Patent Description:
The present disclosure generally relates to additively manufactured end effectors, and more specifically to additively manufactured end effectors for fluid interfaces in additively manufactured nodes.

Nodes perform important connection functions between various components in transport structures. The nodes may be bonded to other components including tubes, extrusions, panels, and other nodes. For example, nodes can be used to perform connections for panels. A transport structure such as an automobile, truck or aircraft employs a large number of interior and exterior panels. Most panels must be coupled to, or interface with, other panels or other structures in secure, well-designed ways. These connection types may be accomplished by using nodes. The nodes, or joint members, may serve not only to attach to, interface with, and secure the panel, but they also may be used to form connections to other components of the automobile (e.g., another panel, an extrusion, tubes, other nodes, etc.).

The design and manufacture of end effectors for interfacing with nozzles of the nodes has several problems. For example, the end effectors are often specialized structures requiring intricate sub-substructures. It is often extremely difficult to manufacture these types of complex structures efficiently or cheaply using traditional manufacturing processes. For another example, in the manufacturing process, there are a large number of nodes, the conventional interfaces with the nozzles of the nodes may be too time consuming and may not be efficient for mass assembly.

There is a need to develop efficient end effectors with increased sophistication and superior capabilities for the interface nozzles, specifically, for the nozzles of the nodes of transport structures to implement potentially high-performance applications at manageable price points.

<CIT> discloses a change and fixing device for spray apparatus having a locking and actuating element movable between locking and release positions and connected to a closure member.

According to an aspect of the invention there is provided an apparatus according to appended claim <NUM>.

According to another aspect of the invention there is provided a method of using an end effector according to appended claim <NUM>.

End effectors for interfacing with the nozzles of the nodes, including the nodes for transport structures, and the additive manufacture thereof will be described more fully hereinafter with reference to various illustrative aspects of the present disclosure.

There is disclosed herein an end effector for interfacing with a nozzle is provided. The end effector comprises a first end, which includes a receptacle. The receptacle is configured to receive the nozzle. The nozzle includes one or more nozzle retention features and a first nozzle inlet. The end effector comprises one or more retention features positioned along a perimeter of the receptacle, where each of the one or more retention features is movable between a first position and a second position. Each of the one or more retention features is configured to lock the nozzle by securing onto a corresponding one of the one or more nozzle retention features in the first position, and to release the nozzle in the second position. The end effector may further comprise one or more actuators configured to actuate the one or more retention features between the first position and the second position. The end effector comprises a first channel, which includes a first inlet and a first outlet. The first outlet is positioned inside the receptacle and is configured to be coupled to the first nozzle inlet in the first position.

There is disclosed herein a method of using an end effector to interface with a nozzle is provided. The method comprises receiving the nozzle in a receptacle of the end effector. The method comprises actuating one or more retention features of the end effector to a first position to secure onto a corresponding one of one or more nozzle retention features to lock the nozzle. The method comprises applying vacuum to a second inlet of the end effector, where a second outlet of the end effector is coupled to a second nozzle inlet. The method comprises injecting a first fluid to a first inlet of the end effector, wherein a first outlet of the end effector is coupled to a first nozzle inlet.

It will be understood that other aspects of nodes for connecting with various components in transport structures and the manufacture thereof 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 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 invention as defined by the appended claims.

Various aspects of nodes in transport structures and the manufacture thereof 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 appended drawings is intended to provide a description of various exemplary embodiments and is not intended to represent the only embodiments in which the invention may be practiced. The terms "example" and "exemplary" used throughout this disclosure mean "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. In addition, the figures may not be drawn to scale and instead may be drawn in a way that attempts to most effectively highlight various features relevant to the subject matter described.

This disclosure is generally directed an end effector for interfacing with a nozzle. The end effector comprises a first end, which includes a receptacle. The receptacle is configured to receive the nozzle. The nozzle includes one or more nozzle retention features and a first nozzle inlet. The end effector comprises one or more retention features positioned along a perimeter of the receptacle, where each of the one or more retention features is movable between a first position and a second position. Each of the one or more retention features is configured to lock the nozzle by securing onto a corresponding one of the one or more nozzle retention features in the first position, and to release the nozzle in the second position. The end effector may further comprise one or more actuators configured to actuate the one or more retention features between the first position and the second position. The end effector comprises a first channel, which includes a first inlet and a first outlet. The first outlet is positioned inside the receptacle and is configured to be coupled to the first nozzle inlet in the first position.

In many cases, the nodes, and other structures described in this disclosure may be formed using additive manufacturing (AM) techniques, due in part to AM's innumerable advantages as articulated below. Accordingly, certain exemplary AM techniques that may be relevant to the formation of the nodes described herein will initially be discussed. It should be understood, however, that numerous alternative manufacturing techniques, both additive and conventional, may instead be used in forming the nodes (in part or in whole) disclosed herein, and that the identified nodes need not be limited to the specific AM techniques below.

Those that stand to benefit from the structures and techniques in this disclosure include, among others, manufacturers of virtually any mechanized form of transport, which often rely heavily on complex and labor-intensive tooling, and whose products often require the development of nodes, panels, and interconnects to be integrated with intricate machinery such as combustion engines, transmissions and increasingly sophisticated electronics. Examples of such transport structures include, among others, trucks, trains, tractors, boats, aircraft, motorcycles, busses, and the like.

Additive Manufacturing (<NUM>-D Printing). Additive manufacturing (AM) is advantageously a non-design specific manufacturing technique. AM presents various opportunities to realize structural and non-structural connections between various components. AM provides the ability to create complex structures within a part. For example, nodes can be produced using AM. A node is a structural member that may include one or more interfaces used to connect to other spanning components such as tubes, extrusions, panels, other nodes, and the like. Using AM, a node may be constructed to include additional features and functions, depending on the objectives. For example, a node may be printed with one or more ports that enable the node to secure two parts by injecting an adhesive rather than welding multiple parts together, as is traditionally done in manufacturing complex products. Alternatively, some components may be connected using a brazing slurry, a thermoplastic, a thermoset, or another connection feature, any of which can be used interchangeably in place of an adhesive. Thus, while welding techniques may be suitable with respect to certain embodiments, AM provides significant flexibility in enabling the use of alternative or additional connection techniques. AM provides the platform to print components with complex internal channels and geometries, some of which are impossible to manufacture using conventional manufacturing techniques.

A variety of different AM techniques have been used to <NUM>-D print components composed of various types of materials. Numerous available techniques exist, and more are being developed. For example, Directed Energy Deposition (DED) AM systems use directed energy sourced from laser or electron beams to melt metal. These systems utilize both powder and wire feeds. The wire feed systems advantageously have higher deposition rates than other prominent AM techniques. Single Pass Jetting (SPJ) combines two powder spreaders and a single print unit to spread metal powder and to print a structure in a single pass with apparently no wasted motion. As another illustration, electron beam additive manufacturing processes use an electron beam to deposit metal via wire feedstock or sintering on a powder bed in a vacuum chamber. Single Pass Jetting is another exemplary technology claimed by its developers to be much quicker than conventional laser-based systems. Atomic Diffusion Additive Manufacturing (ADAM) is still another recently developed technology in which components are printed, layer-by-layer, using a metal powder in a plastic binder. After printing, plastic binders are removed and the entire part is sintered at once into a desired metal.

One of several such AM techniques, as noted, is DMD. <FIG> illustrates an exemplary embodiment of certain aspects of a DMD <NUM>-D printer <NUM>. DMD printer <NUM> uses feed nozzle <NUM> moving in a predefined direction <NUM> to propel powder streams 104a and 104b into a laser beam <NUM>, which is directed toward a workpiece <NUM> that may be supported by a substrate. Feed nozzle may also include mechanisms for streaming a shield gas <NUM> to protect the welded area from oxygen, water vapor, or other components. The powdered metal is then fused by the laser <NUM> in a melt pool region <NUM>, which may then bond to the workpiece <NUM> as a region of deposited material <NUM>. The dilution area <NUM> may include a region of the workpiece where the deposited powder is integrated with the local material of the workpiece. The feed nozzle <NUM> may be supported by a computer numerical controlled (CNC) robot or a gantry, or other computer-controlled mechanism. The feed nozzle <NUM> may be moved under computer control multiple times along a predetermined direction of the substrate until an initial layer of the deposited material <NUM> is formed over a desired area of the workpiece <NUM>. The feed nozzle <NUM> can then scan the region immediately above the prior layer to deposit successive layers until the desired structure is formed. In general, the feed nozzle <NUM> may be configured to move with respect to all three axes, and in some instances to rotate on its own axis by a predetermined amount.

<FIG> is a flow diagram <NUM> illustrating an exemplary process of <NUM>-D printing. A data model of the desired <NUM>-D object to be printed is rendered (step <NUM>). A data model is a virtual design of the <NUM>-D object. Thus, the data model may reflect the geometrical and structural features of the <NUM>-D object, as well as its material composition. The data model may be created 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 non-linear finite element analysis (FEA), and durability analysis.

