Three-dimensional space frames assembled from component pieces and methods for making the same

Patent metadata

Field	Value
Publication number	US-9745736-B2
Application number	US-201414915154-A
Country	US
Kind code	B2
Filing date	Aug 27, 2014
Priority date	Aug 27, 2013
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

A method for producing three-dimensional space frames or truss structures from simpler components and space frames or truss structures produced by the associated method. The various components, which may be made from virtually any material, are shaped in such a way so that they may be fitted together to create a space frame or truss structure. The components may be held together by any available attachment means, or by the interaction of the components themselves. The method and associated components allows for the assembly of three-dimensional space frames or truss structures from planar materials, significantly reducing cost and manufacturing time. These space frames or trusses can then be used as structural members, as the interior load-bearing portions of sandwich panels, or in any situation where high-strength and light weight are desirable.

First claim

We claim:

1. A method for producing a space frame, said method comprising:
providing a plurality of first members comprising alternating linear struts with inflection areas between said alternating linear struts, said first members having an anterior surface and a posterior surface, a recess at each said inflection area of said first members to define an inflection recess, all of said inflection recesses disposed along said anterior surface of said first member;
arranging said plurality of said first members into an array with a first portion of said plurality of said first members arrayed substantially parallel to one another; and arranging a second portion of said plurality of said first members arrayed substantially orthogonal to said arrayed first portion of said plurality of said first members, so as to define an intersecting array structure;
wherein said first portion of said plurality of said first members is inverted with respect to said second portion of said plurality of said first members so that said anterior surfaces of said first portion of said plurality of said first members are in communication with said anterior surfaces of said second portion of said plurality of said first members;
said first portion of said plurality of said first members and said second portion of said plurality of said first members aligned so that said inflection recesses of said inflection areas of said first portion of said plurality of said first members are in communication with said inflection recesses of said inflection areas of said second portion of said plurality of said first members to define a tenon or tenon-like structure;

providing a lattice shape member comprising struts disposed between nodes, each of said nodes having a mortise recess configured to interface with said tenon or tenon-like structures, said struts configured such that said nodes are located such that said mortise recesses are properly spaced so as to communicate with said tenons or tenon-like structures from the array comprised of said plurality of said first members; and
disposing said lattice shape member such that said mortise recess of said nodes are in communication with said tenons or tenon-like structures to provide said space frame.

2. The method of claim 1 , wherein said providing a plurality of first members comprises:
producing said plurality of first members from a substantially planar material.

3. The method of claim 2 , wherein said producing includes cutting.

4. The method of claim 2 , wherein said producing includes machining.

5. The method of claim 2 , wherein said producing includes stamping.

6. The method of claim 1 , wherein said providing a plurality of first members comprises molding said plurality of first members.

7. The method of claim 1 , wherein said providing a plurality of first members comprises casting said plurality of first members.

8. The method of claim 1 , wherein said providing a plurality of first members comprises forging said plurality of first members.

9. The method of claim 1 , wherein said providing a plurality of first members comprises sintering said plurality of first members.

10. The method of claim 1 , wherein said providing a lattice shape member comprises:
producing said lattice shape member from a substantially planar material.

11. The method of claim 10 , wherein said producing includes cutting.

12. The method of claim 10 , wherein said producing includes machining.

13. The method of claim 10 , wherein said producing includes stamping.

14. The method of claim 1 , wherein said providing a lattice shape member comprises molding said lattice shape member.

15. The method of claim 1 , wherein said providing a lattice shape member comprises casting said lattice shape member.

16. The method of claim 1 , wherein said providing a lattice shape member comprises forging said lattice shape member.

17. The method of claim 1 , wherein said providing a lattice shape member comprises sintering said lattice shape member.

18. The method of claim 1 , wherein at least a portion of said space frame comprises titanium.

19. The method of claim 1 , wherein at least a portion of said space frame comprises aluminum.

20. The method of claim 1 , wherein at least a portion of said space frame comprises steel.

21. The method of claim 1 , wherein at least a portion of said space frame comprises a metal.

22. The method of claim 1 , wherein at least a portion of said space frame comprises an alloy.

23. The method of claim 1 , wherein at least a portion of said space frame comprises stainless steel.

24. The method of claim 1 , wherein at least a portion of said space frame comprises carbon fiber.

25. The method of claim 1 , wherein at least a portion of said space frame comprises a ceramic.

26. The method of claim 1 , wherein at least a portion of said space frame comprises a polymer.

27. The method of claim 1 , wherein at least a portion of said space frame comprises a cermet.

28. The method of claim 1 , wherein at least a portion of said space frame comprises a glass.

29. The method of claim 1 , wherein at least a portion of said space frame comprises a composite material.

30. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that comprises a joint.

31. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that comprises a halved-joint.

32. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is brazed.

33. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is bonded.

34. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is glued.

35. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is diffusion bonded.

36. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is held together by sintered powder.

37. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is epoxied.

38. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is pinned.

39. The method of claim 1 , wherein said tenon or tenon-like structure provides an interface that is wedged.

40. The method of claim 1 , wherein said inflection recesses snap together to form said tenon or tenon-like structure.

41. The method of claim 1 , wherein a friction fit of said inflection recesses form said tenon or tenon-like structure.

42. The method of claim 1 , wherein an interference fit of said inflection recesses form said tenon or tenon-like structure.

43. The method of claim 1 , wherein said communication of said mortise recess and said tenons or tenon-like structures comprises a joint.

44. The method of claim 43 , wherein said joint is brazed.

45. The method of claim 43 , wherein said joint is bonded.

46. The method of claim 43 , wherein said joint is glued.

47. The method

Assignees

• Univ Virginia Patent Foundation

Inventors

• Wadley Haydn N G
• Dong Liang

Classifications

• E04B1/19 Primary

  Three-dimensional [3D] framework structures · CPC title

• E04B2001/1966

  Formlocking connections other than screw connections · CPC title

• E04B2001/1972

  Welded or glued connection · CPC title

• C23C8/26

  of ferrous surfaces · CPC title

• Y10T29/49625

  Openwork, e.g., a truss, joist, frame, lattice-type or box beam · CPC title