HK40011003A - Methods and apparatus for forming node to panel joints - Google Patents

Description

Method and apparatus for forming a node-panel joint

Technical Field

The present disclosure relates to a transport structure such as an automobile, a truck, a train, a ship, an airplane, a motorcycle, a subway system, or the like, and more particularly, to a technique for forming a node-panel connection structure in a transport structure.

Background

Transportation structures such as automobiles, trucks or airplanes employ a large number of interior and exterior panels. These panels provide structure for automobiles, trucks, and airplanes, and respond appropriately to many different types of forces generated or created by various actions such as acceleration and braking. These panels also provide support. They provide a support for positioning the floor of the seat and for securing large and heavy components. The panel participates in providing key suspension characteristics to the vehicle. Uniquely shaped panels provide special aerodynamic properties for both high performance automobiles and aircraft. Interior door panels and instrument panels may provide important functions and protect occupants during a collision event. The panels are an integral part of the transport structure.

Most panels must be coupled to or securely engaged with other panels or other structures in a safe, well-designed manner. These connection types may be implemented using dedicated joint members (joint members) or nodes (nodes). These joint members or nodes are not only used to attach, join, and secure the panel itself, but they may also be used to couple the panel to other critical components of the automobile (e.g., another panel, extrusion, pipe, other node, etc.) or perform a separate function. Transport structures often use various types of node-panel joints to enable panels to engage other structures and perform the functions described above.

The design and manufacture of these node-panel joint structures is somewhat problematic because joints are often specialized structures that require complex sub-structures for achieving a strong, durable, and durable bond with the panel. These types of complex structures are often extremely difficult to manufacture efficiently or inexpensively using conventional manufacturing processes. For example, machining can produce high precision parts with such levels of detail, but at a high cost. Casting and other methods are not possible to produce the same level of precision required for such panel applications. In addition, due to the above manufacturing limitations, conventional joints for connecting panels are typically unnecessarily bulky and made of heavier materials. Needless to say, the large and heavy structures in the vehicle create geometric design constraints and are inefficient. Furthermore, in situations where different materials are to be joined or otherwise used together, as is often the case in various structural applications, efficient joining techniques using conventional manufacturing processes are complex and often difficult to achieve. Over time, the resulting connection components may be subject to corrosion and other problems.

In short, a more efficient, lighter node design with greater complexity and superior capabilities is needed to interface with the panel to achieve potentially high performance applications at manageable price points.

Disclosure of Invention

Nodes for joining with panels in a transport structure and additive manufacturing thereof will be described more fully below with reference to various illustrative aspects of the disclosure.

In one aspect of the disclosure, a node comprises: a base; a first side and a second side projecting from the base to form a recess for receiving a panel; a first port and a second port; one or more adhesive regions disposed on a surface adjacent each side of the panel; and at least one channel coupled between the first port and the second port and configured to fill an adhesive area with an adhesive that is cured to form a node-panel joint.

In another aspect of the disclosure, a method comprises: an Additive Manufacturing (AM) node, the node comprising: a base; first and second side portions projecting from the base to form a panel recess; a first port and a second port; one or more adhesive zones disposed on the inner surface of each side portion; and at least one channel coupled between (i) the first port, (ii) each of the one or more adhesive regions, and (iii) the second port; and inserting a sealing filler around each of the one or more adhesive regions.

It is understood that other aspects of the node for engaging with panels in a transport structure and its manufacture will be apparent to those skilled in the art from the following detailed description, wherein several embodiments are shown and described, simply by way of illustration. As will be realized by those skilled in the art, the disclosed subject matter is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

Drawings

Various aspects of a node for engaging with panels in a transport structure and its manufacture will now be presented in the detailed description by way of example and not limitation in the accompanying drawings, in which:

FIG. 1 illustrates an exemplary embodiment of certain aspects of a Direct Metal Deposition (DMD)3-D printer.

FIG. 2 shows a conceptual flow diagram of a 3-D printing process using a 3-D printer.

Fig. 3A-3D illustrate an exemplary Powder Bed Fusion (PBF) system during different stages of operation.

Fig. 4A is a perspective front view of a node-panel joint.

Fig. 4B is a perspective rear view of a node-panel joint.

Fig. 4C is a perspective side view of a node-panel joint.

A in fig. 5 is a cross-sectional view of an exemplary seal packing region including different features for receiving a seal packing.

B in fig. 5 is a cross-sectional view of an exemplary adhesive region bounded by a seal filler inserted into the seal filler region.

Fig. 6A-6C are conceptual block diagrams of alternative exemplary connections in a node-panel joint.

Fig. 7 is a flow chart of an exemplary method of additive manufacturing a node-panel joint.

Fig. 8A-8B are perspective views of a pad used in a node.

Detailed Description

The detailed description set forth below in connection with the appended drawings is intended to provide a description of various exemplary embodiments and is not intended to represent the only embodiments in which the present 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 to provide a thorough and complete disclosure that will fully convey 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. Additionally, the drawings may not be to scale, but may be drawn in a manner that is intended to most effectively highlight various features that are relevant to the described subject matter.

The present disclosure relates generally to the assembly and use of node-panel joints in vehicles and other transportation structures. In many cases, the nodes, panels, and other structures described in this disclosure can be formed using Additive Manufacturing (AM) techniques (due in part to the myriad of advantages of additive manufacturing as described below). Accordingly, certain exemplary additive manufacturing techniques that may be associated with the formation of the nodes or panels described herein will first be discussed. However, it should be understood that many alternative manufacturing techniques (both additive and conventional) may alternatively be used to implement the node-panel joints disclosed herein (in part or in whole), and that the determined node-panel joints need not be limited to the specific AM techniques below.

Manufacturers of node-panel joints that benefit from the present invention include manufacturers that make almost any mechanized transportation form, which typically rely heavily on complex and labor-intensive machine tools and molding techniques, and whose products typically require the development of complex panels, nodes, and interconnects to integrate with complex machines such as internal combustion engines, transmissions, and increasingly complex electronics. Examples of such transport structures include trucks, trains, tractors, boats, planes, motorcycles, buses, and the like.

Additive manufacturing (3-D printing). Additive Manufacturing (AM) is advantageously a non-design specific manufacturing technique. AM provides the ability to form complex structures within a component. For example, the nodes may be generated using AM. A node is a structural member that may include one or more joints for connecting to other spanning components (spans) such as tubes, extrusions, panels, other nodes, and the like. Using additive manufacturing, the node may be configured to include additional features and functionality depending on the purpose. For example, a node may be printed with one or more ports that enable the node to secure two components by injecting an adhesive when manufacturing a complex product, rather than welding multiple parts together as is conventionally done. Alternatively, some components may be joined using brazing paste, thermoplastics, thermosets, or other joining features (any of which may be used interchangeably in place of adhesive). Thus, while welding techniques may be suitable for certain embodiments, additive manufacturing provides significant flexibility in allowing the use of alternative or additional connection techniques.

