Insert, assembly comprising an insert and method of use of an insert

Abstract

The present disclosure provides an insert, an assembly including the insert, and a method of using the insert, the insert including a locking mechanism that can be integrally formed with a component or separately attached to the insert body. A top portion of the locking mechanism is offset from a first surface by an offset distance to enable coupling of the insert to a recess of a component, such as an aircraft component. A hole formed in a top surface of the first portion is configured to allow coupling of an additional element to the aircraft component. Coupling of the insert to the aircraft component is further facilitated by a compression mechanism that forces the locking mechanism to couple to an overhanging portion of the top layer such that the top surface of the insert is coplanar with an outermost surface of the aircraft component after a force applied to the insert once the insert is positioned in the recess is removed.

Description

Technical Field

[0001] This application relates to inserts, components including inserts, and methods of using inserts. Background Technology

[0002] Components (such as aircraft components) may include aspects that allow for the attachment of additional elements to the aircraft component. The additional elements are attached to the aircraft component via inserts within the aircraft component, allowing the additional elements to be attached via wire, thread, press fit, or other types of connection. The inserts are secured to the aircraft component so that they do not leave their original position when the additional element is attached to it or during the use of the additional element. Aircraft components may include a large number of inserts, which may require time and / or manpower to assemble. Therefore, there remains a need for an insert that can be quickly and consistently attached to the aircraft component relative to it. Summary of the Invention

[0003] In one aspect, the present disclosure provides a component comprising: a central axis; a first portion having a first surface; a second portion having a second surface; a connector portion extending between the first portion and the second portion; a hole formed in the first portion along the central axis; a locking mechanism integrally formed with the component, the locking mechanism being offset from the first surface by an offset distance; and a compression mechanism coupled to the second portion.

[0004] In one aspect, in conjunction with any of the example components above or below, the component also includes a locking mechanism having multiple tabs, each of the multiple tabs extending between the first and second portions.

[0005] In one aspect, in conjunction with any of the example components above or below, the component also includes a first part, a second part, a connector part, and a locking mechanism, each formed of the same material, including polymers, metals, composite materials, ceramics, or combinations thereof.

[0006] In one aspect, in conjunction with any of the example components above or below, the component also includes a compression mechanism formed of a polymer, metal, composite material, ceramic, or a combination thereof.

[0007] In one aspect, in conjunction with any of the example components above or below, the component also includes a hole comprising an attachment element.

[0008] In one aspect, in conjunction with any of the example components above or below, the component also includes a first outer diameter of the first part that is substantially the same as the second outer diameter of the second part.

[0009] In one aspect, in conjunction with any of the example components above or below, the component also includes a connector portion whose outer diameter is smaller than a first outer diameter and smaller than a second outer diameter.

[0010] In one aspect, in conjunction with any of the example components above or below, the component also includes each of the plurality of flaps of the locking mechanism at an angle (α) of about 10 degrees to about 80 degrees relative to the first surface of the first portion.

[0011] In one aspect, in conjunction with any of the example components above or below, the component also includes an offset distance of approximately 0.020 inches to approximately 0.050 inches.

[0012] This disclosure provides an assembly, in one aspect, comprising: an insert having: a central axis; a first portion having a first surface; a second portion having a second surface; a connector portion extending between the first portion and the second portion; a hole formed in the first portion along the central axis; a locking mechanism circumferentially positioned around the insert, the locking mechanism including a plurality of flaps extending from a first shared element and positioned at an offset distance from the first surface of the first portion; and a compression mechanism coupled to the second portion.

[0013] In one aspect, in conjunction with any of the example components above or below, the component also includes a first shared element coupled to the first outer surface of the first portion.

[0014] In one aspect, in conjunction with any of the example components above or below, the component also includes a locking mechanism having a second shared element.

[0015] In one aspect, in conjunction with any of the example components above or below, the component further includes each of a plurality of blades extending between a first shared element and a second shared element, and a second ring being coupled to a second outer surface of the second portion.

[0016] In one aspect, in conjunction with any of the example components above or below, the component further includes an insert formed of a first material and a locking mechanism formed of a second material, the first material being different from the second material.

[0017] In one aspect, in conjunction with any of the example components above or below, the component also includes a first outer diameter of the first part that is smaller than the second outer diameter of the second part.

[0018] In one aspect, in conjunction with any of the example components above or below, the component also includes each of the plurality of blades at an angle (α) of about 10 degrees to about 80 degrees relative to the first surface.

[0019] In one aspect, in conjunction with any of the example components above or below, the component further includes a member having a first layer forming a first surface of the member and forming above the second layer; a groove formed in the first surface of the member extending into the second layer and defined by an opening and sidewalls in the first surface; a portion of the first layer extending a predetermined distance in the groove around the opening of the groove; the member being positioned in the groove and secured to the groove via a locking mechanism and a connection of the portion of the first layer extending into the groove; and a first surface of the insert being coplanar with the first surface of the member.

[0020] This disclosure provides a method of manufacturing an assembly. In one aspect, the method includes: positioning a first component in a recess of a second component; the first component having: a central axis; a first portion having a first surface; a second portion having a second surface; a first hole formed in the first portion along the central axis; a first locking mechanism extending circumferentially around the first component, the first locking mechanism being offset from the first surface by a first offset distance; and a first compression mechanism coupled to the second surface, the first compression mechanism being in a first uncompressed state. The second component includes a first layer formed on a second layer, a portion of the first layer extending a first predetermined distance in a first opening of the recess. The method of forming the assembly further includes: applying a force along the central axis of the first component in a first direction to place the first compression mechanism in a second compressed state. The central axis of the first component is aligned with a central recess axis of the recess. The method further includes: removing the force applied along the central axis in the first direction; and, in response to removing the force applied in the first direction, coupling the first component to the recess. Removing the force applied in the first direction returns the first compression mechanism to the first uncompressed state, such that the first locking mechanism is secured to a portion of the first layer extending around the first opening of the recess, wherein when the first compression mechanism returns to the first uncompressed state, the first surface is coplanar with the first layer of the second component.