<NUM>-D modeling software, in turn, may include one of numerous commercially available <NUM>-D modeling software applications. Data models may be rendered using a suitable computer-aided design (CAD) package, for example in an STL format. STL is one example of a file format associated with commercially available stereolithography-based CAD software. A CAD program may be used to create the data model of the <NUM>-D object as an STL file. Thereupon, the STL file may undergo a process whereby errors in the file are identified and resolved.

Following error resolution, the data model can be "sliced" by a software application known as a slicer to thereby produce a set of instructions for <NUM>-D printing the object, with the instructions being compatible and associated with the particular <NUM>-D printing technology to be utilized (step <NUM>). Numerous slicer programs are commercially available. Generally, the slicer program converts the data model into a series of individual layers representing thin slices (e.g., <NUM> microns thick) of the object be printed, along with a file containing the printer-specific instructions for <NUM>-D printing these successive individual layers to produce an actual <NUM>-D printed representation of the data model.

The layers associated with <NUM>-D printers and related print instructions need not be planar or identical in thickness. For example, in some embodiments depending on factors like the technical sophistication of the <NUM>-D printing equipment and the specific manufacturing objectives, etc., the layers in a <NUM>-D printed structure may be non-planar and/or may vary in one or more instances with respect to their individual thicknesses.

A common type of file used for slicing data models into layers is a G-code file, which is a numerical control programming language that includes instructions for <NUM>-D printing the object. The G-code file, or other file constituting the instructions, is uploaded to the <NUM>-D printer (step <NUM>). Because the file containing these instructions is typically configured to be operable with a specific <NUM>-D printing process, it will be appreciated that many formats of the instruction file are possible depending on the <NUM>-D printing technology used.

In addition to the printing instructions that dictate what and how an object is to be rendered, the appropriate physical materials necessary for use by the <NUM>-D printer in rendering the object are loaded into the <NUM>-D printer using any of several conventional and often printer-specific methods (step <NUM>). In DMD techniques, for example, one or more metal powders may be selected for layering structures with such metals or metal alloys. In selective laser melting (SLM), selective laser sintering (SLS), and other PBF-based AM methods (see below), the materials may be loaded as powders into chambers that feed the powders to a build platform. Depending on the <NUM>-D printer, other techniques for loading printing materials may be used.

The respective data slices of the <NUM>-D object are then printed based on the provided instructions using the material(s) (step <NUM>). In <NUM>-D printers that use laser sintering, a laser scans a powder bed and melts the powder together where structure is desired, and avoids scanning areas where the sliced data indicates that nothing is 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 a fabricator. In fused deposition modelling, as described above, parts are printed by applying successive layers of model and support materials to a substrate. In general, any suitable <NUM>-D printing technology may be employed for purposes of this disclosure.

Another AM technique includes powder-bed fusion ("PBF"). Like DMD, PBF creates `build pieces' 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. The energy beam is applied to melt areas of the powder layer that coincide with the cross-section of the build piece in the layer. The melted powder cools and fuses to form a slice of the build piece. The process can be repeated to form the next slice of the build piece, and so on. Each layer is deposited on top of the previous layer. The resulting structure is a build piece assembled slice-by-slice from the ground up.

<FIG> illustrate respective side views of an exemplary PBF system <NUM> during different stages of operation. As noted above, the particular embodiment illustrated in <FIG> is one of many suitable examples of a PBF system employing principles of this disclosure. It should also be noted that elements of <FIG> and the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein. PBF system <NUM> can include a depositor <NUM> that can deposit each layer of metal powder, an energy beam source <NUM> that can generate an energy beam, a deflector <NUM> that can apply the energy beam to fuse the powder, and a build plate <NUM> that can support one or more build pieces, such as a build piece <NUM>. PBF system <NUM> can also include a build floor <NUM> positioned within a powder bed receptacle. The walls of the powder bed receptacle <NUM> generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls <NUM> from the side and abuts a portion of the build floor <NUM> below. Build floor <NUM> can progressively lower build plate <NUM> so that depositor <NUM> can deposit a next layer. The entire mechanism may reside in a chamber <NUM> that can enclose the other components, thereby protecting the equipment, enabling atmospheric and temperature regulation and mitigating contamination risks. Depositor <NUM> can include a hopper <NUM> that contains a powder <NUM>, such as a metal powder, and a leveler <NUM> that can level the top of each layer of deposited powder.

Referring specifically to <FIG>, this figure shows PBF system <NUM> after a slice of build piece <NUM> has been fused, but before the next layer of powder has been deposited. In fact, <FIG> illustrates a time at which PBF system <NUM> has already deposited and fused slices in multiple layers, e.g., <NUM> layers, to form the current state of build piece <NUM>, e.g., formed of <NUM> slices. The multiple layers already deposited have created a powder bed <NUM>, which includes powder that was deposited but not fused.

<FIG> shows PBF system <NUM> at a stage in which build floor <NUM> can lower by a powder layer thickness <NUM>. The lowering of build floor <NUM> causes build piece <NUM> and powder bed <NUM> to drop by powder layer thickness <NUM>, so that the top of the build piece and powder bed are lower than the top of powder bed receptacle wall <NUM> by an amount equal to the powder layer thickness. In this way, for example, a space with a consistent thickness equal to powder layer thickness <NUM> can be created over the tops of build piece <NUM> and powder bed <NUM>.

<FIG> shows PBF system <NUM> at a stage in which depositor <NUM> is positioned to deposit powder <NUM> in a space created over the top surfaces of build piece <NUM> and powder bed <NUM> and bounded by powder bed receptacle walls <NUM>. In this example, depositor <NUM> progressively moves over the defined space while releasing powder <NUM> from hopper <NUM>. Leveler <NUM> can level the released powder to form a powder layer <NUM> that has a thickness substantially equal to the powder layer thickness <NUM> (see <FIG>). Thus, the powder in a PBF system can be supported by a powder support structure, which can include, for example, a build plate <NUM>, a build floor <NUM>, a build piece <NUM>, walls <NUM>, and the like. It should be noted that the illustrated thickness of powder layer <NUM> (i.e., powder layer thickness <NUM> (<FIG>)) is greater than an actual thickness used for the example involving <NUM> previously-deposited layers discussed above with reference to <FIG>.

<FIG> shows PBF system <NUM> at a stage in which, following the deposition of powder layer <NUM> (<FIG>), energy beam source <NUM> generates an energy beam <NUM> and deflector <NUM> applies the energy beam to fuse the next slice in build piece <NUM>. In various exemplary embodiments, energy beam source <NUM> can be an electron beam source, in which case energy beam <NUM> constitutes an electron beam. Deflector <NUM> can include deflection plates that can generate an electric field or a magnetic field that selectively deflects the electron beam to cause the electron beam to scan across areas designated to be fused. In various embodiments, energy beam source <NUM> can be a laser, in which case energy beam <NUM> is a laser beam. Deflector <NUM> can include an optical system that uses reflection and/or refraction to manipulate the laser beam to scan selected areas to be fused. In various embodiments, the deflector <NUM> can include one or more gimbals and actuators that can rotate and/or translate the energy beam source to position the energy beam. In various embodiments, energy beam source <NUM> and/or deflector <NUM> can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the energy beam can be modulated by a digital signal processor (DSP).

One aspect of this disclosure presents a node for enabling connection of various components of transport structures. The node may include a port extending inwardly from a surface to form a recess. The node may further include an inlet aperture disposed inside the port and an outlet aperture disposed inside the port. The inlet aperture is configured to receive a fluid injected into at least one region to be filled by the fluid. The outlet aperture is configured to enable the fluid to flow out of the at least one region. The port is configured to receive a nozzle to enable injection of the fluid and removal of the fluid. For example, the fluid can be an adhesive configured to bond various components together. In an embodiment, at least one connection of the node may be a part of a vehicle chassis. This type of node connection may incorporate adhesive bonding between the node and the component to realize the connection. Sealants may be used to provide adhesive regions for adhesive injection. In an exemplary embodiment, a seal may act as an isolator to inhibit potential galvanic corrosion caused, e.g., by the chronic contact between dissimilar materials.

<FIG> illustrates a cross-sectional view of an example of a single port node <NUM> for bonding to various components according to one embodiment of this disclosure. The node <NUM> can include a port <NUM>, an inlet aperture <NUM> and an outlet aperture <NUM>. For example, the port <NUM> may extend inwardly from an external surface <NUM> to form a recess. The inlet aperture <NUM> is disposed inside the port <NUM> and configured to receive a fluid <NUM> injected into at least one region to be filled by the fluid. For example, the fluid may be an adhesive configured to bond to various components through at least one adhesive region. The outlet aperture <NUM> is disposed inside the port <NUM> and configured to enable the fluid <NUM> to flow out of the at least one region. The port <NUM> is configured to receive a nozzle to enable injection and removal of the fluid <NUM>. Adhesive is used below as an example in this disclosure for the fluid, however, the fluid can be any other fluid as well.

The port <NUM> may additionally be a vacuum port for applying negative pressure to draw the adhesive towards the outlet aperture <NUM> to which the port is coupled. The outlet aperture <NUM> is configured to be coupled to a negative pressure source, and the port <NUM> is configured to be both an injection port and a vacuum port. While the adhesive application process in this disclosure may include a combination of vacuum and adhesive applications, the disclosure is not limited as such, and adhesive may in some exemplary embodiments be injected without use of negative pressure. In these cases, the positive pressure causing the adhesive flow may be sufficient to fill the adhesive regions.