Various additive manufacturing techniques have been used for 3-D printed parts constructed from various types of materials. There are many technologies available and more are being developed. For example, directed Energy Deposition (ED) additive manufacturing systems use directed energy derived from a laser or electron beam to melt a metal. These systems utilize both powder and wire feeding. The filament feed system advantageously has a higher deposition rate than other significant additive manufacturing techniques. Single Pass Jetting (SPJ) combines two powder spreaders and a Single printing unit to spread the metal powder and print the structure in a Single pass, apparently without wasteful movement. As another example, electron beam additive manufacturing processes use electron beams to deposit metal via wire feedstock or sinter on powder beds in vacuum chambers. Single-pass jetting is another exemplary technique claimed by its developers to be much faster than conventional laser-based systems. Atomic Diffusion Additive Manufacturing (ADAM) is yet another recently developed technique in which parts are printed layer by layer using metal powders in plastic binders. After printing, the plastic adhesive is removed and the entire part is immediately sintered to the desired metal.

As described above, one of several such additive manufacturing techniques is DMD. Fig. 1 illustrates an exemplary embodiment of certain aspects of a DMD 3-D printer 100. DMD printer 100 uses a feed nozzle 102 that moves in a predetermined direction 120 to advance powder streams 104a and 104b into a laser beam 106, which laser beam 106 is directed toward a workpiece 112 that may be supported by a substrate. The feed nozzle may also include a mechanism for flowing a shielding gas 116 to shield the weld area from oxygen, water vapor, or other components.

The powdered metal is then fused by the laser 106 in the melt pool region 108, and the melt pool region 108 may then be bonded to the workpiece 112 as a region of deposited material 110. The dilution region 114 may include a region of the workpiece in which the deposited powder is integrated with local material of the workpiece. The feed nozzle 102 may be supported by a Computer Numerically Controlled (CNC) robot or gantry or other computer control mechanism. The feed nozzle 102 may be moved under computer control along the predetermined direction of the substrate a plurality of times until an initial layer of deposition material 110 is formed on the desired area of the workpiece 112. The feed nozzle 102 may then scan the area immediately above the previous layer to deposit successive layers until the desired structure is formed. In general, the feed nozzle 102 may be configured to move relative to all three axes, and in some cases, may rotate a predetermined amount about its own axis.

FIG. 2 is a flow chart 200 illustrating an exemplary process of 3-D printing. A data model of a desired 3-D object to be printed is rendered (render) (step 210). The data model is a virtual design of the 3-D object. Thus, the data model may reflect the geometric and structural features of the 3-D object, as well as its material composition. The data model may be formed using a variety of methods including CAE-based optimization, 3D modeling, photogrammetry software, and camera imaging. CAE-based optimization may include, for example, cloud-based optimization, fatigue analysis, linear or nonlinear Finite Element Analysis (FEA), and durability analysis.

The 3-D modeling software, in turn, may comprise one of many commercially available 3-D modeling software applications. The data model may be presented using a suitable computer-aided design (CAD) package (e.g., in STL format). STL is one example of a file format associated with commercially available stereolithography-based CAD software. The CAD program may be used to generate a data model of a 3-D object as an STL file. The STL file may then undergo processing by which errors in the file are determined and resolved.

After the error is resolved, the data model may be "sliced" by a software application called a slicer, thereby generating a set of instructions for 3-D printing the object, where the instructions are compatible and associated with the particular 3-D printing technology to be used (step 220). Many slicer programs are commercially available. Typically, the slicer program converts the data model into a series of individual layers representing thin slices (e.g., 100 microns thick) of the object to be printed, and a file containing printer-specific instructions for 3-D printing these successive individual layers to produce an actual 3-D printed representation of the data model.

The layers associated with the 3-D printer and associated printing instructions need not be planar or the same thickness. For example, in some embodiments, the layers in a 3-D printed structure may be non-planar and/or may vary in their respective thicknesses in one or more instances, depending on factors similar to the technical complexity and specific manufacturing objectives of the 3-D printing device, and so forth.

A common type of file used to slice data models into layers is the G-code file, which is a numerical control programming language that includes instructions for 3-D printing objects. The G-code file or other files that constitute the instructions are uploaded to the 3-D printer (step 230). Since the files containing these instructions are typically constructed to be operable with a particular 3-D printing process, it will be appreciated that many formats of instruction files are possible depending on the 3-D printing technology used.

In addition to the printing instructions indicating what to render and how to render the objects, the appropriate physical materials necessary for the 3-D printer to render the objects are loaded into the 3-D printer using any of a number of conventional and generally printer-specific methods (step 240). In DMD technology, for example, one or more metal powders may be selected for layering a structure with such metals or metal alloys. In Selective Laser Melting (SLM), Selective Laser Sintering (SLS) and other PBF-based additive manufacturing methods (see below), the material may be loaded as a powder into a chamber that feeds the powder to the build platform. Other techniques for loading the printed material may be used in accordance with the 3-D printer.

The material(s) are then used to print a corresponding data slice of the 3-D object based on the provided instructions (step 250). In 3-D printers that use laser sintering, the laser scans the powder bed and fuses the powder together at the desired structures, and avoids scanning areas where the slice data represents structures that do not need to be printed. This process may be repeated thousands of times until the desired structure is formed, after which the printed part is removed from the manufacturer. In fused deposition modeling, as described above, a part is printed by applying successive layers of a model and a support material to a substrate. In general, any suitable 3-D printing technique may be employed for purposes of this disclosure.

Another additive manufacturing technique includes powder-bed fusion ("PBF"). Similar to DMDs, PBFs form "builds" layer by layer. Each layer or "slice" is formed by depositing a layer of powder and exposing portions of the powder to an energy beam. An energy beam is applied to melt an area of the powder layer that coincides with a cross-section of a build piece in the layer. The melted powder cools and fuses to form a slice of the build. The process may be repeated to form the next slice of the build, and so on. Each layer is deposited on the previous layer. The resulting structure is a building element assembled piece by piece from the ground.

Fig. 3A-3D show respective side views of an exemplary PBF system 300 during different stages of operation. As noted above, the particular embodiment shown in fig. 3A-3D is one of many suitable examples of a PBF system employing the principles of the present disclosure. It should also be noted that the elements of fig. 3A-3D and other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustrating the concepts described herein. The PBF system 300 can include a depositor 301 that can deposit each layer of metal powder, an energy beam source 303 that can generate an energy beam, a deflector 305 that can apply the energy beam to fuse the powder, and a build plate 307 that can support one or more builds, such as build 309. PBF system 300 may also include a build floor 311 positioned within the powder bed container. The walls 312 of the powder bed container generally define the boundaries of the powder bed container, which are sandwiched between the walls 312 from the sides and abut a portion of the underlying build floor 311. The build base plate 311 may gradually lower the build plate 307 so that the depositor 301 may deposit the next layer. The entire mechanism may be located in a chamber 313 that may house other components, protecting the device, enabling atmospheric and temperature regulation and mitigating contamination risks. The depositor 301 may include: a hopper 315, the hopper 315 containing a powder 317 (such as a metal powder); and a leveler 319 that can level the top of each layer of deposited powder.