[0021] In one aspect, in conjunction with any of the example methods above or below, the method further includes: positioning a third component in a recess in a second component, the recess being a through-hole extending along a central axis from a first opening on a first surface of the second component to a second opening on a second surface of the second component, the second surface opposite to the first surface; the third component having: a third portion having a third surface; a fourth portion having a fourth surface; a second hole formed along the central axis in the third portion; a second locking mechanism extending circumferentially around the first component, the second locking mechanism being offset from the third surface by a second offset distance; and a second compression mechanism coupled to the fourth surface, the second compression mechanism being in a first uncompressed state. The second component includes a third layer formed on a second layer, a portion of the third layer extending a second predetermined distance in the second opening. The method further includes: applying a force in a second direction along the central axis of the third component to place the second compression mechanism in a second compressed state; removing the force applied in the second direction along the central axis; and, in response to removing the force applied along the central axis, coupling the third component to the recess. Removing the force applied along the central axis returns the second compression mechanism to the first uncompressed state, causing the second locking mechanism to be fixed to the portion of the third layer extending around the second opening of the groove. When the second compression mechanism returns to the first uncompressed state, the third surface of the third component is coplanar with the third layer of the second component.

[0022] In one aspect, in conjunction with any of the example methods above or below, the method further includes placing a plurality of potting materials into a recess in a second component via a first notch formed in a first surface of a first component. Attached Figure Description

[0023] To gain a more detailed understanding of the features described above, a more specific description can be obtained by referring to the examples, some of which are shown in the accompanying drawings.

[0024] Figure 1A Example inserts are depicted according to various aspects of this disclosure.

[0025] Figure 1B An isometric view of an example insert according to various aspects of this disclosure is depicted.

[0026] Figure 2 A top view of an example insert according to various aspects of this disclosure is depicted.

[0027] Figure 3 A side view of an example insert according to various aspects of this disclosure is depicted.

[0028] Figure 4A Another example insert is depicted according to various aspects of this disclosure.

[0029] Figure 4BA side view of an example insert according to various aspects of this disclosure is depicted.

[0030] Figure 5A A top view of the components including the inserts according to various aspects of this disclosure is depicted.

[0031] Figure 5B A side view of the components including the inserts according to various aspects of this disclosure is depicted.

[0032] Figure 5C The various aspects described in this disclosure are as follows. Figure 5B An example of a component.

[0033] Figure 5D A cross-sectional view of an assembly including an insert, according to various aspects of this disclosure, is depicted.

[0034] Figure 6A A top view of another component according to various aspects of this disclosure is depicted.

[0035] Figure 6B A side view of the components according to various aspects of this disclosure is depicted.

[0036] Figure 6C A cross-sectional view of the components according to various aspects of this disclosure is depicted.

[0037] Figure 7 A flowchart depicts a method for assembling according to various aspects of this disclosure. Detailed Implementation

[0038] This disclosure provides a system including components configured to engage one or more additional elements. Each component includes a first component, such as an aircraft component, and one or more second components, which are alternatively referred to herein as “insertions” when inserted, for example, into, a recess in a first component. The aircraft component discussed herein may include a composite panel having multiple layers. The composite panel may be used in an aircraft fuselage or interior. Each of the multiple layers of the component may be formed of one or more of a polymer, fabric, metal, alloy, ceramic, composite material, superalloy, or other material or combination of materials.

[0039] Individual aircraft components, such as panels on the fuselage, interior (cabin), wings, or engines, can include dozens, hundreds, or thousands of inserts, sometimes referred to as potting inserts. Therefore, significant time, labor, and cost may be required to ensure that the inserts are flush with the aircraft component and properly secured in each recess. It is desirable that inserts, such as potting inserts, are flush with laminates, such as decorative laminates, to provide not only sufficient strength but also for aesthetic purposes. Inserts can be secured via connections such as press fits, spring loading, threads, magnetic elements, or potting materials that can be applied and then cured in a non-solid form. In embodiments, inserts are manufactured to be pressed in and bent, and then punched out to engage with the underside of the panel skin. As used herein, if two elements of an assembly are coplanar, i.e., when the surface of one element of the assembly (such as an insert discussed herein) shares a plane with the surface of another element of the assembly (such as an aircraft component), the two elements of the assembly are said to be “flush” relative to each other.

[0040] As described above, an aircraft component may include multiple layers, including a first layer, which may be referred to as the top layer, and is the outermost layer of the aircraft component, thereby forming the top (first) surface of the aircraft component. The groove discussed herein is defined by at least one opening and sidewalls. A portion of the first layer extends circumferentially a predetermined distance around the opening of the groove. This predetermined distance may be referred to as a sag distance because this portion of the top layer hangs over the edge of the opening. In some examples, the groove of the aircraft component includes a bottom surface. In this example, the groove extends through the top layer and into at least a portion of the second layer adjacent to the top layer, but the groove does not extend through the aircraft component. In some examples, the aircraft component includes a third layer, which may be referred to as the bottom layer, positioned adjacent to the second layer on a side opposite to the first layer. In this example, the third layer is also the outermost layer on a different side of the aircraft component, opposite the top layer and the top surface, and thus may be referred to as the bottom surface of the aircraft component. In an example, the groove is a through-hole extending through the aircraft component. In this example, the groove includes two openings, one in the first layer and one in the third layer. In this example, a portion of the third layer, which may be wider or narrower than the overhang portion of the first layer and is also referred to as the overhang portion, extends into the groove of the second opening. Each layer of the aircraft component discussed herein may include two or more sublayers of different thicknesses and / or materials. Therefore, the grooves discussed herein may have different diameters, lengths (heights), tapers (including non-tapered ones), and opening geometries (circular, elliptical, polygonal, triangular, or combinations thereof).