As shown in <FIG>, the single port <NUM> may be utilized for both the adhesive inlet and outlet operations. The port <NUM> may be in a cylindrical shape and extend in an axial direction in some embodiments. In some other embodiments, the port can be in a conical shape, a cubic shape, or any other shape. In some alternative embodiments, the port may be a protrusion extending upwardly from the external surface <NUM> with a recess in a central portion of the protrusion that includes the apertures or other structures. The ports may also include protrusions built in surrounding holes, such that the tips of the protrusions may be flush with or proximate in height to the external surface of the node. In embodiments utilizing protruding ports, the ports may optionally be fabricated with the intent of being broken off upon completion of the bonding process, which may also reduce mass and volume of the corresponding node or other structure that includes the ports. For example, the port may have other configurations as well. For purposes of this disclosure, ""port" may be broadly construed to include either a recess or protrusion in a structure, along with their constituent aperture(s), that receives or provides a substance (including, e.g., fluids, gasses, powders, etc.), and therefore "port" would encompass any of the embodiments discussed above.

As shown in <FIG>, two apertures <NUM> and <NUM> are disposed inside the port <NUM>. The adhesive inlet aperture <NUM> is configured for receiving adhesive <NUM> injected into the channel <NUM> and toward the adhesive regions. The adhesive outlet aperture <NUM> is configured for removing the adhesive <NUM> from the channel <NUM> and/or for determining whether and when the adhesive <NUM> has substantially filled the necessary regions of the node or structure. For example, the inlet aperture <NUM> is disposed on a side wall of the port <NUM>. Thus, the adhesive <NUM> is injected into the channel <NUM> by a positive pressure perpendicular to an axial direction <NUM> of the port <NUM>. This would advantageously prevent the displacement of the nozzle during the adhesive injection process. If the adhesive is injected along the axial direction <NUM> of the port <NUM>, the injection pressure may push the effector or applicator for injecting the adhesive out of the port. Thus in this embodiment, the adhesive injection is perpendicular to the axial direction <NUM>.

The outlet aperture <NUM> may disposed on a bottom of the port <NUM>. In some embodiments, the node <NUM> may further include a second inlet aperture disposed inside the port <NUM>, for example, on the side wall of the port <NUM>. In some embodiments, the node <NUM> may further include a plurality of inlet apertures disposed inside the port <NUM>. For example, the plurality of inlet apertures may be disposed circumferentially around the port <NUM>. Similarly, in some embodiments, the node <NUM> may further include a second outlet aperture disposed inside the port <NUM>, for example, on the bottom of the port <NUM>. In some embodiments, the node <NUM> may further include a plurality of outlet apertures disposed inside the port <NUM>. For example, the plurality of outlet apertures may be disposed in the bottom of the port <NUM>. It will also be noted in this simplified embodiment that, while the adhesive <NUM> is shown as flowing from input aperture <NUM> through a short channel <NUM> to outlet aperture <NUM>, in practice, the adhesive <NUM> may be designed to flow through a desired region of the node <NUM> where the adhesive <NUM> is needed. Thus, the short channel <NUM> may instead be a long channel or series of channels coupled intermediately to one or more adhesive bond regions, which are spaces or regions of the node <NUM> desired for adhesive deposit. These details are omitted from the view of <FIG> for simplicity and clarity.

There are many possible variations and configurations of the location and arrangement of the inlet aperture <NUM> and the outlet aperture <NUM>. The above example is for illustration purposes only and is not intended to limit the scope of the disclosure. In some embodiments, the inlet and outlet apertures <NUM> and <NUM> may have a diameter of <NUM> or greater, although smaller values are possible and may be equally suitable in some embodiments. For example, the inlet and outlet apertures <NUM> and <NUM> may have a diameter between <NUM> and <NUM> in an embodiment. The inlet and outlet apertures may have the same or different diameters. The inlet and outlet apertures <NUM> and <NUM> need not have the same shape, and may be shaped in geometries other than elliptical geometries. For example, the apertures <NUM> and <NUM> may be rectangular or otherwise arbitrarily shaped. In some cases, the shape of the apertures <NUM> and <NUM> coincides with the shape of one or more portions of the channels that join them. The port <NUM> may have a cylindrical shape or any other shape. The inlet aperture and the outlet aperture may have any suitable shape as noted. The port may also include any other shape, such as a cubic shape, a conical shape, or any arbitrary shape.

The node <NUM> may further include at least one channel <NUM> extending from the adhesive inlet aperture <NUM> to the at least one adhesive bond region (not shown) and further to the adhesive outlet aperture <NUM>. The port <NUM> is coupled to the channel <NUM> through both the adhesive inlet aperture <NUM> and the adhesive outlet aperture <NUM> disposed inside the port <NUM>. Instead of having two separate ports for injection and removal of the adhesive as is the conventional practice, the adhesive inlet aperture <NUM> inside the port <NUM> receives injection of the adhesive, and the adhesive outlet aperture <NUM> inside the same port <NUM> performs removal of the adhesive (or, in other embodiments, a visual, tactile or other indication that the adhesive is full so that the injection operation can be ended e.g., when the adhesive begins to exit aperture <NUM>). In this way, the single port <NUM> performs the functions of both injection and removal of the adhesive. The channel(s) <NUM> may extend from the adhesive inlet aperture <NUM>, may travel through the node <NUM> to apply adhesive to the bond region(s), and may be coupled to the adhesive outlet aperture <NUM>. For example, the channel may be an elliptical channel that traverses the node in a desired location and may connect to a wider or bigger bond region, and then may be routed from the bond region as a similarly-shaped elliptical channel to the adhesive outlet aperture <NUM>. In some embodiments, multiple parallel channels may be employed as an alternative to a single, segmented channel. Moreover, the diameter of the channels can be varied along their lengths. These structures can advantageously be manufactured using AM techniques without requiring any significant post-processing operations.

In other embodiments, adhesive inlet aperture <NUM> may comprise more than one aperture and may receive injected adhesive <NUM> in parallel. With reference to the single-port embodiment of <FIG>, for example, the inlet aperture <NUM> may in these embodiments comprise a plurality of inlet apertures disposed along a designated circumference of the cylindrical region of the port. In addition, in these or other embodiments, more than one adhesive outlet aperture may be arranged on a bottom portion of the cylindrical region. These one or more apertures <NUM> and/or <NUM> may correspond to one or more channels <NUM> for delivering adhesive to and from the adhesive bond region(s). In still other embodiments, as noted above, each of the one or more apertures and/or channels may include a variety of geometries, as suitable for the application.

The channel <NUM> may be a part of the node <NUM> and may be additively manufactured using any suitable AM technique. The channel <NUM> may comprise multiple channel portions after it enters and then exits an adhesive region. Depending on the embodiment and whether adhesive is injected serially or in parallel, the node may be considered to have one or more channels as described above. In general, the design of the channels may enable sequential flow of the adhesive into specific adhesive bond regions between an inner surface of the node and an outer surface of a component intended to be connected to the node.

The node may also be extended, elongated, or shaped in any way to enable multiple sets of interface regions (i.e., sets of one or more adhesive bond regions with sealants and channels as described above to realize a connection) to exist on a single node. For example, in one embodiment, the node is rectangular, with separate interfaces on two or more sides of the rectangular node connecting to different panels via the adhesive process and techniques described above. In other embodiments, nodes may be constructed to have interface regions in close proximity so that two respective panels may be spaced very closely, or so that the panels may make contact. Numerous embodiments and geometries of the node may be contemplated.

To better facilitate assembly, the node may be printed in two or more parts, with the two or more parts being connected together prior to adhesive injection. The node may constitute additional features, such as connection features to other structures or other structural or functional features that are not explicitly shown in the illustrations herein to avoid unduly obscuring the concepts of the disclosure. These additional features of the node may cause portions of the node to take a different shape or may add structures and geometrical features that are not present in the illustrations herein. These additional features and structures may be additively manufactured along with the remainder of the node, although this may not necessarily be the case, as in some applications, traditional manufacturing techniques such as casting or machining may be used.

Advantageously, the single port design of the node <NUM> is efficient, as the port <NUM> is configured to perform multiple functions, such as an adhesive inlet port and an adhesive outlet port. The port <NUM> of the node <NUM> enables the adhesive injection process and removal process through a single port. The port <NUM> is both an entry point and an exit point for the adhesive <NUM> or other fluids. In some embodiments, the port <NUM> is further a vacuum port where the adhesive outlet port is connected to a negative pressure source. In other embodiments, the port <NUM> need not be a vacuum port but may, for example, be an exit point for excess adhesive.

The single port node <NUM> is further advantageous to reduce the complexity of the adhesive applicator system, which may in some embodiments include a nozzle for performing the adhesive injection/vacuum procedure. Only one nozzle is required to draw a vacuum (where desired), inject the adhesive and remove the excessive adhesive. This procedure is in contrast to conventional multi-port designs. The nozzle can further have the ability to allow for the transfer of two or more fluids through the port <NUM>. This would make the single port design conducive to embodiments wherein other fluids, for example, sealants, may be used to cap off the port after adhesive injection.