Referring specifically to FIG. 3A, there is shown the PBF system 300 after a slice of the build 309 has been fused, but before the next layer of powder is deposited. Indeed, fig. 3A shows the moment at which the PBF system 300 has deposited and fused slices of multiple layers (e.g., 150 layers) to form the current state of the build 309 (e.g., formed from 150 slices). The already deposited layers have formed a powder bed 321 comprising deposited but unfused powder.

Fig. 3B shows PBF system 300 at a stage where build floor 311 can reduce powder layer thickness 323. The lowering of the build floor 311 causes the build 309 and powder bed 321 to drop by the powder layer thickness 323 such that the top of the build and powder bed is lower than the top of the powder bed container wall 312 by an amount equal to the powder layer thickness. In this way, for example, a space with a thickness equal to the powder layer thickness 323 can be created on top of the building member 309 and the powder bed 321.

Fig. 3C shows the PBF system 300 at a stage where the depositor 301 is positioned to deposit powder 317 in the space above the top surface of the build member 309 and powder bed 321 and bounded by the powder bed container wall 312. In this example, the depositor 301 is gradually moved over the defined space while releasing the powder 317 from the hopper 315. The flattener 319 may flatten the released powder to form a powder layer 325 having a thickness substantially equal to the powder layer thickness 323 (see fig. 3B). Thus, the powder in the PBF system may be supported by a powder support structure, which may include, for example, a build plate 307, a build floor 311, a build 309, a wall 312, and the like. It should be noted that the illustrated thickness of the powder layer 325 (i.e., the powder layer thickness 323 (fig. 3B)) is greater than the actual thickness used in the example involving the 350 previously deposited layers discussed above with reference to fig. 3A.

Fig. 3D shows the PBF system 300 at a stage after deposition of the powder layer 325 (fig. 3C), the energy beam source 303 generates an energy beam 327 and the deflector 305 applies the energy beam to fuse the next slice in the build piece 309. In various exemplary embodiments, the energy beam source 303 may be an electron beam source, in which case the energy beam 327 constitutes an electron beam. Deflector 305 may include a deflection plate that may generate an electric or magnetic field that selectively deflects the electron beam to scan the electron beam through a designated area to be fused. In various embodiments, the energy beam source 303 may be a laser, in which case the energy beam 327 is a laser beam. Deflector 305 may include an optical system that uses reflection and/or refraction to manipulate the laser beam to scan a selected area to be fused.

In various embodiments, the deflector 305 may include one or more gimbals and actuators that may rotate and/or translate the energy beam source to position the energy beam. In various embodiments, the energy beam source 303 and/or the deflector 305 may modulate the energy beam, e.g. turn the energy beam on and off when the deflector is scanned, such that the energy beam is applied only in suitable areas of the powder layer. For example, in various embodiments, the energy beam may be modulated by a Digital Signal Processor (DSP).

The present disclosure proposes a technique for enabling the connection of additively manufactured nodes to panels (also referred to herein as node-panel connection structures, node-panel joints, and node-panel joints). In one embodiment, the at least one node-panel connection structure may be part of a vehicle chassis. This type of node-panel connection may include an adhesive between the node and the panel to effect the connection. A sealing filler (sealant) may be used to provide an adhesive area for adhesive injection. In exemplary embodiments, the seal may act as a barrier to inhibit potential galvanic corrosion, for example, caused by long-term contact between dissimilar materials.

The packing region may include features such as grooves, dovetail grooves, embedding or other features built into the surface of the node. The seal packing area may receive a seal packing (such as an O-ring or gasket) and effectively define a boundary or perimeter of each adhesive area. The sealant area with the received sealant can ensure that the adhesive area, around which the sealant is bordered, is hermetically sealed, thereby preventing foreign matter or environmental elements from contaminating the adhesive area. Furthermore, the sealant region and/or the adhesive region discussed below may act as spacers to prevent direct contact between the panel and the node. For example, where the panels and nodes are constructed of different metals, such isolation may be critical to achieving a reliable, durable node-panel connection.

The region of sealant can be additively manufactured with the node itself. In one embodiment, these features include dovetail grooves for the O-rings. Many other types of seal packing features and seal packings may be used as alternatives to accomplish similar objectives. Additionally, the node may further comprise an adhesive injection port, a vacuum port, or both. In some embodiments, the port may be a recess or hole rather than a protrusion. The port may also include a protrusion built into the surrounding hole such that the tip of the protrusion may be flush with or in height proximity to the outer surface of the node. In exemplary embodiments, the holes may be tapped holes or threaded holes, which may advantageously result in weight savings. In embodiments utilizing protruding ports, the ports may be fabricated for breaking off upon completion of the bonding process, which may also reduce mass and volume. For the purposes of this disclosure, the term "port" may be broadly construed to mean a protrusion, or alternatively a recess or aperture, and thus will encompass any of the embodiments discussed above. A port is simply an entry point or exit point for a fluid or other substance. Examples of ports include adhesive inlet ports and adhesive outlet ports. In one embodiment, the adhesive outlet port may be a vacuum port. In other embodiments, the adhesive outlet port need not be a vacuum port, but may for example be a take-off point for excess adhesive.

As described in the embodiments below, the ports may be coupled to channels that may lead to the adhesive region. The port may be an adhesive inlet port for injecting adhesive into the channel and towards the adhesive area. Alternatively, the port may be a vacuum port for applying negative pressure to draw adhesive toward the end of the channel to which the port is coupled. While the adhesive application process in the present disclosure may include a combination of vacuum and adhesive application, the present disclosure is not limited thereto, and the adhesive may be injected without using a negative pressure in some exemplary embodiments. In these cases, the positive pressure that causes the adhesive to flow may be sufficient to fill the adhesive area.

The channels may be part of a node and may be additively manufactured using any suitable additive manufacturing technique. The channels may have the following characteristics: which after entering the adhesive area and subsequently leaving the adhesive area is broken into several channel portions, but these channel portions may be parts of the same channel. Depending on the embodiment and whether the adhesive is injected continuously or in parallel, the node may be considered to have one or more channels. In general, the design of the channels may enable a continuous flow of adhesive into specific adhesive areas between the inner surface of the node and the outer surface of the panel, the edges of which have been inserted into the recesses of the node.

To better facilitate assembly, the node may be printed in two or more parts, wherein the two or more parts are mechanically fastened prior to adhesive injection. In an exemplary embodiment, the node may comprise a base structure having sides projecting therefrom to define a recess for receiving the panel. In other embodiments, the node may include additional features, such as connection features to other structures or other structural or functional features that are not explicitly shown in the description herein to avoid unduly obscuring the concepts of the present invention and to focus on the node-panel interface aspects of the node. These additional features of the node may cause portions of the node to take different shapes or may add structural and geometric features not mentioned in the illustrations herein. These additional features and structures may be additively manufactured with the remainder of the node, although this may not necessarily be the case, as in some applications conventional manufacturing techniques such as casting or machining may be used.