[0041] An assembly including an insert and an aircraft component can be implemented by positioning the insert relative to a recess such that the central axis of the recess is aligned with the central axis of the insert, such that the recess and the insert share a central axis. The shared central axis can be at any angle relative to the top (or bottom) surface of the aircraft component. The insert may include a locking mechanism and a compression mechanism. As used herein, a “locking mechanism” is an element capable of securing a first component, such as the insert, to a second component, such as the aircraft component. Furthermore, as used herein, a “compression mechanism” is an element configured to undergo compression without damage. Additionally, the compression mechanism discussed herein is configured to change from a first state (e.g., an uncompressed state) to a second state (e.g., a compressed state) in response to the application of a force, and return to the first state when the force is removed. The insert discussed herein may also include a hole configured to engage with an additional element. The hole may extend through a portion of the insert or may extend through the entire length of the insert. In some examples, the hole may include an attachment element that allows the insert to engage with an additional element, such as a wire, threaded element, or other element. Therefore, the attachment element may include threads, spirally wound wire, or may be configured as a magnetic element or a press-fit mechanism. The locking mechanism may be configured to engage with a recess in the aircraft component via a hanging portion. This engagement is achieved when a force is applied to the insert, for example, along its central axis. The force applied to the insert causes compression of the compression mechanism. When the force is removed, the compression mechanism moves the insert in the opposite direction to the applied force, causing the locking mechanism to engage (“engage”) with the hanging portion of the top layer of the aircraft component, which extends into the recess. This engagement secures the insert to the recess. The insert discussed herein may be referred to as “self-adjusting” because the insert becomes flush with the surface of the external component via the compression mechanism. This contrasts with inserts or other components that can be manually or mechanically manipulated and / or adjusted after initial engagement to the stated position.

[0042] In one example, a first insert is coupled to a recess via a first opening in the top surface of the aircraft component, such that the top surface of the first insert is coplanar with the top surface of the aircraft panel. In this example, the recess can be a hole with a bottom surface or a through-hole. In another example, when the recess is configured as a through-hole, a second insert is coupled to a second opening in the bottom surface of the aircraft component, such that the top surface of the second insert is coplanar with the bottom surface of the aircraft panel. In any example of the recess, the recess can be formed at various angles relative to the first and / or second surfaces of the composite panel.

[0043] Example insert

[0044] Figure 1AA first insert 100A is depicted according to various aspects of this disclosure. The first insert 100A includes a first portion 102, a second portion 108 connected to the first portion 102 via a connector portion (not shown here), a plurality of recesses 112, a locking mechanism 106, and a compression mechanism 110. The first portion 102 has a first surface 102A (which may be referred to as a “top” surface), a second surface 102D (which may be referred to as a “bottom” surface) opposite the first surface 102A, an outer surface 102B, and an inner wall 102C forming a hole 104 aligned along a central insert axis 116 in the first portion 102. According to an example, the hole 104 may include a thread, a helical winding element, or other coupling mechanism. The second portion 108 includes a first surface 108A (which may be referred to as a “top” surface), an outer surface 108B, and a second surface 108C (which may be referred to as a “bottom” surface) opposite the first surface 108A.

[0045] The locking mechanism discussed herein can take various forms, including as a plurality of flaps 106A comprising a locking mechanism 106. Example: Each of the plurality of flaps 106A in the locking mechanism 106 extends between a first portion 102 and a second portion 108. Although in Figure 1A Six flaps 106A are shown, but in other examples, the locking mechanism 106 may include more or fewer flaps 106A. In one example, the locking mechanism 106 includes two flaps 106A. In another example, the locking mechanism 106 includes three to five flaps 106A. In yet another example, the locking mechanism 106 includes more than six flaps 106A. Each of the plurality of flaps 106A may be circumferentially positioned around the outer surface 102B and equidistant from each adjacent flap 106A. In one example, a first end 106B of each of the plurality of flaps 106A extends from the outer surface 102B of the first portion 102, and a second end 106C of each of the plurality of flaps 106A is formed to rest between and contact both the first surface 108A and the outer surface 108B of the second portion 108. In other examples, the first end 106B of each of the plurality of flaps 106A extends from the second surface 102D of the first portion and does not contact the outer surface 102B. The first end 106B of each of the plurality of flaps 106A is positioned below the first surface 102A of the first portion 102 to form an offset distance 114. This offset distance 114 is below... Figure 5CThis will be discussed in further detail below. In other examples of the first insert 100A, the second end 106C of each of the plurality of flaps 106A may be positioned on the first surface 108A and not in contact with the outer surface 108B. In still other examples of the first insert 100A, the second end 106C of each of the plurality of flaps 106A may be positioned on the outer surface 108B and not in contact with the first surface 108A. In this example, the locking mechanism 106 is integrally formed with the first insert 100A and is formed of the same material as the first insert 100A. The first insert 100A and therefore the locking mechanism 106 may be formed of ceramic, plastic, polymer, elastomer, metal or alloy, composite material or other material. In one example, the metal may include aluminum or an aluminum alloy.

