Multi-material joint

A method of designing a multi-material component for use in coupling a heat source to a vehicle, the multi-material component comprising a first member formed of a first material and a second member formed of a second material, the first and second members each comprising complementary protrusions that form a multi-material join and define a interface between the first and second members;

• and a lattice member situated and joined between the first member and a third member;
• the method comprising:
• selecting the first material and second material;
• identifying an operating temperature for the third member;
• identifying a maximum acceptable temperature of the second material;
• determining a range of acceptable values for thermal conductivity of the lattice which will, at the operating temperature of the third member, prevent the temperature of the second member exceeding the maximum acceptable temperature;
• and
• using software to generate the design of the lattice with a thermal conductivity within the range of acceptable values.

A method of creating a multi-material component, the component comprising a multi-material join where two different materials are joined together, the method comprising:

• a first step of providing a second member formed of a second material, the second member comprising a plurality of protrusions;
• a second step of constructing via additive manufacturing a first member formed of the first material on the second member by first constructing a plurality of protrusions complementary to those of the second member so as to create an interface between the complementary protrusions of the second and first member;
• a third step of constructing via additive manufacturing a lattice formed of the first material on the first member;
• a fourth step of constructing via additive manufacturing the third member formed of the first material on the lattice;
• wherein
• the lattice is configured to elastically deform so as to substantially isolate the interface between the complementary protrusions from distortions in a third member connected to the lattice.

A method of creating a multi-material component, the component comprising a multi-material join where two different material are joined together, the method comprising:

• a first step of providing a third member formed of a first material;
• a second step of constructing via additive manufacturing a lattice formed of the first material on the first member, the lattice being configured to elastically deform so as to substantially isolate the side of the lattice distal from the third member from distortions in the third member;
• a third step of constructing via additive manufacturing a first member formed of the first material on the lattice, the first member comprising a plurality of protrusions;
• and
• a fourth step of constructing via additive manufacturing a second member formed of a second material, the second member comprising a plurality of protrusions complementary to those of the first member so as to create an interface between the complementary protrusions of the first and second member.