Fig. 4A-4C are front, rear, and side perspective views of a node-panel joint 450 according to the present disclosure. Node 400 is shown coupled to panel 430. In an exemplary embodiment, node 400 is additive manufactured. Node 400 may be constructed from plastic, metal, alloy, or any suitable material or combination thereof. The panels 430 may be simple single material panels, multi-layer panels, sandwich panels (e.g., with a honeycomb or mesh structure disposed between the panels), or may be other types of panels that may be full or hollow, or intervening. For clarity, the components in fig. 4A-4C are transparent, although they may or may not be partially or fully transparent in practical applications. The node 400 may have a base 400. First side 404a and second side 404b of node 400 are configured to protrude from base 408, forming a recess for receiving panel 430, the edges of which may be inserted into the recess of the node as shown.

In an exemplary embodiment, the node-panel junction 450 may include a plurality of adhesive regions 406a-406f for making connections. In this embodiment, three adhesive zones are shown on each side. However, there may be any number of adhesive regions 406 depending on factors such as the desired bond strength, the size and dimensions of the panels, the given available space in the area within the transport structure in which the joint is to be positioned, and the like. In other embodiments, one side of the node 400 may have more or less adhesive area than the other side.

In other embodiments, it may also be desirable to have additional rows of adhesive regions 406 on each side. If desired, the adhesive area 406 may be dispersed in any manner or more evenly over the panel edge, for example to more evenly accommodate the received force. The adhesive area 406 may also vary in size from very small to large, and in some cases will actually be allowed to be as large as the joint 450. In making these design decisions, considerations may include: the size, weight, and dimensions of the panel 430 and node 400, the application of the joint 450, the expected forces that the structure will experience over time, and the like. The shape of the adhesive region 406 is also embodiment specific and may also vary widely. Larger or thicker panels may need to be connected to additional nodes in some transport structures.

In the illustrated embodiment, three of the six adhesive regions 406a-406c are formed on the front side (FIG. 4A) of the node 400 and the remaining three adhesive regions 406d-406f are formed on the back side (FIG. 4B). Adhesive regions 406a-406f may be located on the inner surface of each side 404a-404b of the node adjacent the corresponding surface of panel 430. Each adhesive region 406a-406f has a sealant region extending around the perimeter of the adhesive region. Although not visible due to the seal packings 410a-410f, the seal packing regions may each include one or more features for receiving a seal packing. Such features may be built into the inner surface of the panel and may include grooves, edges, concave curves, convex curves, bumps, ridges or any suitable geometry or other suitable set of features for receiving a sealing compound as desired for use in the application. In another embodiment, described below with reference to fig. 8A-8B, a gasket may be inserted between the node and the panel edge. The gasket may serve as a sealing filler and a spacer, and it may serve to define the adhesive area. In embodiments using gaskets, other seal packing features (such as grooves) and seal packing (such as liquid seal packing or O-rings) may not be needed as the gasket may already incorporate this function. In alternative embodiments, the node-panel joint may comprise a hybrid form in which a gasket and another type of sealing packing may be used.

A in fig. 5 shows four different cross-sectional examples of the seal packing region at the surface of the node 400 including different seal packing features. As noted above, these features in the seal matrix area generally surround the adhesive area for receiving the seal matrix that will define the adhesive area. Element 501 shows that the seal packing region includes a concave curve built into the surface of the node. Element 503 shows a dovetail slot into which an O-ring seal packing may be inserted in an exemplary embodiment. Example 505 shows another example groove, where the left side is a vertical wall built down from the surface, and the right side is similar to the right side of a dovetail groove. Element 507 is a protrusion that may be used to receive a sealing compound. In some embodiments, the protrusion may be inserted into a recess in the nodal surface.

Each packing region is typically configured with at least one feature for receiving packing. The sealing compound more precisely defines the adhesive region 406 by forming a seal between the node 400 and the surface of the panel 430 surrounding the area to be filled with adhesive. While the seal filler defines an adhesive region, it should be noted that in some cases, a small amount of adhesive may enter a portion of one of the grooves and technically exceed the adhesive region; however, this effect is generally negligible if a good sealing design is provided. While a in fig. 5 shows four exemplary features for sealing the packing region, many alternative feature geometries are possible and are intended to fall within the scope of the present disclosure. For example, each side of node 400, and thus the joint, may include any portion from a single adhesive area to a matrix of adhesive areas, and even to include a uniform or randomly dispersed adhesive area. In these cases, appropriate channels and channel portions may be implemented for each adhesive region, and regardless of the design, there should be sufficient pressure and/or negative pressure to fill each adhesive region (e.g., a full adhesive region) with an appropriate amount of adhesive. Similarly, depending on the number of channels (which may be one) serving a given adhesive area, there may be one or more apertures on each side of the adhesive area. In some exemplary embodiments, the channel portion may extend vertically, and the adhesive area may be elongated in the vertical direction. In these embodiments, opposing adhesive may be vertically disposed in each adhesive region to fill the channel with adhesive in a vertical manner. In some embodiments, diagonal adhesive regions and channel portions with properly aligned diagonal apertures are also contemplated.

B in fig. 5 is a cross-sectional view of an exemplary adhesive region bounded by a seal filler inserted into the seal filler region. The arrows 450 define the boundaries between node-panel joints. The dashed line represents one panel surface indicated by the circled letter PS. The solid lines represent the corresponding node surfaces identified by the circled letters NS. Manufactured additively or otherwise built into node surface NS is a groove (which is similar to groove 503 in B in fig. 5). Although two grooves 502, 504 are present, this actually represents a single groove due to the cross-sectional nature of the figure. That is, the grooves 502, 504 protrude from and into the plane of the paper to form an area (such as an oval or rectangular area) to form the perimeter of the adhesive area 406, which is also denoted as the encircled AR.

After the node 400 is additively manufactured or otherwise built, a sealing compound may be applied or inserted into the sealing compound regions 502, 504. The seal packing in this figure is denoted by SE and, like the seal packing regions 502, 504, the seal packing may be a single seal packing (depending on the seal packing used) and may protrude from and into the illustrated plane to form a perimeter around the adhesive region 406. As mentioned, a large number of sealing packings may be available and may be adapted to different embodiments. Some sealing fillers are initially injected as a fluid and then cured or otherwise hardened. Other seal packings have a predefined shape and may be deformable. In the exemplary embodiment, seal filler SE constitutes an O-ring that is inserted into an oval seal filler area to form a corresponding oval adhesive area 406. The sealing gasket SE may alternatively constitute a liquid sealing gasket inserted in the groove. In an embodiment, the liquid sealing packing may be hardened to form a certain shape.

The sealing filler may be used to impede the flow of adhesive beyond the corresponding adhesive area. In another exemplary embodiment, the sealing packing additionally serves to hermetically seal the corresponding adhesive area prior to adhesive injection to achieve a clean and sterile area for adhesive injection. In yet another embodiment, a sealing filler may similarly be used to hermetically seal the corresponding adhesive area after the adhesive is cured to keep the adhesive area free from its environment. This helps to ensure that potential damage or corrosion caused by various contaminants or pollutants over time is reduced or minimized. In yet another exemplary embodiment, the seal packing may help inhibit galvanic corrosion that may occur over time due to contact between the panel surface and the node surface (where the two structures comprise different materials).