[0046] The compression mechanism 110 can be configured in various ways such that applying a force along the central insert axis 116 toward the first surface 102A compresses the compression mechanism 110. Conversely, releasing the applied force causes the compression mechanism 110 to move the first insert 100A upward in the opposite direction of the applied force, resulting in the locking mechanism 106A engaging with the component, as discussed in detail below. The compression mechanism 110 can be formed of a material including metals, alloys, polymers, elastomers, composite materials, or other materials capable of functioning as discussed above. In one example, the metal may include aluminum or aluminum alloys, steel, or other metals or alloys. In this example, the compression mechanism 110 extends from the second surface 108C of the second portion 108. In other examples, the compression mechanism may additionally or alternatively be coupled to the outer surface 108B of the second portion 108. The compression mechanism 110 can be formed of the same material as the first insert 100A. In this example, the compression mechanism 110 may be integrally formed with the first insert 100A. In other examples, the compression mechanism 110 may be formed of a different material than the first insert 100A. In this example, the compression mechanism 110 may be attached to the second surface 108C of the second portion via an adhesive, polymer, or elastomer including thermosetting materials, press fit, or other mechanical, chemical, or combined means.

[0047] Figure 1B An isometric view of the second insert 100B according to aspects of this disclosure is depicted. The second insert 100B is similar to... Figure 1A The first insert 100A is shown, and a connector portion 126 extending between a first portion 102 and a second portion 108 is also shown. In contrast to the first insert 100A, the second insert 100B includes a locking mechanism 122 having a plurality of flaps 124, each flap extending between a first shared element 118 (which may be referred to as a first ring) and a second shared element 120 (which may be referred to as a second ring). Figure 1BThe locking mechanism 122 includes six flaps 124. In other examples, the locking mechanism 122 includes two flaps 124. In another example, the locking mechanism 122 includes three to five flaps 124. In yet another example, the locking mechanism 122 includes more than six flaps 124. Each of the plurality of flaps 124 may be circumferentially positioned around the outer surface 102B and equidistant from each adjacent flap 124. Although the flaps 124 (and Figure 1A 106A in Figure 1A and Figure 1B The winglets 124 and 106A are shown as rectangular, but in other examples, they may have one or more circular or triangular features.

[0048] The first shared component 118 is in Figure 1B The diagram shows each first end 124A of each of the plurality of flaps 124. The first shared element 118 is further shown as being coupled to the outer surface 102B of the first portion 102. In other examples of the second insert 100B, the first shared element 118 may be coupled to the second surface 102D of the first portion. The second shared element 120 is... Figure 1B The second shared element 120 is shown as each of the second ends 124B of each of the plurality of flaps 124. The second shared element 120 is further shown as being coupled to the outer surface 108B of the second portion 108. In other examples of the second insert 100B, the second shared element 120 may be coupled to the second surface 108C of the second portion 108. In other examples of the locking mechanism 122, a single shared element (which may be positioned as shown or otherwise with the first shared element 118 and the second shared element 120) is coupled to each of the plurality of flaps 124 and used to secure the locking mechanism 122 to the second insert 100B. In the example of the second insert 100B, the locking mechanism 122 may be formed separately with the first portion 102, the second portion 108, and the connector portion 126 and subsequently assembled via a combination of mechanical, chemical, or other methods. In this example, the locking mechanism 122 may be coupled to the insert body. As discussed herein, the "insert body" includes the first portion 102, the second portion 108, and the connector portion 126. In examples where locking mechanism 106 or other locking mechanisms discussed herein are integrally formed with first part 102, second part 108 and connector part 126, locking mechanism 106 can be considered as part of the insert body.

[0049] Figure 1B It also shows that Figure 1AThe compression mechanism 110 is shown in the figure. The compression mechanism 110 is coupled to the second surface 108C of the second portion and includes a first compression element 110A and a second compression element 110B intersecting at the overlap point 110C. Each of the first compression element 110A and the second compression element 110B... Figure 1B The diagram shows a curved shape, and similar shapes. In other examples, one or both of the first compression element 110A and the second compression element 110B may have different shapes, including one or more geometries such as spiral, straight leg, curved leg, spiral geometry extending outward from the second surface 108C along the central insert axis 116, or combinations thereof.

[0050] Figure 2 A top view of an insert 200 according to an aspect of this disclosure is depicted. The insert 200 includes components that are connected to the insert above... Figure 1A and Figure 1B The similar elements discussed in the text. Figure 2 A first surface 102A of a first portion 102 is shown, the first portion 102 having a first portion outer diameter 204. An aperture 104 formed in the first portion 102 has an aperture outer diameter 202 defined by an inner sidewall 102C of the first portion 102. The aperture outer diameter 202 may differ from the first portion outer diameter 204 of the insert 200 by a different amount. In one example, the aperture outer diameter 202 is from about 10% to about 75% of the first portion outer diameter 204. As used herein, “about” means a measured value within 1%, 3%, or 5% of said value. If two or more measured values ​​are “about” the same, then the two or more measured values ​​are indistinguishable to the naked eye and will not negatively affect the function of the component at hand (insert or otherwise). In another example, the aperture outer diameter 202 is from about 25% to about 60% of the first portion outer diameter 204. In yet another example, the outer diameter of the hole 202 is approximately 35% to approximately 50% of the outer diameter of the first portion 204.