The single port node <NUM> is further advantageous in that it reduces the complexity of designing an automated system for applying adhesives. As an example, the nozzle for applying adhesive may be carried or used by a robot. Since the robots would have to interface with just one port, the robots can be leaner and more compact than may otherwise be required in a conventional assembly system requiring multiple ports. Furthermore, because assembly systems often involve a large number of nodes, the single port node can greatly increase the efficiency of the assembly process.

A plurality of nozzles, or interface nozzles, may be utilized with the nodes having a single port for adhesive as described above. The terms "nozzle" and 'interface nozzle" are used interchangeably in this disclosure. The nozzles may include a plurality of channels, depending on the number of materials used in the adhesive injection process or other factors. O-Rings or other seals may be utilized to obtain a sealed interface between the surface of the port on the node, and the nozzle. This sealed interface would ensure that the adhesive injection process occurs in a sealed manner. This sealed interface is particularly advantageous in embodiments utilizing a vacuum connection during the adhesive injection process. The nozzles may be additively manufactured.

<FIG> illustrates a cross-section view of a two-channel nozzle <NUM> for the single port node <NUM>, where the nozzle <NUM> is connected to the node <NUM>. <FIG> illustrates a perspective view of the two-channel nozzle <NUM>. Referring to <FIG> and <FIG>, the nozzle <NUM> includes a first channel <NUM> and a second channel <NUM>. The first channel <NUM> includes a first inlet <NUM> of nozzle and a first outlet <NUM> of nozzle. The first outlet <NUM> of nozzle is coupled to the inlet aperture <NUM> disposed inside the port <NUM> of the node <NUM>. The second channel <NUM> includes a second inlet <NUM> of nozzle and a second outlet <NUM> of nozzle. The second outlet <NUM> of nozzle is coupled to the outlet aperture <NUM> disposed inside the port <NUM>. The first channel <NUM> and the second channel <NUM> are isolated from one another. The first channel <NUM> is configured to inject an adhesive through the first outlet <NUM> of nozzle into the inlet aperture <NUM>. The second channel <NUM> is configured to receive the adhesive from the outlet aperture <NUM>. In some embodiments, the second inlet <NUM> of nozzle is configured to be coupled to a negative pressure source to apply vacuum to the outlet aperture <NUM>. The nozzle <NUM> may be additively manufactured as well.

The nozzle <NUM> includes a first end 500a and a second end 500b. The first end 500a is also referred to as a port end, which is configured to be inserted into the port <NUM>. The port end 500a of the nozzle may have a size compatible with a diameter of the port <NUM>. The second end 500b is also referred to as an effector end, which is configured to be coupled to an effector.

The nozzle <NUM> may work with one fluid, which is referenced herein as a single circuit embodiment. The nozzle <NUM> may be used to inject the adhesive and remove the adhesive without applying vacuum. The single circuit embodiment may be utilized to simplify the number of variants in a manufacturing system. For example, the first outlet of nozzle <NUM> is disposed on a side wall of the port end 500a, in order to enable the adhesive to be injected into the inlet aperture <NUM> with a positive pressure perpendicular to an axial direction <NUM> of the port <NUM>. The second outlet of nozzle <NUM> may be disposed on a bottom of the port end of 500a. The single circuit embodiment can have a great flow capability, but the single circuit embodiment only works with a single fluid, such as an adhesive, or a sealant, that would not be vacuumed and would be injected with positive pressure only.

The nozzle <NUM> may further work with two fluids, which is referenced herein as a two circuit embodiment. The nozzle <NUM> may be used to apply vacuum to the adhesive outlet aperture <NUM> of the node <NUM> through the second channel <NUM>, and inject the adhesive into the adhesive inlet aperture <NUM> of the node <NUM> through the first channel <NUM>.

The port end 500a of the nozzle <NUM> may be inserted into the port <NUM> of the node <NUM>. The vacuum may be applied to the port <NUM>. The negative pressure from the vacuum may cause the nozzle <NUM> to be pulled more tightly into the port <NUM>, which is an interface receptacle port. This tight connection helps ensure that the correct inlets and outlets of the nozzle meet snugly with the respective apertures of the node <NUM> and that the adhesive application procedure flows smoothly and efficiently. The adhesive can be applied to the inlet aperture <NUM> of the port <NUM>. Here again, while the channel between inlet aperture <NUM> and outlet aperture <NUM> is shown for simplicity as a simple loop, the channel in practice may extend to one or more adhesive bond regions of the node <NUM> as described above with reference to <FIG>.

In an exemplary embodiment, the adhesive is injected into the inlet aperture <NUM> with a positive pressure perpendicular to the axial direction <NUM> of the port <NUM>. For example, the first outlet of nozzle <NUM> is disposed on a side wall of the port end 500a. The pressure from the injection of the adhesive acts radially in the nozzle <NUM> and port <NUM>. That is, the injection of the adhesive causes a force applied on the nozzle along a radial direction. The force from the injection is perpendicular to the axial direction <NUM> of the port <NUM>. Thus, the force neither pulls nor pushes the nozzle <NUM> in or out of the receptacle port <NUM> during the adhesive injection process. This configuration is advantageous to form a stable connection between the nozzle <NUM> and the node <NUM>. The stability may be further increased in embodiments using a vacuum. As indicated above, the negative pressure from the vacuum together with the orientation of the outlet aperture <NUM> at the bottom of the port <NUM> ensures an even tighter fit of the nozzle <NUM> into the port <NUM> as the vacuum is drawn.

The first channel <NUM> and the second channel <NUM> of the nozzle <NUM> may have various relative orientations and configurations. For example, the first channel <NUM> and the second channel <NUM> may extend away from each other at the second end 500b (referred to herein also as the effector end 500b) as shown in <FIG>. The first channel <NUM> and the second channel <NUM> may alternatively be parallel to each other at the second end 500b. In some embodiments, the first channel <NUM> and the second channel <NUM> substantially extend along the axial direction <NUM> at the port end 500a, such that the two channels <NUM> and <NUM> can be effectively inserted into the port <NUM>.

The nozzle <NUM> may further include one or more O-Rings, or sealants. O-Rings or sealants may be used at the nozzle-port interface as well as the nozzle-effector interface. A sealant region may include features such as a groove, dovetail groove, inset or other feature built into a surface of the nozzle. The sealant region may accept a sealant such as an O-Ring.

Referring to <FIG>, the nozzle <NUM> may include a first O-ring 535a disposed between the first outlet of nozzle <NUM> and the second outlet of nozzle <NUM>. The second outlet of nozzle <NUM> is coupled to the outlet aperture <NUM> of the node <NUM> to apply the negative pressure. The first O-ring 535a is used to provide a seal to the vacuum, to prevent unwanted flow of the adhesive, and to isolate the first outlet of nozzle <NUM> from the second outlet of nozzle <NUM>. The nozzle <NUM> may further include a second O-ring 535b disposed above the first outlet of nozzle <NUM> at the port end 500a. The second O-ring 535b is used to provide an additional seal to the port <NUM> and further prevent unwanted flow of the adhesive. It will be appreciated that the first and second O-rings 535a and 535b in <FIG> are partially obscured from view in this drawing since they extend out of and into a plane of the drawing, and laterally behind other structures (e.g. first and second channels <NUM> and <NUM>). <FIG> shows an alternative perspective view of the structure including an illustration of the external contour of the structure according to an embodiment. O-rings 535a and 535b are shown encircling portions of the port end 500b. An external view of nozzle <NUM> is also shown in <FIG>, and includes a view of the first and second inlets <NUM> and <NUM>. In an embodiment, effector end 500b is designed to easily and efficiently fit into a corresponding portion of a robot or other structure for supplying fluids and negative pressure to the appropriate channels and for moving the effector as required from one port to another.

In addition to the nozzle with two circuits described above, a third circuit can be added in another embodiment to introduce another fluid, for example, a sealant which can be used to encapsulate the injected adhesive. The sealant can be dispensed after the adhesive at the time of removal of the interface nozzle from the interface port. The sealant may be configured to cure or solidify well in advance of the adhesive curing. The nozzle with three circuits may include three channels, one channel for each respective fluid.