Referring back to fig. 4A, the port 412 may be coupled to the channel portion 420 a. Channel portion 420a may form a portion of a larger channel 420 that may include a sum of intermediate elements (e.g., adhesive regions 406a-406f) and individual channel portions through one or both of sides 404a and 404b of node 400. In an embodiment, channel portion 420a may be a via built in the additive manufacturing process that exits port 412 and extends (route) to the rightmost side of adhesive region 406a in fig. 4A. Thus, the channel portion 420a may enter the rightmost side of the adhesive region 406a through an aperture (not visible from the view). In an embodiment, channel portion 420a is raised relative to the inner surface of seal packing area 410 a. As used herein, the first structure being "raised" relative to the second structure means that the first structure is further from the inner planar surface of the side 404a (or 404b) than the second structure. In this embodiment, the inner surface of seal packing area 410a is defined by the maximum vertical depth to which the feature of seal packing area 410a protrudes into the side 404a of the node from the inner planar surface of side 404a in a direction normal to side 404a toward the peak of the feature. That is, in this embodiment, channel portion 420a builds deeper into the inner surface of side 404a than the maximum depth of the features of seal packing area 410 a. In general, the maximum depth of a feature of the seal charge region may constitute the bottom of the feature, such as the lowest point or portion (below) of elements 501, 503, 505, and 507 of a in fig. 5. This enables channel portion 420a to extend across seal packing area 410a or over seal packing area 410a and into adhesive area 406a via an aperture without interfering with seal packing area 410 a. This in turn enables the channel portion 420a to contact the adhesive area 406a via the aperture without breaking the seal formed by the seal packing. As will be seen, in embodiments, adhesive may thus flow through channel portion 420a via port 412 and into adhesive region 406a on side 404a of node 400 without contacting the sealing packing or interfering with the seal.

The channel 420 may have any number of cross-sectional shapes that help provide adhesive or pressure flow. In one embodiment, the channel 420 may be circular or teardrop shaped, or may have other shapes that advantageously reduce or eliminate the need for support material during the additive manufacturing process.

At the opposite left end of the sealing region 406a is another aperture, similarly not visible from the view, which connects to the channel portion 420 b. Channel portion 420b (also part of channel 420) builds from the left aperture of adhesive region 406a to the first aperture located to the right of the next adhesive region 406 b. Similar to 420a, channel portion 420b is raised relative to adhesive regions 406a and 406b to avoid interfering with the seal caused by the sealing compound while allowing the adhesive to flow.

As will be seen, in an embodiment, each of the adhesive regions 406a-406f may have an aperture on one side and an opposing aperture on the other side. For the purposes of this disclosure, relative need not be exactly relative. Rather, the apertures on the opposite side simply means that the apertures are properly positioned to allow adhesive to flow from one side of the adhesive area to the other. It should also be noted that in alternative embodiments, more than one aperture may be used. For example, in one embodiment, the channel portion 420a may be further divided into two channel portions, each channel portion contacting the adhesive area via an aperture on one side of the adhesive area. On the other side of the adhesive area, two apertures opposite the respective right apertures may lead to two additional channel portions, and so on. Such embodiments are encompassed within the structures herein.

The opposite orifice is positioned to the left of the adhesive region 406b, which leads to a channel portion 420c (also part of the channel 420). In a manner similar to channel portion 420b, channel portion 420c is elevated relative to seal filler regions 410b and 410c and opens into the right aperture in adhesive region 406 c. At the opposite left aperture in the adhesive region 406c, the channel 420d extends downward toward the rear of the base 408. In this embodiment, channel 420d is also elevated relative to seal packing area 410 c. In this case, the channel 420d thus extends across the base 408 to the second side 404b of the node. Channel 420d may be considered a delivery channel in that it serves as a pathway for the delivery of a substance, e.g., to enable adhesive to flow from one side of the node to the other.

Referring now to fig. 4B, the opposite sides of node-panel junction 450 are shown. On the right side, channel 420d is configured to change direction and enter the right aperture (or in other embodiments, more than one aperture) associated with adhesive region 406d over or across seal packing region 410 d. As previously described, in the illustrated embodiment, channel portions 420d, 420e, and 420f are each raised relative to the applicable gasket area 410d-410f in a manner similar to that discussed with reference to FIG. 4A, except that the flat inner surfaces of side portions 404b are used as a reference. The opposing apertures (or sets thereof) disposed on opposing left sides of adhesive region 406d are coupled to channel portion 420e, channel portion 420e being elevated relative to adhesive regions 410d-410e and extending to the first aperture to the right of adhesive region 410 e. The opposing left aperture of adhesive region 410e is the entrance to adhesive region 406f via channel portion 420f, which is elevated relative to seal pack regions 410e-410f and is in contact with the right aperture on adhesive region 406 f. The opposing left aperture in adhesive region 406f is coupled to channel portion 420g, which is elevated relative to seal packing region 410 f. Channel portion 420g travels vertically toward base 408, traversing to the other side of node 400 and reaching port 414.

In an exemplary embodiment, the node is additive manufactured. The panels are manufactured or received using additive manufacturing or conventional techniques such as molding, casting processes, or some combination thereof. A sealing packing, such as a gasket or O-ring, is inserted into the respective sealing packing regions 410a-410 f. In one embodiment, the process is performed automatically by a robot or other automated builder, optionally under the control of a central control station. To this end, vector 508 may indicate the installation direction of the seal packing (see B in fig. 5). In other embodiments, the process of inserting the sealing compound is performed manually. The panel is received into the panel recess between node sides 404a and 404 b. Also, the panel insertion process may be automated and, in some embodiments, controlled by the same central control station.

Thus, in one embodiment, the panels are joined to the nodes as follows. A source of adhesive may be applied to port 412 and a source of negative pressure (vacuum) may be applied to port 414 that will be communicated through the channels and adhesive regions via the sets of opposing orifices but in the reverse order to that described above. The negative pressure may be applied first, which helps to establish a near vacuum condition as follows: first to side 404b of node 400 through transfer channel 420g, then through successive channel portions and adhesive areas on side 404b, and then back to side 404a of node 400 through successive channel portions and adhesive areas via respective sets of opposing orifices until negative pressure is transferred through channel portion 420a and emerges at port 412.

Referring back to fig. 4A, adhesive may then be inserted via port 412 and may pass through channel portion 420a through a corresponding aperture on the right side of adhesive region 406 a. The adhesive will begin to fill the adhesive region until the adhesive region is full or substantially full, at which point (or before the adhesive region 406a becomes full) the adhesive exits through the opposing apertures of the adhesive region 406a and passes through the channel portion 420b, where the process may repeat as the adhesive fills the adhesive region 406b and then fills the adhesive region 406 c. The adhesive may then pass through the opposing apertures on the left side of the adhesive area 406c, through the transfer channel portion 420d, and to the other side 404b of the node 400.

Referring back to fig. 4B, the process may continue as adhesive enters via the right aperture of adhesive region 406d and exits the opposing aperture as adhesive region 406d is filled, and its process continues to fill the remaining adhesive regions 410e and 410 f. In this case, adhesive may flow through channel 420g to port 414. Once adhesive is detected at port 414, it is known that adhesive regions 406a-406f are filled, and thus adhesive flow (and any negative pressure) may cease. The adhesive may then be cured by application of heat (e.g., in a chamber) or time as appropriate. Once the adhesive cures, a connection is made between the node and the panel.

