张，可以实现用于结合节点和板件的更简单和更有成本效益的方案。增材制造提供了生成具有几何特征(否则使用常规制造技术是不可能的)的零件的能力。
提供之前的描述是为了使任何本领域技术人员能够实践本文描述的各个方面。贯穿本公开呈现的对这些示例性实施例的各种变型对于本领域技术人员而言将是显而易见的，并且本文公开的构思可以应用至用于打印节点和互连件的其它技术。因此，权利要求书并不旨在限于贯穿本公开呈现的示例性实施例，而是要符合与语言权利要求一致的全部范围。贯穿本公开所描述的示例性实施例的元件的对于本领域的普通技术人员而言是已知的或后来将是已知的所有结构和功能等同方案均旨在被权利要求书所包含。另外，本文公开的任何内容都不旨在贡献给公众，不管这种公开是否在权利要求书中明确记载。权利要求元素不得根据35 U.S.C.§112(f)的规定或可适用权限中的类似法律来解释，除非元素使用短语“用于...的机构”明确记载，或者在方法权利要求的情况下，元素使用短语“用于...的步骤”记载。

Claims (17)

1.一种用于将板件与节点互连的设备，所述设备包括：
具有插槽的增材制造的节点；以及
与所述节点互连的板件，所述板件包括相对的表面层和在所述表面层的至少一部分之间的芯部，其中所述板件的端部部分扩张到所述插槽的内部形状中，
其中所述插槽包括锥形特征，该锥形特征接合所述板件的端部部分并响应于所述板件的端部部分在所述插槽中的插入而使所述板件的端部部分上的相对的表面层从第一相对间隔距离成形到第二相对间隔距离，并且其中所述第二相对间隔距离大于所述第一相对间隔距离。
2.根据权利要求1所述的设备，其中，所述板件的端部部分上的表面层在它们之间没有所述芯部的至少一部分。
3.根据权利要求2所述的设备，其中，相对的表面层进一步包括在所述板件的端部部分上的表面层之间的材料，该材料比所述芯部具有更大的柔性。
4.根据权利要求2所述的设备，其中，所述板件进一步包括粘合剂填充材料，该粘合剂填充材料包括在所述板件的端部部分上的表面层之间的多个微球囊。
5.根据权利要求1所述的设备，其中，所述芯部的一部分在所述板件的端部部分的表面层之间延伸，并且其中所述芯部的该部分包括凹口。
6.根据权利要求5所述的设备，其中，粘合剂从所述凹口延伸到所述插槽中。
7.根据权利要求6所述的设备，进一步包括密封剂，所述密封剂在所述板件与所述插槽之间以将所述粘合剂密封在所述插槽中。
8.根据权利要求5所述的设备，其中，所述插槽包括锥形部分，该锥形部分随着距所述插槽开口的距离增加而变宽，并且其中所述凹口随着所述锥形部分而被扩张。
9.一种用于将板件与节点互连的方法，其特征在于，包括：
通过增材制造打印具有插槽的节点；
将板件与所述节点互连，该板件包括在第一相对间隔距离处的相对的表面层和在所述表面层的至少一部分之间的芯部；
将所述插槽的锥形特征与所述板件的端部部分接合，该锥形特征被构造成响应于所述板件的端部部分与所述插槽的接合而使所述板件的端部部分上的相对的表面层从第一相对间隔距离移动到第二相对间隔距离，其中所述第二相对间隔距离大于所述第一相对间隔距离；以及
通过所述插槽，使所述板件的端部部分上的相对的表面层成形到第二相对间隔距离。
10.根据权利要求9所述的方法，进一步包括：移除所述板件的端部部分上的表面层的至少一部分之间的芯部。
11.根据权利要求10所述的方法，进一步包括：在所述板件的端部部分上的表面层之间注入材料，其中该材料具有比所述芯部更大的可压缩性。
12.根据权利要求10所述的方法，进一步包括：在所述板件的端部部分上的表面层之间注入多个微球囊。
13.根据权利要求9所述的方法，其中，所述芯部的一部分在所述板件的端部部分上的表面层之间延伸，并且该方法进一步包括在所述芯部的一部分中切割凹口。
14.根据权利要求13所述的方法，进一步包括：预注入粘合剂，所述粘合剂从所述凹口延伸到所述插槽中。
15.根据权利要求14所述的方法，进一步包括：
向密封剂施加热量；以及
使所述密封剂在所述板件和所述插槽周围扩张，以将所述粘合剂密封在所述插槽中。
16.根据权利要求13所述的方法，其中，所述插槽包括锥形部分，该锥形部分随着距所述插槽开口的距离增加而变宽，该方法进一步包括通过所述锥形部分使所述凹口扩张。
17.根据权利要求16所述的方法，其中，使所述板件的端部部分上的表面层成形进一步包括在所述插槽中使用发泡粘合剂。
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