[0051] Figure 2 It is also shown how each of the multiple flaps 106A of the locking mechanism 106 is positioned at a distance 206 equidistant from each adjacent flap 106A. Figure 2 Several notches 112 are also shown. Although Figure 2Two notches 112 are shown, but in other examples, the inserts discussed herein may include three or more notches 112. Each notch 112 is formed in the outer surface 102B of the first portion 102 and extends into the first surface 102A of the first portion 102. Each of the plurality of notches 112 may be equidistantly positioned with respect to adjacent notches 112. The inserts discussed herein according to various aspects of this disclosure are engaged to the component when positioned in a recess of the component. This engagement may occur via a compression mechanism 110 (or other configurations of compression mechanisms as discussed herein) that engages a locking mechanism (106 or 122, or others as discussed) into the overhanging portion of the component, as discussed in detail below. In one example, the insert (100A, 100B, 200, or other inserts as discussed herein) is engaged to the component without the use of additional elements. In other examples, multiple notches 112 are used to deposit potting material into the recesses where the insert 200 is positioned to further secure the insert 200 to the component. In examples using potting material, the potting material may include thermosetting or other adhesive materials, and potting material may be used, for example, when the hole 104 of the insert 200 is configured to be coupled to a heavy additional component, or in other cases as required. For example, potting material may be used if the insert 200 is to be used in applications where high strain, angular strain, or long-term strain may be applied to the insert 200, and / or depending on factors such as the dimensions of the insert 200 and the recesses, the number of inserts 200 to be coupled to a component or area of ​​a component, or other factors or combinations thereof.

[0052] Figure 3 The various aspects described in this disclosure are as follows. Figure 1A A side view of the first insert 100A. The side view of the first insert 100A includes a first portion 102, a second portion 108, and a connector portion 126 extending between the first portion 102 and the second portion 108. The outer diameter 204 of the first portion and the outer diameter 310 of the second portion are... Figure 3 As shown in the diagram. In one example, the outer diameter 204 of the first portion is approximately the same as the outer diameter 310 of the second portion. In this example, both the first portion 102 and the second portion 108 are aligned along the central insert axis 116, such that the outer surfaces 108B and 102B of the second portion 108 are aligned along a common plane. In other examples, the outer diameter 204 of the first portion is larger than the outer diameter 310 of the second portion. In still other examples, the outer diameter 204 of the first portion is smaller than the outer diameter 310 of the second portion.

[0053] Figure 3The connector portion 126 is also shown to have a connector portion outer diameter 314. In one example, the connector portion outer diameter 314 is smaller than each of the first portion outer diameter 204 and the second portion outer diameter 310. The difference in measurement between the connector portion outer diameter 314 and one or both of the first portion outer diameter 204 and the second portion outer diameter 310 forms a circumferential insertion recess 310A. In some examples, the circumferential insertion recess 310A may be left as a negative, unfilled space. In other examples of the components discussed below, after the first insert 100A (or other inserts discussed herein) is coupled to a component such as an aircraft component, the circumferential insertion recess 310A may be filled with a potting material (epoxy resin, thermosetting material, metal, alloy, composite material, or other material or combination of materials).

[0054] In another example, the outer diameter 314 of the connector portion may be the same amount or a different amount smaller than each of the outer diameters 204 and 310 of the first portion, depending on whether the outer diameters 204 and 310 are the same. In one example, the outer diameter 314 of the connector portion is about 10% to about 90% of one or both of the outer diameters 204 and 310 of the first portion. In another example, the outer diameter 314 of the connector portion is about 20% to about 75% of one or both of the outer diameters 204 and 310 of the first portion. In yet another example, the outer diameter 314 of the connector portion is about 35% to about 50% of one or both of the outer diameters 204 and 310 of the first portion. The diameter and relative diameter of the first insert 100A or other inserts as discussed herein (first part 102, connector part 126, second part 108) can be selected based on factors such as the material forming the insert (100A or others), the configuration of the insert (integral locking mechanism 106 or separately formed (non-integral) locking mechanism 122), the type and configuration / size of the locking mechanism, the cross-sectional geometry of the groove, the intended use of the insert, or other factors or combinations thereof.

[0055] Figure 3 The thickness of each of the first portion 102, the second portion 108, and the connector portion 126 is also shown. The thickness (height) 320 of the first portion 102 is shown as less than the thickness (height) 318 of the second portion 108 and less than the thickness (height) 306 of the connector portion 126. In other examples, the thickness of each portion of the first insert 100A may have different measured and relative values, depending on the overall size of the insert, the size of the recess to which the insert is to be coupled, additional elements to be coupled to the insert, or other factors or combinations thereof. Figure 3The orientation of the first compression element 110A relative to the second compression element 110B is shown. The two compression elements 110A and 110B are shown in the compression mechanism 110 and are shown configured at an angle δ of 90 degrees relative to each other. In other examples, the compression mechanism discussed herein, including compression mechanism 110, may include three or more elements, and the relative angle δ between each element may be less than 90 degrees. Compression mechanism 110 has a compression mechanism outer diameter 304. In one example, the compression mechanism outer diameter 304 is smaller than one or both of the first portion outer diameter 204 and the second portion outer diameter 310. In another example, the compression mechanism outer diameter 304 is the same as one or both of the first portion outer diameter 204 and the second portion outer diameter 310, such that compression mechanism 110, first portion 102, and second portion 108 are aligned along the central insert axis 116. Compression mechanism 110, as... Figure 3 The device shown is in its uncompressed state and has a height of 302, which is the distance from the second surface 108C of the second portion 108 to the bottom 110D of the compression mechanism 110. In the second compressed state of the compression mechanism 110, when a force is applied along the axis 116 of the central insert (as indicated by arrow 322), the height 302 decreases. For example, when the first insert 100A is compressed (e.g., when force 322 is applied), the height 302 decreases. When the applied force 322 is removed, the height 302 increases. In some examples, the height of the compression mechanism 110 when force 322 is removed (as shown in the component examples herein) is the same as the height 302 before force 322 is applied. In other examples, the height of the compression mechanism 110 when force 322 is removed (as shown in the component examples in this article) may be 1%-10% smaller than the height 302 before force 322 is applied, depending on the thickness of the layer of the component to which the first insert 100A is attached, the depth of the groove in which the first insert 100A is positioned, or other factors or combinations thereof.