As described above, other embodiments may contemplate parallel flow of adhesive through multiple channels into and out of the adhesive region via multiple orifices. In alternative embodiments involving multiple rows of adhesive zones or discrete adhesive zones, the parallel channels may each flow along one row and then sequentially pass to the other side. In short, a variable number of channels with or without additional ports and additional orifices in addition to the two inlet and outlet orifices in the adhesive zone may be realized without departing from the scope of the invention.

As described above, the transfer channels 420d and 420g may serve as paths that enable adhesive to flow from one side of the node to the other. The orifices described above may be holes and, as noted, may be designed so that no support material, such as a channel with a tear drop shaped cross section, is required during the additive manufacturing process. Regardless of the number and location of the adhesive zones, the vacuum may draw adhesive into each successive zone until the adhesive channels are full. In one embodiment, only the adhesive inlet port is used, and no negative pressure is applied. The adhesive will flow out of the adhesive outlet port.

Referring now to fig. 4C, to prevent contact between the inner surface of the node and the panel, features to receive spacers may be additively manufactured or otherwise included within the node. In one embodiment, the feature may be a recess 432 that receives a nylon spacer (such as a gasket). Although only one recess for the spacer is explicitly shown, the panel may include any number of such features on the inner surface of the node or elsewhere where protection from galvanic corrosion is desired.

Referring back to fig. 4A-4C, the node 400 may have a gasket feature 410a-410f to receive a spacer between the node and the surface of the panel that cooperates to form an adhesive bond (adhesive bond). For example, the O-rings, in addition to serving as a sealing packing, may also ensure a hermetically sealed environment for the adhesive in each of the adhesive zones 406a-406 f. As mentioned above, this bond will be formed between the node and the surface of the panel.

In another exemplary embodiment, the portions of the surface not bonded to the nodes may be separated by spacers or other isolation mechanisms to provide further isolation to prevent potential galvanic corrosion problems. In another embodiment, the isolation material may integrate parallel surfaces and a bottom surface instead of the nylon liner described above with reference to fig. 4C. In these alternative embodiments involving an integrated isolator, the integrated isolator may also serve as a seal. The seal may be a custom gasket and may be additively manufactured.

Fig. 6A-6C are conceptual block diagrams of alternative exemplary connections in a node-panel joint. As an alternative to filling the adhesive in a simple sequential or continuous manner in the order 406a, 406b, 406c, 406d, 406e, 406f, an alternative parallel mechanism may be used. Fig. 6A shows a conceptual diagram of a node 600A having a base 608 and sides 604 and 610. In this embodiment, node 600A has eight adhesive areas 606 ("AR"), four on side 604 and four on side 610. In addition, node 600A has two ports 602A-602B. A continuous or sequential adhesive filling process is discussed with reference to fig. 6A. Port 602A represents a vacuum port that can be evacuated. In other embodiments, no vacuum is used and only pressure from the adhesive injection is relied upon to fill the adhesive area. The ports 602A-602B may also be holes, recesses, protrusions within recesses, and the like.

The configuration of node 600A is similar to that of fig. 4A-4C. Adhesive region 606 is defined by a seal pack region that includes a seal pack and includes two apertures (opposing apertures on each side). As mentioned above, having orifices on the "opposite" or "opposing" side does not require that the orifices be precisely arranged so that they are equidistant from the mid-point separating the two. It also does not require that the opposing or opposing apertures be perfectly aligned in any dimension. Rather, "opposing" or "opposing" apertures are apertures that are distributed sufficiently apart such that the flow of adhesive in the respective adhesive region allows for filling or substantially filling of adhesive in the adhesive region. In some embodiments, more than two apertures may be used per adhesive region. Although a single channel having multiple portions is shown, in other embodiments, multiple channels may be used, such as where there are multiple rows of adhesive regions 606 or an otherwise greater number of adhesive regions 606. The multiple channels may use these multiple orifices, or they may branch off and supply adhesive to different adhesive areas.

The panel may be inserted into a recess defined by the sides 604 and 610 and the base 608. The panel need not be a planar panel. In some embodiments, the panels may be bent or oriented in different ways as they extend beyond the joint. In addition, to avoid excessively obscuring the illustration, vacuum and adhesive mechanisms are not included in the illustration.

The process described below may be automated, for example, by using one or more robots with self-learning capabilities, or controlled by a central station (or both). The robots may be dedicated to the manufacturing application involved, or they may be general purpose robots. The robot may participate in any part or substantially all of the panel node assembly process. In some embodiments, the robot is used for one or more tasks, including transporting panels, transporting nodes to and from an additive manufacturing station, inserting panels into node recesses, applying sealing compound, applying adhesive, and/or assisting any post-processing steps (including curing and transporting the finished product to the next station). In other embodiments, the process may involve human labor in whole or in part. Node-panel assembly may be performed on an automated assembly line. For example, if the node-panel joint is to be constructed for use as part of the chassis of an automobile or the fuselage of an aircraft, the node-panel joint may be assembled at a station in an assembly line dedicated to those types of tasks.

Referring back to fig. 6A, upon insertion of the panel, seal packing, and any necessary spacers, a negative pressure may be applied at port 602A, and an adhesive may be applied at port 602B therebetween or thereafter. The adhesive flows to the first adhesive area 606, filling that area, and then continues to fill the remaining adhesive area on the side 604. The adhesive is then transferred to the other side 610 of the node where it sequentially or continuously fills the four adhesive areas on the side 610. Thereafter, excess adhesive may be expelled from port 602A. The presence of adhesive at port 602A may indicate that the adhesive filling process is complete. The node-panel joint may then be cured to allow the adhesive to dry.

Fig. 6B shows a parallel configuration for applying adhesive. A vacuum may be drawn at vacuum port 602B. Adhesive may be injected at inlet port 602A. The adhesive may be split between side 604 and side 610 to fill four adhesive areas on each side simultaneously. That is, the adhesive flows in parallel on each side and flows continuously within a side to fill the four adhesive areas 606. Since the adhesive at the input port may take more time to pass through the transfer passage T, this process may not occur exactly simultaneously on each side. However, in this parallel channel embodiment, the parallel filling of the adhesive regions 606 may accelerate the adhesive application process.

Many other configurations of adhesive/vacuum channels are possible and within the scope of the present disclosure. In fig. 6C, each adhesive zone is filled independently using separate channels defined by ports 602A and 602B for side 604 and ports 602C and 602D for side 610. The adhesive area 606 on one side may be filled first using an adhesive injection device, or both sides may be filled in parallel if additional adhesive/vacuum is available.

In an exemplary embodiment where the ports 602A-602D in any of fig. 6A-6C are protrusions, the protrusions may be broken after they are no longer needed to reduce the mass, volume, and volume of the joint. Where ports 602A-602D are holes or protrusions in recesses and are flush with the surface of the node, they need not be broken off.

In fig. 6A-6C, the number of channels may be, but need not be, the same as the number of ports. In exemplary embodiments, the number of channels doubles or triples from a single port and is extended to the intended destination, such as a different row of adhesive regions.