<FIG> illustrates a cross-section view of a three-channel nozzle <NUM> for the single port node <NUM>. <FIG> illustrates another cross-section view of the three-channel nozzle <NUM> from another plane. More specifically, as described further below, <FIG> is offset relative to <FIG> about a longitudinal axis <NUM> such that cross-sections of the nozzle <NUM> are viewable at two different section planes. Referring to <FIG>, the nozzle <NUM> includes a first channel <NUM>, a second channel <NUM> and a third channel <NUM>. The first channel <NUM> includes a first inlet of nozzle <NUM> and a first outlet of nozzle <NUM>. The first outlet of nozzle <NUM> is configured to be coupled to the inlet aperture <NUM> of the node <NUM> (<FIG>). The second channel <NUM> includes a second inlet of nozzle <NUM> and a second outlet of nozzle <NUM>. The second outlet of nozzle <NUM> is configured to be coupled to the outlet aperture <NUM>. The first channel <NUM> and the second channel <NUM> are isolated from one another. The first channel <NUM> is configured to inject an adhesive through the first outlet of nozzle <NUM> into the inlet aperture <NUM>. The second channel <NUM> is configured to remove the adhesive from the outlet aperture <NUM> (<FIG>). In some embodiments, the second inlet of nozzle <NUM> is configured to be coupled to a negative pressure source to apply vacuum to the outlet aperture <NUM>. The first inlet of the nozzle <NUM> can be connected to the first outlet of nozzle <NUM> through the first channel <NUM>. The adhesive can be injected from the robot into the first inlet of nozzle <NUM> and can travel to first outlet of nozzle <NUM> and then injected into the port. The second inlet of the nozzle <NUM> can be connected to the second outlet of nozzle <NUM> through the second channel <NUM>. The excess adhesive from the port can travel from the second outlet of nozzle <NUM> to the second inlet of nozzle <NUM>, and to the robot or other controlling device.

In addition to the first channel <NUM> and the second channel <NUM>, a third channel <NUM> can be added to introduce a third fluid, for example, which can be a sealant to encapsulate the injected adhesive. The third channel <NUM> includes a third inlet of nozzle <NUM> and a third outlet of nozzle <NUM>. For example, the third channel <NUM> is configured to dispense a sealant through the third outlet of nozzle <NUM>. The third inlet of nozzle <NUM> can be connected to the third outlet of nozzle <NUM> through the third channel <NUM>. The sealant can travel from the third inlet of nozzle <NUM> to the third outlet of nozzle <NUM>, and can be injected into an appropriate inlet aperture in the port. The third channel <NUM> is isolated from the first channel <NUM> and the second channel <NUM>. In an embodiment, the third fluid can be dispensed after the adhesive immediately before removal of the interface nozzle from the interface port. The nozzle <NUM> may be additively manufactured as well.

As is evident from the above description, <FIG> illustrate two cross-sections of the same nozzle <NUM> in order to show the positions of the various features relative to each other. <FIG> illustrates a cross-section including the first channel <NUM> and the third channel <NUM>. <FIG> illustrates another cross-section including the second channel <NUM> and the third channel <NUM>. As shown in <FIG>, the three channels <NUM>, <NUM>, and <NUM> may be disposed in different cross-sections and offset from each other. For example, the first channel <NUM> and the second channel <NUM> may be disposed on a first plane, and the third channel <NUM> may be disposed offset from the first plane.

Referring to <FIG>, the nozzle <NUM> includes a first end 600a and a second end 600b. As shown in <FIG>, the first end 600a includes the portion of the nozzle <NUM> below the dotted line <NUM> and the second end 600b includes the portion of the nozzle <NUM> above the dotted line <NUM>. The first end 600a is also referred to as a port end, which is configured to be inserted into a port of a node. The second end 600b is also referred to as an effector end. The effector end 600b may be connected to an effector, which would be connected to the sealant, adhesive and vacuum apparatuses.

Since the port end 600a is configured to be inserted into the port of the node, the port end 600a may have a size compatible to a size of the port. In some embodiments, the first channel <NUM>, the second channel <NUM> and the third channel <NUM> are extending along an axial direction <NUM> at the port end 600a. For example, at the port end 600a, the first channel <NUM>, the second channel <NUM> and the third channel <NUM> may be parallel to each other along the axial direction <NUM>. However, at the effector end 600b, the first channel <NUM>, the second channel <NUM> and the third channel <NUM> may have different orientations. For example, the first channel <NUM>, the second channel <NUM> and the third channel <NUM> may extend away from each other.

<FIG> illustrates the nozzle <NUM> including a plurality of regions 635a-f for receiving O-rings/sealants. As shown in <FIG>, O-Rings or sealants can be used at both the nozzle-port interface and the nozzle-robot interface. A sealant region 635a-f may include features such as a groove, dovetail groove, inset or other feature built into a surface of the nozzle <NUM>. The sealant regions 635a-f may accept a sealant such as an O-ring. The sealant regions may be used to separate different circuits, or different channels. The sealant regions may also be used to prevent unwanted flow between different channels. For example, an O-ring in region 635a may be disposed between the first outlet of nozzle <NUM> (obscured from view) and the second outlet of nozzle <NUM>. As another example, the O-rings in regions 635d and 635e may be disposed between the first inlet of nozzle <NUM>, the second inlet of nozzle <NUM> and the third inlet of nozzle <NUM>, respectively.

Referring to <FIG> and <FIG>, the nozzle <NUM> may include a first O-ring disposed in region 635a between the first outlet of nozzle <NUM> and the second outlet of nozzle <NUM>, as noted above. The second outlet of nozzle <NUM> is coupled to the outlet aperture <NUM> of the node to apply the negative pressure. The first O-ring in region 635a may be used to provide a seal to the vacuum and prevent unwanted flow of the adhesive. The nozzle <NUM> may further include a second O-ring disposed in region 635b above the first outlet of nozzle <NUM> at the port end. In an embodiment, the second O-ring 635b is used to provide additional seal to the port and to further prevent unwanted flow of the adhesive. The nozzle <NUM> may be additively manufactured. The nozzle <NUM> may be disposable. This can be advantageous as nozzles can be discarded after the channels in them have been clogged due to extended use. O-rings in remaining regions 635c-f may be similarly discarded for providing isolation and sealing, and preventing contamination, etc..

<FIG> illustrates a bottom view of a nozzle with a plurality of sealant outlets, according to one embodiment of this disclosure. Referring to <FIG> and <FIG>, a third channel can be added in the nozzle <NUM> to dispense a sealant through the third outlet of nozzle <NUM>. In an exemplary embodiment, the sealant or sealer can be dispensed after the adhesive is injected and at the time before removal of the interface nozzle from the port and the cure of the adhesive. The sealant or sealer may form a cap for the port. The sealant or sealer may alternatively or additionally be used as an isolator to seal the port and prevent direct contact between the node and the component to and from the connection. Where, for example, the component and node are composed of dissimilar metals, this isolation may be crucial to preventing galvanic corrosion and therefore to enable reliable, long-lasting node-component connections.

<FIG> further illustrates a bottom view of a nozzle with a plurality of sealant outlets in one embodiment. Instead of having one third outlet of nozzle, the nozzle <NUM> can include a plurality (e.g. six (<NUM>)) of third outlets of nozzle <NUM>. For example, the plurality of third outlets of nozzle <NUM> may be evenly distributed around the second outlet of the nozzle <NUM>, which may be a vacuum port. The sealant or sealer may flow out from the plurality of third outlets of nozzle <NUM>, instead of a single hole. The sealant may be deposited from the plurality of third outlets of nozzle <NUM> to form a sealant layer. The plurality of third outlets of nozzle <NUM> may be advantageous to evenly distribute the sealant and form a layer of sealant with a more uniform thickness, in comparison to the single third outlet of nozzle configuration. In general, one or more outlets of nozzles <NUM> may be suitable depending on the implementation. In still other embodiments (not explicitly shown), the first and second channels may include multiple outlets as well, e.g., to spread adhesive evenly and/or to correspond to multiple inlet and/or outlet apertures in the associated ports, as discussed with reference to an earlier embodiment of the port <NUM>.

<FIG> illustrates a bottom view of a nozzle with a plurality of sealant outlets in another embodiment. The second outlet of nozzle <NUM> is disposed at a side at the bottom of the nozzle <NUM>, and the plurality of third outlets of nozzle <NUM> are disposed at another side. This configuration may be used in a nozzle with a small cross-sectional bottom area.

<FIG> is a flow diagram of an exemplary method <NUM> of using a single port node to form a bond with various components. Various embodiments of the method <NUM> of using the single port node are disclosed herein. When in use, a nozzle (also referred as an interface nozzle) can be inserted into the single port of the node. The step of inserting the nozzle into the port of the node <NUM> can be performed by a robot or other automated machinery for volume production. The step <NUM>, of inserting a nozzle into a port of a node, can also be performed by a human. For example, an effector of the robot can grab an effector end of the nozzle and insert a port end of the nozzle into the port. The nozzle can include a plurality of channels. An outlet of nozzle of a vacuum channel, which may be a second channel of the nozzle, can be connected to a corresponding outlet aperture disposed inside the port. The step of applying vacuum <NUM> includes applying vacuum to the outlet aperture disposed inside the port.

In some embodiments, a step of applying vacuum <NUM> is used to draw the nozzle close to the port and lock the nozzle to the port. The negative pressure of vacuum may also help to speed up the process of filling the node with adhesive, e.g., by a robot sensing the presence of an output adhesive flow from the port in the second channel. For example, the step of applying vacuum <NUM> may include applying vacuum to the outlet aperture along an axial direction of the port. The outlet aperture may be disposed on a bottom of the port. Thus, the negative pressure is applied along the axial direction of the port. In some other embodiments, the adhesive is removed without applying vacuum. The step of applying vacuum <NUM> may be omitted.