[0056] The thickness and relative thickness of the features of the first insert 100A or other inserts discussed herein (first part 102, connector part 126, second part 108) can be based on factors such as the material forming the insert (100A or others), the configuration of the insert (e.g., as... Figure 1A The type and configuration / size of the locking mechanism (as shown in the integrated locking mechanism 106, or as a non-integrated locking mechanism 122), the cross-sectional geometry of the groove, the depth of the groove, the angle of the groove relative to the surface of the component in the assembly, the intended use of the insert, or other factors or combinations thereof are selected.

[0057] Figure 4AAnother example insert 400A according to various aspects of this disclosure is depicted. Example insert 400A, referred to herein as third insert 400A, may be configured similarly to first insert 100A and second insert 100B, having a first portion 102, a second portion 108, and a connector portion 126 extending between the first portion 102 and the second portion 108. Figure 1B Conversely, the third insert 400A has a locking mechanism 106, as well as... Figure 1A As shown. However, with Figure 1A and Figure 1B Conversely, the third insert 400A has a compression mechanism 402 configured as a plurality of extensions 404 that protrude at an angle from the second surface 108C (e.g., the bottom surface) of the second portion 108 relative to the second surface 108C. In other examples of the third insert 400A, similar to... Figure 1B The locking mechanism 122 may be included in and combined with the compression mechanism 402. The compression mechanism 402 may be integrally formed with the third insert 400A and therefore may be formed of the same material as the other elements of the third insert 400A. In other examples, the compression mechanism 402 may be formed of a different material than the insert bodies 102, 108, and 126 of the third insert. The compression mechanism 402 operates in the same manner as other compression mechanisms discussed herein, compressing from a first uncompressed state to a second state when a force is applied to the first surface 102A to position the third insert 400A in the groove. When the applied force is removed, the compression mechanism 402 may subsequently unfold in the direction opposite to the direction of the applied force.

[0058] Figure 4B A side view of the third insert 400A according to various aspects of this disclosure is depicted, and includes... Figure 4A The same components are shown. Furthermore, Figure 4B Each of the plurality of extensions 404 is shown to be at an angle γ relative to the second surface 108C of the second portion 108 of the third insert 400A. In one example, the angle γ may be from about 95 degrees to about 145 degrees. In another example, the angle γ may be from about 105 degrees to about 135 degrees. In yet another example, the angle γ may be from about 115 degrees to about 125 degrees.

[0059] In one example, compression mechanism 110, first portion 102, and second portion 108 are aligned along the axis 116 of the central insert. Compression mechanism 402 has a compression mechanism outer diameter 406. In one example, the compression mechanism outer diameter 406 is smaller than one or both of the outer diameters 204 and 310 of the first portion. In another example, the compression mechanism outer diameter 406 is the same as one or both of the outer diameters 204 and 310 of the first portion. Compression mechanism 402, as... Figure 4A and Figure 4B The compression mechanism 402, in its uncompressed state, has a height 408 relative to the second surface 108C of the second portion 108. When a force is applied along the axis 116 of the central insert (as indicated by arrow 410), for example, when the third insert 400A is in a second compressed state, the height 408 of the compression mechanism 402 decreases. When the applied force 410 is removed, the height of the compression mechanism 402 can return to height 408. Although in Figure 4A and Figure 4B The three extensions 404 are shown as including the compression mechanism 402, but in other examples, more or fewer extensions, such as two extensions 404 or four or more extensions 404, may be included in the compression mechanism 402.

[0060] The height 408 and the outer diameter 406 of the compression mechanism can be selected based on factors such as the material forming the compression mechanism 402 (or other compression mechanisms discussed herein), the geometry of the compression mechanism (402 or other examples), the cross-sectional geometry of the groove, the depth of the groove, the angle of the groove relative to the surface of the component in the assembly, factors of the intended use of the insert, or other factors or combinations thereof. The material for the compression mechanism 402 can also be selected based on similar factors. The compression mechanism 402 can be attached to the second surface 108C of the second portion 108 via adhesive, injection molding, press fitting, or by other means or combinations thereof. The compression mechanism 402 and its extension 404 in Figure 4B The second surface 108C is shown as being coupled to the second portion 108. In other examples, the compression mechanism 402 may be configured such that the extension 404 is coupled to the outer surface 108B of the second portion 108.

[0061] The inserts discussed herein may include various combinations of geometry, material, and position or locking and compression mechanisms, such that the insert is configured to self-adjust when positioned in the groove in response to the removal of a force on the insert positioned in the groove. Components including one or more inserts as described above are discussed below.

[0062] Example components including inserts

[0063] Figure 5AA top view of component 500 including insert 502 is depicted according to various aspects of this disclosure. Insert 502 is positioned in a recess in component 506. Component 506 is in Figure 5A The diagram is shown as a partial view and can be extended in various directions to have various top-view geometries, such as polygons, circles, ellipses, triangles, or combinations thereof. Therefore, two or more inserts 502 can be included in component 506. Section AA is a side view of component 500, discussed below. Figure 5B As shown in the diagram. Section BB is the cross-section of component 500 taken through insert 503. Figure 5D It is shown in the figure and discussed below.

