Systems and methods for arc and node design and manufacture

Patent metadata

Field	Value
Publication number	US-2017355003-A1
Application number	US-201715619326-A
Country	US
Kind code	A1
Filing date	Jun 9, 2017
Priority date	Jun 9, 2016
Publication date	Dec 14, 2017
Grant date	—

Abstract

A metal extrusion and nodes based structure is provided. The structure comprises one or more arc members connected by one or more node members, wherein the arc comprises (i) a wing feature which is configured to mate with one or more non-structural components, (ii) an internal passage feature which is configured to be inserted into a connecting feature of the corresponding node member, and (iii) one or more keying features formed from a mating interface with the corresponding node member.

First claim

1 . A structure comprising:
a metal extrusion including a first structure and a second structure, the metal extrusion having a length, wherein
the first structure includes an elongated cavity along the length of the metal extrusion, and
the second structure includes an elongated surface along the length of the metal extrusion, the elongated surface being arranged away from the first structure and overlapping at least a portion of the first structure, the first and second structures being connected along the length of the metal extrusion.

2 . The structure of claim 1 , wherein the elongated cavity includes a first longitudinal edge and a second longitudinal edge, the first and second longitudinal edges defining an opening in a wall of the elongated cavity, the opening running along a length of the elongated cavity, the metal extrusion further including
a support structure that connects the first and second longitudinal edges to the second structure.

3 . The structure of claim 2 , wherein the elongated cavity includes a cylindrical tube.

4 . The structure of claim 2 , wherein the second structure is a plate, and the plate is directly connected to the support structure.

5 . The structure of claim 2 , wherein the support structure is configured to deform in response to a bending of at least the first structure or the second structure, such that the deformation of the support structure relieves a mechanical stress within the extruded structure that results from the bending.

6 . The structure of claim 1 , wherein a shape of a cross-section of the elongated cavity includes a concave shape such that the elongated cavity has first and second longitudinal edges running along a length of the elongated cavity, and the first and second edges are connected to the second structure.

7 . The structure of claim 6 , wherein the second structure is a plate, and the plate is directly connected to the first and second edges of the elongated cavity.

8 . The structure of claim 1 , wherein at least the first structure or the second structure is deformed such that a shape of a first cross-section of the metal extrusion at a first location along a length of the metal extrusion is different than a shape of a second cross-section of the metal extrusion at a second location along the length of the metal extrusion.

9 . The structure of claim 1 , wherein the first structure is deformed in a first direction, and the second structure is deformed in a second direction different than the first direction.

10 . The structure of claim 9 , wherein the first direction is a direction that is transverse to the length of the metal extrusion, and the second direction is a direction of rotation around a direction parallel to a length of the elongated cavity.

11 . A vehicle comprising:
a metal extrusion including a first structure and a second structure, the metal extrusion having a length, wherein
the first structure includes an elongated cavity along the length of the metal extrusion, and
the second structure includes an elongated surface along the length of the metal extrusion, the elongated surface being arranged away from the first structure and overlapping at least a portion of the first structure, the first and second structures being connected along the length of the metal extrusion, and
wherein an A-surface of the vehicle includes at least a portion of the elongated surface.

12 . The vehicle of claim 11 , further comprising:
a door frame, wherein the door frame includes the A-surface.

13 . A method of manufacturing a structure, the method comprising:
accepting a metal extrusion, the metal extrusion including a first structure and a second structure, the metal extrusion having a length, wherein the first structure includes an elongated cavity along the length of the metal extrusion, and the second structure includes an elongated surface along the length of the metal extrusion, the elongated surface being arranged away from the first structure and overlapping at least a portion of the first structure, the first and second structures being connected along the length of the metal extrusion; deforming the first structure in a first direction; and deforming the second structure in a second direction different than the first direction.

14 . The method of claim 13 , wherein the first and second structures are deformed such that a shape of a first cross-section of the metal extrusion at a first location along a length of the metal extrusion is different than a shape of a second cross-section of the metal extrusion at a second location along the length of the metal extrusion.

15 . The method of claim 13 , wherein the first direction is a direction that is transverse to the length of the metal extrusion, and the second direction is a direction of rotation around a direction parallel to a length of the elongated cavity.

16 . A die for deforming a metal extrusion, the die comprising:
a first die component that deforms a first portion of the metal extrusion in a first direction; and a second die component that deforms a second portion of the metal extrusion in a second direction different than the first direction.

17 . The die of claim 16 , wherein the metal extrusion has a length, and the first and second portions are deformed such that a shape of a first cross-section of the metal extrusion at a first location along the length of the metal extrusion is different than a shape of a second cross-section of the metal extrusion at a second location along the length of the metal extrusion.

18 . The die of claim 16 , wherein the metal extrusion has a length, the first portion includes an elongated cavity along the length of the metal extrusion, the first direction is a direction that is transverse to the length of the metal extrusion, and the second direction is a direction of rotation around a direction parallel to a length of the elongated cavity.

19 . The die of claim 16 , wherein the first die component and the second die component define a shape of portion of a die cross-section, and the deforming by the first and second die components causes the shape of the portion of the die cross-section to change.

20 . The die of claim 16 , wherein the first die component is arranged in a first layer, and the second die component is arranged in a second layer that overlaps the first layer.

Assignees

• Divergent Tech Inc

Inventors

• Tenhouten Broc William
• El Naga Eahab Nagi
• HOYLE Richard Winston
• Czinger Kevin Robert

Classifications

• B21C35/023

  Work treatment directly following extrusion, e.g. further deformation or surface treatment  (B21C35/03 takes precedence; gas treatment B21C23/009) · CPC title

• B62D27/023

  Assembly of structural joints · CPC title

• B21D9/05

  co-operating with forming members · CPC title

• B21D7/12

  with program control · CPC title

• B21C25/02

  Dies · CPC title