The method of using the single port node <NUM> includes a step of injecting the adhesive <NUM>. An outlet of nozzle of an adhesive injection channel, which is a first channel of the nozzle, can be connected an inlet aperture disposed inside the port. The step of injecting the adhesive <NUM> includes injecting the adhesive to the inlet aperture disposed inside the port. For example, the inlet aperture may be disposed on a side wall of the port. Thus, the positive injection pressure is applied perpendicular to an axial direction of the port. In other words, the positive injection pressure is acting radially. Therefore, the positive pressure will not push the nozzle out of the port. In some embodiments, the step of injecting the adhesive <NUM> includes injecting the adhesive with the positive pressure perpendicular to the axial direction of the port.

The method <NUM> may further include enabling the adhesive to fill at least one region of the node <NUM>. After the adhesive is injected, the adhesive can travel through a channel inside the node. The channel extends from the inlet aperture inside the port, to one or more one adhesive regions to be filled with the adhesive, and returns to the outlet aperture disposed inside the port. The method <NUM> can enable the adhesive to fill the one or more adhesive regions in the node to form bonds with various components. In some embodiments, the method <NUM> may further include removing the adhesive from the outlet aperture through the second channel of the nozzle. The process of removing the adhesive can be performed by applying the vacuum pressure, or can be performed without applying the vacuum.

The method <NUM> may further include dispensing another fluid, for example, a sealant or sealer, to encapsulate the injected adhesive inside the port through a third channel of the nozzle, which may be a sealant channel. For example, when the first traces of adhesive overflow are sensed in the second channel, the robot may be enabled to sense when to stop the adhesive flow in an embodiment. For example, after the injection and removal of the excessive adhesive, the sealant or sealer can be dispensed from one or more sealant outlets of the nozzle. The sealant or sealer may form a cap to encapsulate the injected adhesive. The sealant or sealer may be dispensed before the adhesive is cured. The sealant or sealer may be cured before the adhesive is cured. For example, the sealant or sealer sealant cures quicker than the adhesive. Thus, the sealant or sealer may protect the port and the process of curing the adhesive. The sealant or sealer may be dispensed from a plurality of third outlets such that the sealant or sealer may be evenly distributed and form a uniform layer of cap.

In some embodiments, the method <NUM> may further include separating the apertures of the nozzle by one or more O-rings of the nozzle. The nozzle may include one or more O-rings at a nozzle-port interface, and a nozzle-effector interface. The O-rings of the nozzle can separate the different channels, and prevent unwanted flow between channels. The O-rings may also help applying the vacuum. In the case that multiple circuits are actuated to apply the adhesive, vacuum and sealant, the O-rings may also help to prevent a short circuit (e.g., a breach of adhesive from an adhesive inlet channel into a vacuum channel, etc.). Advantageously, the method <NUM> disclosed herein can significantly increase the efficiency of the manufacturing process. The complexity of the adhesive injection system can be reduced because the robot only needs to move to one location to inject the adhesive and sense a complete fill of the adhesive, with or without using negative pressure. Since the robots or other automated machines only have to interface with one port, these robots/machines can be made leaner and more compact than those in the conventional assembly system needed for applying adhesive to nodes requiring two (or more) ports. Because the assembly system involves a large number of nodes, the method <NUM> can greatly increase the efficiency and reduce the complexity of the assembly process.

In another aspect of this disclosure, a node for enabling connection of various components without an outlet aperture is disclosed. The node may include a port extending inwardly from a surface to form a recess. The node may further include an inlet aperture disposed inside the port. The inlet aperture is configured to receive a fluid injected into at least one bond region to be filled by the fluid. The port is configured to receive a nozzle to enable injection of the fluid. For example, the fluid can be an adhesive configured to bond various components together. In an embodiment, at least one connection of the node may be a part of a vehicle chassis. In another embodiment, at least one connection of the node may be a part of other structures.

<FIG> illustrates a perspective view of an example of a single port node <NUM> for bonding to various components according to another embodiment of this disclosure. <FIG> illustrates a top view of the single port node <NUM>. <FIG> illustrates another perspective view of the single port node <NUM>. Referring to <FIG>, the node <NUM> can include a port <NUM>, and an inlet aperture <NUM>. For example, the port <NUM> may extend inwardly from an external surface 903to form a recess. The inlet aperture <NUM> is disposed inside the port <NUM> and configured to receive a fluid injected into at least one bond region to be filled by the fluid. For example, node <NUM> may be part of a node/panel interace, and the fluid may be an adhesive configured to bond node <NUM> to the panel using at least one adhesive bond region. The port <NUM> is configured to receive a nozzle to enable injection of the fluid. Adhesive is used below as an example in this disclosure for the fluid, however, the fluid can be any other fluid as well.

The single port <NUM> may be utilized for the adhesive inlet operations. The port <NUM> may be similar as the port <NUM>, as shown in <FIG>. For example, the port <NUM> may be in a cylindrical shape and extend in an axial direction in some embodiments. In some other embodiments, the port can be in a conical shape, a cubic shape, or any other shape. In some alternative embodiments, the port may be a protrusion extending upwardly from the external surface <NUM> with a recess in a central portion of the protrusion that includes the apertures or other structures. The ports may also include protrusions built within recesses in the node, such that the tips of the protrusions may be flush with or proximate in height to the external surface of the node in which the recesses are inset. In other embodiments, the protrusions may be higher or lower than the external surface. In embodiments utilizing protruding ports, the ports may optionally be fabricated with the intent of being broken off upon completion of the bonding process, which may also reduce mass and volume of the corresponding node or other structure that includes the ports. The port may have other configurations as well.

The apertures <NUM> may be disposed inside the port <NUM>. The adhesive inlet aperture <NUM> is configured for receiving adhesive injected into the channel <NUM> and toward the adhesive regions. The aperture <NUM> may be similar to the aperture <NUM>, as shown in <FIG>. For example, the inlet aperture <NUM> may be disposed on a side wall of the port <NUM>. Thus, the adhesive is injected into the channel <NUM> by a positive pressure perpendicular to an axial direction <NUM> of the port <NUM>. The injection pressure may push the effector or applicator for injecting the adhesive out of the port when the adhesive is injected along the axial direction <NUM> of the port <NUM>. In some embodiments, the node <NUM> may further include a plurality of inlet apertures disposed inside the port <NUM>. For example, the plurality of inlet apertures may be disposed circumferentially around the port <NUM>. There are many variations and configurations of the location and arrangement of the inlet aperture <NUM>. The above examples are for illustration only and are not intended to limit the scope of the disclosure. In some embodiments, the inlet and outlet apertures <NUM> may have a diameter of <NUM> or greater, although smaller values are possible and may be equally suitable in some embodiments. For example, the inlet <NUM> may have a diameter between <NUM> and <NUM> in an embodiment. The port <NUM> may have a cylindrical shape or any other shape. The inlet aperture may have any suitable shape as noted. The port may also include any other shape, such as a cubic shape, a conical shape, or any arbitrary shape.

The node <NUM> may further include at least one channel <NUM> extending from the adhesive inlet aperture <NUM> to the at least one adhesive region (not shown). The port <NUM> is coupled to the channel <NUM> through the adhesive inlet aperture <NUM>. In other embodiments, adhesive inlet aperture <NUM> may comprise more than one aperture and may receive injected adhesive in parallel. The channel <NUM> may be similar to the channel <NUM> as shown in <FIG>. For example, the inlet aperture <NUM> may in these embodiments comprise a plurality of inlet apertures disposed along a designated circumference of the cylindrical region of the port. These one or more apertures <NUM> may correspond to one or more channels <NUM> for delivering adhesive. In still other embodiments, as noted above, each of the one or more apertures and/or channels may include a variety of geometries, as suitable for the application.

The channel <NUM> may be a part of the node <NUM> and may be additively manufactured using any suitable AM technique. The channel <NUM> may comprise multiple channel portions after it enters and then exits an adhesive bond region. Depending on the embodiment and whether adhesive is injected serially or in parallel, the node may be considered to have one or more channels as described above. In general, the design of the channels may enable sequential flow of the adhesive into specific adhesive bond regions between an inner surface of the node and an outer surface of a component whose edge has been inserted into a recess of the node.

A plurality of nozzles, or interface nozzles, may be utilized with the node <NUM> having a single port for adhesive as described above. For example, the nozzle may include a first channel comprising a first inlet of nozzle and a first outlet of nozzle. The first outlet of nozzle may be configured to be coupled to the inlet aperture <NUM> disposed inside the port <NUM> of the node <NUM>. Similar to the nozzle <NUM>, as shown in <FIG> and <FIG>, the nozzle for the single port <NUM> may include a first end and a second end. The first end may also referred to as a port end, which is configured to be inserted into the port <NUM>. The port end of the nozzle may have a size compatible with a diameter of the port <NUM>. The second end may be also referred to as an effector end, which is configured to be coupled to an effector.

In an exemplary embodiment, the adhesive is injected into the inlet aperture <NUM> with a positive pressure perpendicular to the axial direction <NUM> of the port <NUM>. For example, the first outlet of nozzle is disposed on a side wall of the port end. The pressure from the injection of the adhesive acts radially in the nozzle and port <NUM>. That is, the injection of the adhesive causes a force applied on the nozzle along a radial direction. The force from the injection is perpendicular to the axial direction <NUM> of the port <NUM>. Thus, the force neither pulls nor pushes the nozzle in or out of the receptacle port <NUM> during the adhesive injection process. This configuration is advantageous to form a stable connection between the nozzle and the node <NUM>, as discussed above.