[0064] Figure 5B A side view AA depicts an assembly 500 including an insert 502 according to various aspects of this disclosure. The insert 502 is positioned in a recess 504 via a recess opening 504A. The recess 504 is formed in a component 506, which may be an aircraft component. The recess 504 is formed along a central assembly axis 550, so named because the central axis of the insert 502 (as discussed in the above figure) is aligned along the same axis as the central axis of the recess 504. Component 506 includes a first layer 510 (which may also be referred to as a top layer) forming a first surface 528 of component 506, which may also be referred to as the top surface of component 506. The first layer 510 is formed on a second layer 508 having a thickness 508A, and the recess 504 extends through the first layer 510 and through a portion of the second layer 508. Figure 5B As shown, the groove 504 can extend through the entire thickness 508A of the second layer 508 to reach the third layer 514, which can be referred to as the bottom layer. The third layer 514 defines the second surface 560 of the component 506, which can be referred to as the bottom surface of the component 506. In this example, the second surface 560 is opposite to and substantially parallel to the first surface 528. In other examples, one or more of the second surface 560 and the first surface 528 may be angled relative to each other at right angles or in a convex or concave manner. Although the second surface 560 and the first surface 528 are in Figure 5B The surface is shown as smooth, but in other examples, one or more of the second surface 560 and the first surface 528 may include raised or recessed features, or other features.

[0065] Returning to the recess, in other examples, the recess 504 may extend through the entire thickness 508A of the second layer 508, for example, extending a distance parallel to the central component axis 550, equal to approximately 10% to approximately 90% of the thickness 508A of the second layer 508. Thus, the recess 504 may be defined by a recess opening 504 having a recess opening width 544, sidewalls 516, a recess width 558 (defined by the distance between the sidewalls 516), and a recess bottom 504B opposite the second surface 560 of the component 506. In this example, the recess bottom 504B is also the third layer 514.

[0066] Insert 502 in Figure 5B The figure shows a first surface 502A, a first portion 534, a second portion 538, and a connector portion 536 extending therebetween. The insert 502 has a locking mechanism 540, which may be similar to locking mechanism 106. Figure 1A ) or locking mechanism 122 ( Figure 1B ) configured, or otherwise configured to connect to the first layer 510. The following is... Figure 5C The connection is discussed in detail below. The insert 502 also includes at least one notch 568 and a compression mechanism 530, which can be configured to... Figure 1A The compression mechanism 110 shown, or configured as Figure 4A The compression mechanism 402 may be configured to operate as discussed herein. The compression mechanism 530 is shown in FIG. 5 as positioned adjacent to the bottom 504B of the recess but not in contact with the sidewall 516 of the recess. In other examples, one or more portions of the compression mechanism 530 may contact one or more portions of the sidewall 516.

[0067] As discussed above, the operation of insert 502 includes subsequently positioning insert 502 in recess 504 and applying force 532, as indicated by arrow 502 parallel to the axis 550 of the central assembly. The application of force 532 causes compression mechanism 530 to compress in the direction of force 532. The outer diameter 554 of the first portion is larger than the recess opening diameter 556, and the overhang portion extending into the recess 504 (in...) Figure 5C (See detailed diagram). The first layer 510 is made of a flexible material to allow the insert 502 to be positioned in the recess 504 without tearing or permanently deforming the first layer 510. When the compression mechanism 530 is in a compressed state, the application of force 532 pushes the insert 502 over the overhanging portion of the first layer 510. When force 532 is removed, the compression mechanism 530 is released to (decompressed to) an uncompressed state, as shown in the diagram. Figure 5BAs shown. This decompression causes the locking mechanism 540 to move upward and secure it to the overhanging portion of the first layer 510. Decompression causes the insert 502 to self-adjust such that the first surface 502A of the insert 502 is flush with, i.e., coplanar with, the first surface 528 of the component 506. The shared plane 552 of the first surface 528 and the first surface 502A is in... Figure 5B As shown in the image.

[0068] Figure 5C An example of a portion 512 of component 500 according to aspects of this disclosure is depicted. Figure 5C Showing wing 524 and locking mechanism 540 (from Figure 5B The first portion 534 extends from the first portion 534 to the second portion 538, as discussed in other examples of inserts above. A first end 520 of each wing 524 is positioned (e.g., when the locking mechanism 540 is integrally formed with the insert 502) or formed (when the locking mechanism 540 is not integrally formed with the insert 502) at the first portion 534. A second end 522 of each wing 524 is positioned or formed (depending on the example) at the second portion 538. Each of the plurality of winglets 524 of the locking mechanism 540 can be configured such that the first end 520 of the wing 524 forms an angle α relative to the first surface 528 of the component 506. In one example, the angle α can be from about 35 degrees to about 85 degrees. In another example, the angle α can be from about 45 degrees to about 75 degrees. In one example, the angle α can be from about 55 degrees to about 85 degrees. Depending on the angle of the sidewall 516 of the recess 504, the second end 522 of the wing 524 (and other wing 524s of the locking mechanism 540) can be at an angle β relative to the sidewall 516. In one example, angle β can be from about 10 degrees to about 45 degrees. In another example, angle β can be from about 15 degrees to about 35 degrees. In yet another example, angle β can be from about 10 degrees to about 25 degrees.