Fig. 7 is a flow chart 700 of an exemplary method of additive manufacturing a node-panel joint. The node (702) may be additively manufactured. The nodes may be made of plastic, one or more metals, alloys, composites, and the like. The type of material may affect the additive manufacturing method selected for manufacturing the node. During the additive manufacturing process, the base, the two sides, the seal packing area, the isolation area, the channel, and the port may be 3-D printed. In one embodiment, the nodes are printed by using two renderings on both sides.

In addition to the features described in this disclosure, the nodes may be additively manufactured to incorporate additional features. These additional features may include, for example, connection features for enabling the node-panel joint to be connected to another structure, such as another node, panel, extrusion, pipe, etc. In an exemplary embodiment, a node as described herein is a portion of a larger structure or larger node having various geometric features and functions. In another embodiment, the node may be manufactured with a panel recess on the other side to receive another panel.

A sealing compound may then be inserted into the sealing compound region (704). Spacers (706) may also be inserted. The panel may then be received in the panel recess (708). The panels may be obtained or manufactured from a supplier. The panels may be conventionally manufactured or additively manufactured. In one embodiment, the panel is a sandwich panel. The panel may be made of any suitable material depending on the application for which the node-panel joint is intended. The size of the panels may vary. In some embodiments, a node may be manufactured to receive more than one panel placed consecutively in a panel recess. The panel may comprise a single material.

After receiving the panel, a vacuum may be drawn and adhesive injected to fill the adhesive area (710), as described herein. The vacuum can be maintained throughout the adhesive injection process and can be broken once complete filling is achieved. Once the adhesive area is filled with adhesive and the adhesive injection process is complete, the port can be snapped off (if necessary or desired). The adhesive may then be cured (712). Once the adhesive hardens, a node-panel bond (714) is formed. Depending on the destination and application of the tunnel, the panel may then be implemented as part of a transport structure.

In various embodiments, a single node may be connected to two or more panels in a structure using the features described above. The nodes may also be extended, elongated or shaped in any manner to enable multiple sets of joint regions (i.e., multiple sets of one or more adhesive regions with sealing fillers and channels as described above to effect the connection) on a single node. For example, in one embodiment, the nodes are rectangular with separate joints on two or more sides of the rectangular nodes that connect to different panels via the bonding process and techniques described above. In other embodiments, the node may be configured to have a joint region in close proximity so that two respective panels may be very closely spaced, or so that the panels may be in contact. Many embodiments of nodes, node-panel joints, and panels may be envisioned based on the above description and accompanying illustrations without departing from the spirit and scope of the present disclosure.

Fig. 8A is a perspective view 800A of a gasket 802 to be used as a sealing packing and spacer for insertion into an inner surface of a node 812, according to an embodiment. In other embodiments, the pads 802 may be applied to panels rather than nodes. In embodiments where the pads 802 are applied to the panel, the pads should be applied before the panel pads are inserted into the nodes to ensure proper operation. As shown in fig. 8A, the interior surface of the node may include a channel portion 808, closely related apertures 809 terminating at the ends of the channel portion 808, an adhesive inlet port 810, and an adhesive outlet port 815. The node 812 may have a seal packing feature or joint to receive or house a gasket, which in this embodiment is realized by a wall of the interior portion of the node 812 in fig. 8A. It should be noted that node 812 is transparent as in the previous figures to illustrate the configuration of the internal passage portion. In other embodiments, it may be opaque, transparent, or in between.

Referring to perspective view 800B of fig. 8B, pad 802 may be slid into node 812 by a robot or manually. The pads 802 may be designed such that their respective adhesive areas 804 are aligned with the channel portions 808 and apertures 809 on the node 812. In this embodiment, it can be seen that the apertures 809 are offset relative to each other in a diagonal manner within the aligned adhesive regions 804, rather than being offset horizontally as in the previous embodiment. Adhesive may be introduced into adhesive inlet port 810 to fill the two adhesive regions 804 on each respective side in parallel, after which the adhesive may exit adhesive exit port 815. In some embodiments, the adhesive outlet port 815 may be a vacuum port.

As described above, the gasket 812 may serve as a spacer and a sealing filler for defining an adhesive area. As shown in this embodiment, the base of the node 812 may also interact with the pad 804.

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 will be readily apparent to those skilled in the art given throughout this disclosure, and the concepts disclosed herein may be applied to other technologies for printing nodes and interconnect structures. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout this 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. Furthermore, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. Claim elements should not be construed in accordance with the provisions of 35u.s.c. § 112(f) or similar laws in the applicable jurisdiction, unless the element is explicitly recited using the phrase "means for.

Claims (40)

1. A node, comprising:

a base;

a first side and a second side projecting from the base to form a recess for receiving a panel;

a first port and a second port;

one or more adhesive regions disposed on a surface adjacent each side of the panel; and

at least one channel coupled between the first port and the second port and configured to fill the adhesive area with an adhesive that is cured to form a node-panel joint.

2. The node of claim 1, wherein the channel extends continuously from the first port to the second port through each adhesive region on the first and second sides by utilizing apertures disposed on opposite sides of each adhesive region as respective entry and exit regions for adhesive.

3. The node of claim 2, wherein the channel is configured to enable parallel transfer of adhesive through each adhesive area on the respective first and second side portions.

4. The node of claim 2, wherein the channel is configured to enable the transfer of adhesive continuously through each adhesive area on the first side, through the base, and then continuously through each adhesive area on the second side.

5. The node of claim 1, wherein at least the base, the first and second sides, the first and second ports, and the at least one channel are Additive Manufactured (AM).

6. The node of claim 1, wherein at least the base, the first and second sides, the first and second ports, and the at least one channel are co-printed.

7. The node of claim 1, wherein each of the one or more adhesive regions is bounded by a seal packing region configured to receive a seal packing.

8. The node of claim 7, wherein the sealant region includes the sealant.

9. The node of claim 8, wherein the seal packing is configured to perform one or more of the following functions:

(i) impeding the flow of adhesive beyond the corresponding adhesive area;

(ii) hermetically sealing the corresponding adhesive area prior to adhesive injection;

(iii) hermetically sealing the corresponding adhesive area after the adhesive is cured; and

(iv) galvanic corrosion between different materials is prevented.

10. The node of claim 8, wherein the sealing packing comprises an O-ring, a gasket, or a liquid sealing packing.

11. The node of claim 8, wherein the seal filler is automatically applied to each corresponding seal filler region.

12. The node of claim 8, wherein the one or more adhesive regions each comprise:

a recess in the first wall or the second wall proximate the corresponding surface of the panel, the recess characterized at least in part by an area bounded by the sealing compound; and

apertures disposed on opposite sides of the recess, the apertures coupled to portions of the channel, the apertures configured as respective entry and exit regions to fill the recess with adhesive when the panel is inserted and to flow adhesive between channel portions until each of the one or more adhesive regions is filled.

13. The node of claim 7, wherein the seal packing region includes features embedded in the respective first and second sides, each feature configured to receive the seal packing.

