Joining approaches for sandwich structures

Patent metadata

Field	Value
Publication number	US-9457434-B2
Application number	US-201414496994-A
Country	US
Kind code	B2
Filing date	Sep 25, 2014
Priority date	Sep 25, 2014
Publication date	Oct 4, 2016
Grant date	Oct 4, 2016

Abstract

A method for securing sandwich structures together, especially vehicle structures. In one embodiment, two sandwich structures are perpendicularly secured together, where a first one of the sandwich structures includes a micro-truss core having one unit cell geometry and second one of the sandwich structures includes a micro-truss core having different unit cell geometry. The micro-truss core of the second sandwich structure includes a micro-truss extension fabricated at the same time as the micro-truss core and having the same unit cell geometry as the micro-truss core for the first sandwich structure. The extension is inserted in an open area between face sheets in the first sandwich structure so that it abuts against the micro-truss core in the first sandwich structure.

First claim

What is claimed is:

1. A method for joining structures, said method comprising:
providing a first sandwich structure including opposing first and second face sheets defining a space therebetween and a first micro-truss core positioned within the space between the first and second face sheets of the first sandwich structure so that an open area remains between the first and second face sheets at one end of the first sandwich structure, said first micro-truss core including segments defining a unit cell configuration;
providing a second sandwich structure including opposing first and second face sheets defining a space therebetween and a second micro-truss core positioned within the space between the first and second face sheets of the second structure, said second micro-truss core including contiguous and integral or overlapping segments defining a different unit cells configuration than the unit cell configuration of the first micro-truss core, wherein providing a second sandwich structure includes providing a core extension of the second micro-truss core such that a portion of the core extension extends from the first face sheet of the second sandwich structure, wherein the core extension has the same unit cell configuration as the unit cell configuration of the first micro-truss core; and
joining the first sandwich structure to the second sandwich structure by inserting the portion of the core extension that extends from the first face sheet of the second sandwich structure into the open area between the first and second face sheets of the first sandwich structure so that an end of the core extension abuts against an end of the first micro-truss structure core in the first sandwich structure.

2. The method according to claim 1 wherein joining the first structure and the second structure includes welding the first structure and the second structure.

3. The method according to claim 1 wherein joining the first structure and the second structure includes providing a sealant bead around an area where ends of the first and second face sheets of the first structure abut against an outside surface of the first face sheet of the second structure.

4. The method according to claim 1 wherein joining the first structure and the second structure includes defining an opening in the core extension during fabrication of the core extension, placing a mechanical fastener through aligned openings in the first face sheet of the first structure and an opening in the second face sheet of the first structure, and securing the fastener.

5. The method according to claim 1 wherein the core extension is fabricated at the same time that the second micro-truss core for the second structure is fabricated.

6. The method according to claim 1 wherein the first and second structures are vehicle structures.

7. The method according to claim 1 wherein the first and second structures are joined perpendicular to each other.

8. A method for joining two vehicle structures, said method comprising:
providing a first sandwich structure including opposing first and second face sheets having and a micro-truss core positioned therebetween;
providing a second sandwich structure including opposing first and second face sheets and a micro-truss core positioned therebetween, wherein the micro-truss cores of the first sandwich structure and the second sandwich structure have different designs and configurations;
providing a micro-truss core extension within the micro-truss core of the second sandwich structure and extending from the micro-truss core in the second sandwich structure where a unit cell design of the micro-truss core extension is the same as a unit cell design of the micro-truss core in the first sandwich structure; and
joining the first sandwich structure to the second sandwich structure by inserting the portion of the core extension that extends from the micro-truss core in the second sandwich structure into an open space between the first and second face sheets of the first sandwich structure so that the micro-truss core extension abuts against an end of the micro-truss core in the first sandwich structure between the first and second face sheets of the first sandwich structure.

9. The method according to claim 8 wherein joining the first structure and the second structure includes welding the first structure and the second structure.

10. The method according to claim 8 wherein joining the first and second structures includes adhering the portion of the core extension that extends into the first structure to an inside surface of the first and second face sheets of the first structure and the core of the first structure using an adhesive.

11. The method according to claim 8 wherein joining the first structure and the second structure includes providing a sealant bead around an area where ends of the first and second face sheets of the first structure abut against an outside surface of the first face sheet of the second structure.

12. The method according to claim 8 wherein joining the first structure and the second structure includes placing a bolt through aligned openings in the first face sheet of the first structure, the portion of the core extension that extends out of the second structure and an opening in the second face sheet of the first structure.

13. The method according to claim 8 wherein the first and second structures are joined perpendicular to each other.

14. A method for perpendicularly joining two vehicle structures, said method comprising:
providing a first sandwich structure including opposing first and second face sheets defining a space therebetween and a first type micro-truss core positioned within the space between the first and second face sheets of the first structure so that an open area remains between the first and second face sheets at one end of the micro-truss core;
providing a second sandwich structure including opposing first and second face sheets defining a space therebetween and a second type micro-truss core positioned within the space between the first and second face sheets of the second structure, said first face sheet of the second structure including a slot and said second type micro-truss core including a slot aligned with the slot in the first face sheet of the second structure;
providing a first type micro-truss core extension positioned within the slot in the second type micro-truss core and the slot in the first face sheets of the second structure so that the core extension extends from the first face sheet of the second structure; and
joining the first structure perpendicular to the second structure by inserting the portion of the core extension that extends from the first face sheet of the second structure into the open area between the first and second face sheets of the first structure so that an end of the core extension abuts against an end of the first type micro-truss structure core in the first structure.

15. The method according to claim 14 wherein joining the first and second structures includes adhering the portion of the core extension that extends into the first structure to an inside surface of the first and second face sheets of the first structure and the core of the first structure using an adhesive.

16. The method according to claim 14 wherein joining the first structure and the second structure includes providing a sealant bead around an area where ends of the first and second face sheets of the first structure abut against an outside surface of the first face sheet of the second structure.

17. The method according to claim 14 wherein j

Assignees

• Gm Global Tech Operations Llc

Inventors

• Mankame Nilesh D
• Aase Jan H
• Vann Mark O

Classifications

• B23K2101/006

  Vehicles · CPC title

• B23K2103/172

  wherein at least one of the layers is non-metallic · CPC title

• B23K2101/02

  Honeycomb structures · CPC title

• B23K2103/10

  Aluminium or alloys thereof · CPC title

• B23K26/21

  by welding · CPC title