<FIG> illustrates a side view of an example of an end effector <NUM> for interfacing with a nozzle (e.g., the nozzle <NUM> in <FIG>, the nozzle <NUM> in <FIG>) according to one embodiment of this disclosure. <FIG> illustrates a top view of the end effector <NUM> in a first position 1000a. <FIG> illustrates another top view of the end effector <NUM> in a second position 1000b. <FIG> illustrates a perspective view of the end effector <NUM>.

In an aspect of the disclosure, the end effector <NUM> for interfacing with a nozzle (e.g., <NUM>, <NUM>) is disclosed. The end effector <NUM> comprises a first end 1000e, which includes a receptacle <NUM> (<FIG>, <FIG>). The receptacle <NUM> in this embodiment is a downward protrusion having a generally circular opening at the first end 1000e and cylindrically-shaped side walls that are configured to receive the nozzle <NUM> and sized to the body of the nozzle <NUM> at the effector end. The side walls may include inlets and outlets for enabling fluids or negative pressure to flow between the end effector <NUM> and nozzle <NUM>. A variety of receptacle shapes are possible, including shapes for accommodating non-cylindrical nozzles. The nozzle <NUM> includes one or more nozzle retention features (e.g., 688a) and a first nozzle inlet (e.g. <NUM>). The nozzle <NUM> is used as only an example of nozzles for illustration in <FIG> in this disclosure. However, the end effector <NUM> can be used to interface with a variety of nozzles, not being limited to the nozzle <NUM>.

Referring to <FIG>, the end effector <NUM> comprises one or more retention features (e.g., 1088a, 1088b) positioned along a perimeter of the receptacle <NUM>, where each of the one or more retention features (e.g., 1088a, 1088b) is movable between a first position 1000a and a second position 1000b. Each of the one or more retention features (e.g., 1088a, 1088b) is configured to lock the nozzle <NUM> by securing onto a corresponding one of the one or more nozzle retention features (e.g., 688a) in the first position, and to release the nozzle <NUM> in the second position 1000b. The end effector <NUM> further comprises one or more actuators, for example, 1068a and 1068b, configured to actuate the one or more retention features (e.g., 1088a, 1088b) between the first position 1000a and the second position 1000b. The end effector <NUM> comprises a first channel <NUM> (<FIG>), which includes a first inlet <NUM> and a first outlet <NUM>. The first outlet <NUM> is positioned inside the receptacle <NUM> and is configured to be coupled to the first nozzle inlet <NUM> in the first position 1000a.

As shown in <FIG>, the end effector <NUM> is configured to connect to the nozzle <NUM>, for example, a multi-channel adhesive nozzle. The end effector <NUM> is the component that may connect to an effector end 600a of the nozzle <NUM>. The end effector <NUM> may include feed ports that may be coupled to the inlet ports of the nozzle <NUM>. For example, the end effector <NUM> may include a first inlet port <NUM> connected to a first outlet <NUM>, and further coupled to a first inlet port <NUM> (e.g., adhesive port) of the nozzle <NUM>. The end effector <NUM> may include a second inlet port <NUM> connected to a second outlet <NUM>, and further coupled to a second inlet port <NUM> (e.g., vacuum port) of the nozzle <NUM>. The end effector <NUM> may include a third inlet port <NUM> connected to a third outlet <NUM>, and further coupled to a third inlet port <NUM> (e.g., sealant port) of the nozzle <NUM>. The inlet ports and outlet ports may have other configurations, depending on the requirements. The end effector <NUM> thus has the capability to inject or apply a variety of fluids at the same time.

As shown in <FIG>, the end effector <NUM> includes a receptacle <NUM> to receive the nozzle <NUM>. The end effector <NUM> includes one or more retention features 1088a and 1088b, to retain the nozzle <NUM> to the end effector <NUM> during the injection process. One or more corresponding retention features 688a are present on the nozzle <NUM>. For example, the one or more retention features 1088a, 1088b in the end effector <NUM> may include cleats, or tangs, or protrusions, or tabs, or projections that can lock into the one or more corresponding retention feature 688a on the nozzle <NUM> in a first position 1000a (<FIG>) and can thus lock the end effector <NUM> to the nozzle <NUM> such that the fluid or vacuum application operations described herein can be initiated. Once these operations are completed, end effector <NUM> can be released from the nozzle <NUM> by moving retention features 1088a, 1088b into a second position 1000b (<FIG>) as described in further detail below.

One or more actuators 1068a, 1068b are utilized to lock and release the nozzle <NUM> by actuating the one or more retention features 1088a and 1088b. For example, the one or more actuators 1068a, 1068b may be hydraulically actuated, pneumatically actuated, electrically actuated, and the like. In an embodiment, the one or more actuators comprises one or more pneumatic cylinders, as shown in <FIG>.

<FIG> illustrates the end effector <NUM> in a first position 1000a, when the one or more pneumatic cylinders 1068a, 1068b are actuating the cleats 1088a, 1088b to an extended (locking the nozzle) position. As shown in <FIG>, the one or more retention features 1088a, 1088b are positioned along a perimeter of the receptacle <NUM>. For example, the one or more retention features 1088a, 1088b in the end effector <NUM> may include cleats, or tangs, or protrusions, or tabs, or projections, etc. Each of the one or more retention features 1088a, 1088b may be movable between the first position 1000a which is a locked position, and a second position 1000b which is a retracted position. Each of the one or more retention features 1088a, 1088b is configured to lock the nozzle <NUM> by securing onto a corresponding one of the one or more nozzles <NUM> in the first position 1000a.

The end effector <NUM> can then be released from the nozzle <NUM> when operations are complete. For example, the one or more retention features 688a may be locked in the first position 1000a by their respective actuators 1068a, 1068b when fluid application and related procedures are ongoing. Upon completion of the process, end effector <NUM> may then be released into a retracted position by releasing the features 1088a, 1088b from nozzle <NUM> as describe below.

Various embodiments may be used in <FIG> for locking the end effector <NUM> in place. In one example, the features 1088a, 1088b may be configured as cleats having curved edges and being movable along the X direction as shown in <FIG>. When the cleats 1088a, 1088b move along the X-direction, the curved edges of the cleats 1088a, 1088b may be placed to secure onto, or lock into, the one or more corresponding retention feature 688a, for example, a corresponding groove or one or more recesses on the nozzle <NUM>. In another example, the one or more retention features 1088a, 1088b on the end effector <NUM> may instead be configured to be movable along the Y direction, and may be placed to secure onto, or lock into the one or more corresponding retention feature on the nozzle when the retention features are moved along the Y direction. In another example, the one or more retention features 1088a, 1088b may be tabs, or tongs that are movably attached to the receptacle and that can be moved into the one or more corresponding retention features 688a, 688b of the nozzle <NUM> to lock the end effector in place. In another example, the one or more retention features can be movable in any directions and can move anywhere on the X-Y plane.

<FIG> illustrates the end effector <NUM> in a second position 1000b, when the one or more pneumatic cylinders 1068a, 1068b are actuating the cleats 1088a, 1088b to a retracted position. As shown in <FIG>, the one or more retention features 1088a, 1088b may be moved away from the one or more corresponding retention features 688a on the nozzle <NUM> to release the nozzle <NUM> from the end effector <NUM>.

In some other embodiments, the one or more retention features of the end effector may be grooves or one or more recesses, and the one or more corresponding retention features on the nozzle may be cleats, or tangs, or protrusions, or tabs, or projections, etc..

In embodiments as described above, one or more actuators 1068a, 1068b are configured to actuate the one or more retention features 1088a, 1088b between the first position 1000a, and the second position 1000b. The one or more actuators 1068a, 1068b may comprise hydraulic actuators, pneumatic actuators, electronic actuators, or other types of actuators. In an alternative embodiment, the one or more retention features 1088a, 1088b may be actuated manually.

As shown in <FIG>, the end effector <NUM> includes the receptacle <NUM> to accommodate the nozzle <NUM>. The nozzle <NUM> may have an effector end, and the receptacle <NUM> may have a size compatible with a size of the effector end of the nozzle <NUM> to enable the effector end to fit into the receptacle <NUM>. The end effector <NUM> comprises a first channel <NUM>, which includes a first inlet <NUM> and a first outlet <NUM>. The end effector <NUM> may further comprise a second channel <NUM>, which includes a second inlet <NUM> and a second outlet <NUM>. The end effector <NUM> may further comprise a third channel <NUM>, which includes a third inlet <NUM> and a third outlet <NUM>. The first outlet <NUM>, the second outlet <NUM>, the third outlet <NUM> may be positioned inside the receptacle <NUM> and are configured to be coupled to the first nozzle inlet <NUM>, the second nozzle inlet <NUM>, the third nozzle inlet <NUM> respectively, in the first position 1000a. The end effector <NUM> may further comprise an exterior surface, where the first inlet <NUM>, the second inlet <NUM>, the third inlet <NUM> may be positioned on the exterior surface of the end effector <NUM>.