14. The node of claim 5, wherein at least a portion of the channel comprises a geometry that facilitates additive manufacturing of the at least one channel without the use of a support structure during additive manufacturing.

15. The node of claim 1, further comprising at least one isolation feature disposed on at least one of the first side, the second side, and an inner surface of the base to prevent contact of the node with the panel when an isolator is installed in the isolation feature.

16. The node of claim 15, wherein the isolation feature comprises a recess for receiving a nylon isolator.

17. The node of claim 1, wherein the first or second side further comprises one or more gaskets configured to prevent galvanic corrosion.

18. The node of claim 1, wherein,

the channel extends continuously from the first port through each adhesive region on the first side, through the base, and through each adhesive region on the second side, and then to the second port, and

the channels are configured to fill each adhesive area to form a bond with the panel when the adhesive cures.

19. The node of claim 18, wherein the second port is disposed on the first side such that the channel returns to the first side via the base after extending through each of the one or more adhesive regions on the second side.

20. The node of claim 1, wherein,

the channel extends from the first port to the second side portion via the base, continuously through each adhesive region on the second side portion, returns to the first side portion via the base, and continuously through each adhesive region on the first side portion, after which the channel is coupled to the second port.

21. The node of claim 1, wherein the negative pressure applied at the second port and the adhesive subsequently applied at the first port progressively fills the one or more adhesive regions with the adhesive as panels are inserted.

22. The node of claim 8, wherein at least a portion of the channel extending across the first side or the second side is elevated relative to an inner surface of the one or more seal packing regions such that each channel portion can contact the adhesive region via the aperture without breaking a seal formed by the seal packing.

23. The node of claim 1, wherein each channel portion contacts the one or more adhesive regions at an angle via an aperture.

24. The node of claim 1, wherein:

the first side comprises N-N adhesive regions;

each of the N adhesive regions comprises at least two apertures including at least one aperture disposed on an opposite side of at least one other aperture;

(a) the first port is coupled to an (n-1) channel portion on the first side;

(b) the (n-1) channel portion is coupled to a first aperture of an (n-1) adhesive region on the first side;

(c) the second aperture of the (n +1) adhesive region is coupled to the (n + 12) channel portion on the first side; and

(b) - (c) continuing (N2, 3.. N) times until, at (c), the second aperture of the nth adhesive region on the first side is coupled to the (N +1) th channel portion.

25. The node of claim 24, wherein:

the (N +1) th channel portion extends through the base portion to the second side portion to become an (m-1) channel portion on the second side portion;

the second side comprises M-M adhesive regions;

each of the M adhesive regions comprises at least two apertures, including at least one aperture on an opposite side of at least one other aperture;

(f) a (m 1) channel portion on the second side coupled to a first aperture of an (m 1) adhesive region on the second side;

(g) a second aperture of the first (m + 1-2) adhesive region on the second side is coupled to an (m + 1-1) channel portion on the second side; and

(f) - (g) continuing (M2, 3..... M) times until, at (g), the second aperture of the mth adhesive region on the second side is coupled to the (M +1) th channel portion.

26. The node of claim 25, wherein,

the adhesive area on the first and second sides is configured to receive adhesive via the first port; and

the (M +1) th channel portion is coupled to the second port.

27. The node of claim 25, wherein N-M.

28. The node of claim 1, wherein the first port comprises a protrusion or a recess, or a protrusion at least partially within a recess, to allow an end of the protrusion to be proximate to or flush with a surface of the first side.

29. The node of claim 1, wherein at least one of the first port and the second port is configured to break after the adhesive cures.

30. A method, comprising:

an Additive Manufacturing (AM) node, the node comprising: a base; a first side and a second side projecting from the base to form a panel recess; a first port and a second port; one or more adhesive zones disposed on the inner surface of each side portion; and at least one channel coupled between (i) the first port, (ii) each of the one or more adhesive regions, and (iii) the second port; and

a sealing filler is inserted around each of the one or more adhesive regions.

31. The method of claim 30, further comprising:

receiving a panel in the panel recess;

applying negative pressure to the second port;

injecting an adhesive into the first port until each of the one or more adhesive regions is filled with adhesive; and

curing the adhesive to form a bonded node-panel joint.

32. The method of claim 30, wherein,

the additive manufactured node further includes a feature formed around each of the one or more adhesive regions to receive a sealing filler, and

inserting a packing seal includes inserting an O-ring or gasket into each feature.

33. The method of claim 30, wherein additively manufacturing one or more adhesive regions comprises:

forming an adhesive recess in the first wall or the second wall proximate the desired surface of the panel, including forming a feature to receive a sealing compound; and

apertures are formed on opposite sides of the adhesive recess for coupling to respective channel portions.

34. The method of claim 30, wherein additively manufacturing at least one channel comprises:

forming a channel extending from the first port, the channel elevated relative to features adjacent the one or more adhesive regions to avoid breaking a seal formed when a sealing compound is inserted;

continuously extending the channel to each of the one or more adhesive regions on the first side using a first aperture on one side of each adhesive region as an adhesive entry region and a second aperture on an opposite side of each adhesive region as an adhesive exit region;

extending the channel through the base to the second side;

continuously extending the channel to each of the one or more adhesive regions on the second side using a first aperture on one side of each adhesive region as an adhesive entry region and a second aperture on an opposite side of each adhesive region as an adhesive exit region; and

coupling the channel extending continuously on the second side to the second port, the second port being located on the first side or the second side.

35. The method of claim 30, wherein additively manufacturing at least one channel comprises:

forming a first channel extending from a first port on the first side, the first channel being elevated relative to features adjacent to respective adhesive regions on the first side to avoid breaking a seal formed upon insertion of a sealing compound;

forming a second channel on the second side extending from the first port or the first channel through the base, the second channel being elevated relative to features adjacent to each adhesive area on the second side;

continuously extending the first channel to each of the one or more adhesive regions on the first side using a first aperture on one side of each adhesive region as an adhesive entry region and a second aperture on an opposite side of each adhesive region as an adhesive exit region;

continuously extending the second channel to each of the one or more adhesive areas on the second side using a first aperture on one side of each adhesive area as an adhesive entry area and a second aperture on an opposite side of each adhesive area as an adhesive exit area; and

coupling an outlet of at least one of the first and second channels to the second port,

wherein forming the first and second channels enables adhesive to flow simultaneously on both the first and second sides to fill the respective adhesive areas.

36. The method of claim 35, wherein the coupling the outlet of at least one of the first and second channels to the second port comprises extending the second channel through the base to the second port, wherein the second port is disposed on the first side.

37. The method of claim 30, wherein additively manufacturing the node comprises adding a feature for receiving a spacer.

38. The method of claim 37, further comprising adding spacers to the features.

39. The method of claim 31, wherein the first and second regions are selected from the group consisting of,

wherein the first port and the second port comprise a protruding adhesive inlet port and a protruding adhesive outlet port, respectively,

wherein the method further comprises breaking the first port and the second port after forming the node-panel joint.

40. The method of claim 31, wherein applying negative pressure and injecting adhesive further comprises:

maintaining a vacuum throughout the adhesive injection process; and

once complete filling is achieved, the vacuum is disconnected.