Methods and apparatus for additively manufactured endoskeleton-based transport structures

Patent metadata

Field	Value
Publication number	US-2024173886-A1
Application number	US-202418404799-A
Country	US
Kind code	A1
Filing date	Jan 4, 2024
Priority date	Jul 25, 2017
Publication date	May 30, 2024
Grant date	—

Abstract

Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.

First claim

What is claimed is:

1 . A transport structure, comprising:
a 3-D printed frame comprising a structure configured to accept road loads and to protect an occupant in an impact event; a plurality of cavities, protruding through the 3-D printed frame, for receiving components that use an external interface; and a body disposed over an exterior surface of the 3-D printed frame.

2 . The transport structure of claim 1 , further comprising a set of general components integrated at least in part in the 3-D printed frame.

3 . The transport structure of claim 2 , wherein at least a portion of the set of general components comprise modular components.

4 . The transport structure of claim 3 , wherein a subset of the set of general components comprises the components that use an external interface.

5 . The transport structure of claim 1 , wherein the body is 3-D printed.

6 . The transport structure of claim 1 , wherein the 3-D printed frame is 3-D printed in a single rendering.

7 . The transport structure of claim 1 , wherein the body is co-printed with the 3-D printed frame in sections or in a single rendering.

8 . The transport structure of claim 1 , further comprising at least one nosecone coupled to one or both of a front and rear surface of the 3-D printed frame.

9 . The transport structure of claim 8 , wherein the at least one nosecone is covered with a section of foam or lattice.

10 . The transport structure of claim 9 , wherein the foam or lattice is 3-D printed.

11 . The transport structure of claim 8 wherein the at least one nosecone coupled to the front surface of the 3-D printed frame is configured to mate with a hinge post platform having interfacing centers.

12 . The transport structure of claim 4 , wherein the set of general components comprises a 3-D printed pedal disposed on a floor panel.

13 . The transport structure of claim 8 , further comprising a front impact beam mounted to a front surface of the at least one nosecone coupled to the front surface of the 3-D printed frame.

14 . The transport structure of claim 8 , further comprising a front suspension system mounted to an inner portion of the at least one nosecone coupled to the front surface of the 3-D printed frame.

15 . The transport structure of claim 1 , further comprising a rear suspension system mounted to a rear portion of the 3-D printed frame.

16 . The transport structure of claim 1 , wherein the 3-D printed frame comprises a safety cell configured to protect an occupant in an event impact.

17 . The transport structure of claim 1 , wherein the body comprises at least one of foam, 3-D printed metal or 3-D printed plastic.

18 . The transport structure of claim 1 , wherein the body is optimized for aerodynamic performance and the 3-D printed frame is optimized for accepting structural loads.

19 . The transport structure of claim 4 , wherein the set of general components comprises 3-D printed joining members.

20 . The transport structure of claim 4 , wherein the set of general components comprises a hinge positioned between a control arm and the body.

Assignees

• Divergent Tech Inc

Inventors

• Czinger Kevin Robert
• Tenhouten Broc William
• Macey Stuart Paul
• O'Connell David Charles
• Gunner Jon Paul
• Martinez Antonio Bernerd
• Lakshman Narender Shankar

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B62D65/00

  Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title