Once the nozzle <NUM> is locked into place, the first channel <NUM>, the second channel <NUM> and the third channel <NUM> can line up with the respective first inlet <NUM>, second inlet <NUM>, and third inlet <NUM> on the nozzle <NUM>. The nozzle <NUM> may further include O-Rings to ensure that the volume between the outlets (e.g., <NUM>, <NUM>, <NUM>) of the channels (e.g., <NUM>, <NUM>, <NUM>) in the end effector <NUM> and the corresponding nozzle inlets (e.g., <NUM>, <NUM>, <NUM>) on the nozzle <NUM> are isolated from other inlet and outlet pairs.

For example, when an adhesive inlet, a vacuum inlet and a sealant inlet are utilized, the end effector <NUM> may have three inlet and outlet pairs. The adhesive inlet <NUM>, the vacuum inlet <NUM> and the sealant inlet <NUM> may be disposed on an exterior surface of the end effector <NUM>. The adhesive inlet <NUM>, the vacuum inlet <NUM> and the sealant inlet <NUM> may be connected to the corresponding outlets <NUM>, <NUM>, and <NUM> through isolated channels <NUM>, <NUM>, and <NUM>, as shown in <FIG>.

For example, the first channel <NUM> may be configured to enable injection of a first fluid (e.g., adhesive). For example, the second channel <NUM> may be configured to facilitate removing the first fluid (e.g., adhesive) from the nozzle <NUM>. For another example, the second inlet <NUM> of the second channel <NUM> may be configured to be coupled to a negative pressure source to apply vacuum to the second nozzle inlet <NUM>. For another example, the second channel <NUM> may also be used for a positive pressure to expel a fluid drawn into a vacuum aperture (e.g., <NUM>) during a vacuum operation. For example, the third channel <NUM> may be configured to dispense a second fluid through the third outlet <NUM> to the third nozzle inlet <NUM>. The third channel <NUM> may be configured to dispense a sealant through the third outlet <NUM> to the third nozzle inlet <NUM> in some embodiments.

For example, fluids may be configured to be injected from the inlets <NUM>, <NUM>, and <NUM>, to enter the channels <NUM>, <NUM>, and <NUM>, to exit through the outlets <NUM>, <NUM> and <NUM> radially, which is perpendicular to an axial direction <NUM> of the end effector <NUM>. The fluids exiting the channels (e.g., <NUM>, <NUM>, <NUM>) may be configured to enter the nozzle inlets (e.g., <NUM>, <NUM>, <NUM>) of the nozzle <NUM> radially, which is perpendicular to an axial direction of the nozzle <NUM>. For example, the receptacle <NUM> may include a side wall, and where the first outlet <NUM> may be disposed on the side wall to enable a first fluid to be injected into the first nozzle inlet <NUM> with a positive pressure perpendicular to an axial direction of the nozzle <NUM>. This can ensure that the pressure from the injection of the fluids, for example, the adhesive / sealant injection, acts radially or perpendicular to an axial direction of the nozzle <NUM>, thereby preventing displacement of the nozzle <NUM> during the fluid injection process. For example, the outlets (e.g., <NUM>, <NUM>, <NUM>) may be disposed to enable another fluid to be injected into the corresponding nozzle inlets (e.g., <NUM>, <NUM>, <NUM>) radially.

The sizes and profiles of inlets (e.g., <NUM>, <NUM>, <NUM>), the outlet (e.g., <NUM>, <NUM>, <NUM>) and the channels (e.g., <NUM>, <NUM>, <NUM>) can be a function of the viscosities of the fluids being transported through the end effector <NUM>. More viscous fluids may require greater diameters of the channels (e.g., <NUM>, <NUM>, <NUM>), the inlets (e.g., <NUM>, <NUM>, <NUM>), and the outlets (e.g., <NUM>, <NUM>, <NUM>). For example, the channels can have a cross section in a circular shape, an elliptical shape, a rectangular shape, or any other shape. For example, a diameter of the third channel <NUM> can be larger than a diameter of the first channel <NUM>. For example, the diameter of the inlet <NUM> for the sealant may be larger than the inlet <NUM> for the adhesive, in one embodiment. The nozzle <NUM> may further include O-Rings to isolate different channels (e.g., <NUM>, <NUM>, <NUM>). The fluids can be transferred through the isolated channels (e.g., <NUM>, <NUM>, <NUM>) provided in the end effector <NUM>. This can ensure multiple fluids to be transferred simultaneously without mixing.

The end effector <NUM> may further comprise a second end. In some aspects, the second end is configured to be coupled to a robot and the end effector may be manipulated by a robot. The robot may provide the actuators for manipulating the movements of the end effector <NUM>, for providing the necessary pneumatic pressure for actuating the locking and unlocking mechanisms of the end effector <NUM> to the nozzle, as well as tubes or channels coupled to the necessary fluid storage and vacuum pump equipment for coupling to the necessary inlets and outlets that lead to the nozzle <NUM>,via the receptacle connections, and ultimately to the node via the port in which the nozzle <NUM> is inserted. In some other aspects, the second end of the end effector may be grabbed by a person, and the end effector may be manipulated by a person.

In various embodiments, the one or more actuators 1068a, 1068b may be coprinted with the one or more retention features 1088a, 1088b, and may be further coprinted with the receptacle <NUM> of the end effector <NUM> in the AM process. For example, the entire end effector <NUM> is an additively manufactured end effector. The receptacle <NUM>, the inlets (e.g., <NUM>, <NUM>, <NUM>), the outlets (e.g., <NUM>, <NUM>, <NUM>), the channels (e.g., <NUM>, <NUM>, <NUM>) , the one or more retention features (e.g., 1088a, 1088b), the one or more actuators (e.g., 1068a, 1068b), of the end effector <NUM> are coprinted and produced by the AM process.

<FIG> is a flow diagram of an example method <NUM> of using an end effector to interface with a nozzle. The method <NUM> comprises receiving the nozzle in a receptacle of the end effector, as illustrated at <NUM>. The method comprises actuating one or more retention features of the end effector to a first position to secure onto a corresponding one of one or more nozzle retention features to lock the nozzle, as illustrated at <NUM>.

As illustrated at <NUM>, the method <NUM> may comprise applying vacuum to a second inlet of the end effector, where a second outlet of the end effector is coupled to a second nozzle inlet.

As illustrated at <NUM>, the method <NUM> comprises injecting a first fluid to a first inlet of the end effector, where a first outlet of the end effector is coupled to a first nozzle inlet.

For example, injecting an adhesive may comprise injecting the adhesive into the first nozzle inlet with a positive pressure perpendicular to an axial direction of the nozzle.

For another example, injecting an adhesive may comprise injecting the adhesive into the first nozzle inlet radially.

For another example, the method <NUM> may further comprise removing the adhesive from the second outlet.

For another example, the method <NUM> may further comprise dispensing another fluid to a third inlet of the end effector, wherein a third outlet of the end effector is coupled to a third nozzle inlet.

For example, dispensing another fluid may comprise dispensing a sealant. In other embodiments, the fluid may alternatively or additionally be a different type other than an adhesive or sealant, such as a lubricant.

For example, dispensing another fluid may comprise dispensing the another fluid into the third inlet of nozzle with a positive pressure perpendicular to an axial direction of the nozzle.

For example, dispensing another fluid may comprise dispensing the another fluid into the third inlet of nozzle radially.

For another example, the method <NUM> may further comprise coupling the end effector to a robot.

For example, the method <NUM> may be performed by a robot. For example, the method <NUM> may be performed by a person.

For another example, the method <NUM> may further comprise, after the nozzle is installed in the end effector, performing additional fluid applications and vacuum operations by using the same nozzle.

For another example, the method <NUM> may further comprise, applying a positive pressure to a second inlet of the end effector, where a second outlet of the end effector is coupled to a second nozzle inlet. For example, a second channel, a vacuum channel, may also be used for a positive pressure to expel a fluid drawn into a vacuum aperture during a vacuum operation.

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 nodes and interconnects. 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 of the appended claims.

Claim 1:
An apparatus comprising:
a nozzle (<NUM>; <NUM>) and an end effector (<NUM>) for interfacing with the nozzle, the nozzle comprising:
one or more nozzle retention features (688a) and a first nozzle inlet (<NUM>);
and the end effector comprising:
a first end comprising a receptacle (<NUM>), the receptacle being configured to receive the nozzle;
one or more retention features (1088a, 1088b) positioned along a perimeter of the receptacle, each of the one or more retention features being movable between a first position and a second position, each of the one or more retention features being configured to lock the nozzle by securing onto a corresponding one of the one or more nozzle retention features in the first position, and to release the nozzle in the second position;
one or more actuators (1068a, 1068b) configured to actuate the one or more retention features between the first position and the second position; and
a first channel (<NUM>) comprising a first inlet (<NUM>) and a first outlet (<NUM>), the first outlet being positioned inside the receptacle and being configured to be coupled to the first nozzle inlet in the first position;
characterized in that the nozzle comprises a first nozzle outlet (<NUM>) perpendicular to the axial direction of the nozzle.