Interconnected deflectable panel and node and methods for producing same

Abstract

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

What is claimed is: 
     
         1 . An apparatus, comprising:
 an additively manufactured node having a socket; and   a panel interconnected with the node, the panel comprising opposing surface layers and a core between at least a portion of the surface layers, wherein the socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.   
     
     
         2 . The apparatus of  claim 1 , wherein the surface layers on the end portion of the panel are without at least a portion of the core between them. 
     
     
         3 . The apparatus of  claim 2 , wherein the panel further comprises a material between the surface layers on the end portion of the panel, wherein when the stiffness of the core is reduced, the material has greater flexibility than the core. 
     
     
         4 . The apparatus of  claim 2 , wherein the panel further comprises adhesive filler material comprising a plurality of microballoons between the surface layers on the end portion of the panel. 
     
     
         5 . The apparatus of  claim 1 , wherein a section of the core extends between the surface layers of the end portion of the panel, and wherein the section of the core comprises a notch. 
     
     
         6 . The apparatus of  claim 5 , wherein the adhesive extends from the notch into the socket. 
     
     
         7 . The apparatus of  claim 6 , further comprising a sealant between the panel and the socket to seal the adhesive in the socket. 
     
     
         8 . The apparatus of  claim 5 , wherein the socket comprises a tapered portion that narrows with distance from the socket opening, and wherein the notch is compressed by the tapered portion. 
     
     
         9 . The apparatus of  claim 5 , wherein the socket comprises a tapered portion that widens with distance from the socket opening, and wherein the notch is expanded with the tapered portion. 
     
     
         10 . A method comprising:
 printing a node having a socket by additive manufacturing;   interconnecting a panel with the node, the panel comprising opposing surface layers and a core between at least a portion of the surface layers;   engaging the socket with an end portion of the panel; and   by the socket, shaping the surface layers on the end portion of the panel.   
     
     
         11 . The method of  claim 10 , further comprising removing the core between at least a portion of the surface layers on the end portion of the panel. 
     
     
         12 . The method of  claim 11 , further comprising injecting a material between the surface layers on the end portion of the panel, wherein the material has greater compressibility than the core. 
     
     
         13 . The method of  claim 11 , further comprising injecting a plurality of microballoons between the surface layers on the end portion of the panel. 
     
     
         14 . The method of  claim 10 , wherein a section of the core extends between the surface layers on the end portion of the panel, and the method further comprising cutting a notch in the section of the core. 
     
     
         15 . The method of  claim 14 , further comprising pre-injecting an adhesive that extends from the notch into the socket. 
     
     
         16 . The method of  claim 15 , further comprising:
 applying heat to the sealant; and   causing the sealant to expand around the panel and the socket to seal the adhesive in the socket.   
     
     
         17 . The method of  claim 14 , wherein the socket comprises a tapered portion that narrows with distance from the socket opening, the method further comprising compressing the notch by the tapered portion. 
     
     
         18 . The method of  claim 14 , wherein the socket comprises a tapered portion that widens with distance from the socket opening, the method further comprising expanding the notch with the tapered portion. 
     
     
         19 . The method of  claim 18 , wherein the shaping the surface layers on the end portion of the panel further comprises using a foaming adhesive in the socket.