[0069] The offset distance 564 between the first end 520 of the flap 524 and the top surface 502A of the insert 502 (which can also be described as the offset distance between the tops of the locking mechanism 540) can be determined by the thickness 526 of the first layer 510. In other examples, the offset distance 564 can be determined by factors including the material comprising the flap 524, the material forming the first layer 510, the purpose of the insert 502, the position of the insert 502 relative to other inserts in the component 506, the number of inserts coupled to the component 506, or other factors or combinations thereof. In one example, the thickness 526 can range from about 0.020” to about 0.100”. In other examples, the thickness 526 can range from about 0.024” to about 0.48”. In still other examples, the thickness 526 can range from about 0.030” to about 0.75”. As discussed above, Figure 5C The overhang portion 518 extends into the recess 504. The overhang portion 518 can extend circumferentially within the recess 504. Figure 5B The distance is approximately 1% to approximately 10% of the width 558, which can also be referred to as the inner diameter of the groove 504. In another example, the overhang portion 518 may extend... Figure 5B The distance is approximately 2% to approximately 6% of the width 558. In another example, the overhang portion 518 can extend... Figure 5B The width is approximately 1% of the distance of 558.

[0070] Figure 5D A cross-sectional view BB depicts an assembly 500 including insert 502 according to various aspects of this disclosure. Figure 5D It shows the relationship with Figure 5A , Figure 5B and Figure 5C The insert 502 and component 506 shown are the same elements. The compression mechanism 530 is in... Figure 5D The image shows the component in a first uncompressed state, with the first surface 502A coplanar with the top surface 528 of the component 506 along the plane 552. Additionally, Figure 5D A hole 542 in the first surface 502A of the insert 502 is shown. In some examples, an attachment element 566 may be disposed in the hole 542. The attachment element 566 may include a plurality of threads, helical coils, or other mechanisms including a plurality of male or female features that enable a second component (not shown) to be engaged to component 506 via the insert 502.

[0071] Figure 6A A top view of another component 600, including insert 608A, is depicted according to various aspects of this disclosure. Insert 502 is positioned in a recess in component 506. Component 614 is... Figure 6AThe diagram is shown as a partial view and can be extended in various directions to have various top-view geometries, such as polygons, circles, ellipses, triangles, or combinations thereof. Therefore, two or more inserts 608A can be included in component 614. Section AA is a side view of component 600, discussed below. Figure 6B As shown below. Section BB is a cross-sectional view of component 600 through inserts 608A (and 608B, not shown here), and is shown in the figure below. Figure 6C As shown in the image.

[0072] Figure 6B Depicting aspects from this disclosure Figure 6A A side view AA of component 600. Component 600 is similar to component 500, wherein component 614 has a first layer 616 formed on a second layer 618 and a third layer 620 formed on the second layer 618 opposite to the first layer 616. Component 600 has at least one recess 604 formed therein. However, unlike component 500, the recess 604 of component 600 is a through-hole. Recess 604 extends from a first opening 624 in the first layer 616 (which forms a first surface 652A and may be referred to as the top surface of component 614) through the second layer 618 to a second opening 622 in the third layer 620. The third layer 620 may be referred to as the bottom layer of component 614. Recess 604 is further defined by a sidewall 642. The sidewall 642 is shown herein as parallel to the central component axis 602 of component 600. The diameter of the first opening 624 is approximately the same as the diameter of the second opening 622. In other examples, the sidewall 642 may be tapered, such that the diameter of the first opening 624 is larger than the diameter of the second opening 620. In still other examples, the sidewall 642 may be tapered, such that the diameter of the first opening 624 is smaller than the diameter of the second opening 620. The recess 604 has two inserts positioned and fixed therein. Therefore, the central assembly axis 602 is a shared central axis of the first insert 608A, the second insert 608B, and the recess 604.

[0073] The first insert 608A may be similar to other inserts discussed herein and includes a first portion 632A, a second portion 636A, and a connector portion 634A extending therebetween. The first insert 608A also includes at least one notch 642A formed in the first portion 632A. The first locking mechanism 626A of the first insert 608A may be as follows: Figure 1A The locking mechanism 106 discussed in the context of multiple individual elements, or as... Figure 1B The locking mechanism 122, as discussed herein, takes the form of multiple connecting elements, or other configurations as discussed herein, such that it is configured to be coupled to the overhang portion (in... Figure 6B(Shown as 658A). The first insert 608A also includes a first compression mechanism 640A, which is capable of being in a first uncompressed state, changing to a second compressed state in response to the application of a force, and returning to the first uncompressed state in response to the removal of the applied force. The first compression mechanism 640A can be configured in any of the ways discussed herein, including... Figure 1A and Figure 4A and Figure 4B The compression mechanism discussed herein. A first insert 608A is positioned in a recess 604 such that when the first locking mechanism 626A is secured to the recess 604 via the overhanging portion of the first layer 616, the first surface 654A of the first insert 608A and the first surface 652A of the component 614 are coplanar along the first plane 650A. Multiple engagement regions 660, 662 indicate the positions where the first locking mechanism 626A is engaged with the first layer 616, similar to... Figure 5C The situation is illustrated. It should be understood that the connection area is formed at any location along the overhang of the first layer 616, to which the first locking mechanism 626A is connected, and two connection areas 660 and 662 are shown for illustrative purposes, as more connection areas may exist along openings such as the first opening 624.

[0074] The second insert 608B may be similar to other inserts discussed herein and includes a first portion 632B, a second portion 636B, and a connector portion 634B extending therebetween. The second insert 608B has a top surface 654B, which, although referred to herein as a “top” surface, can be considered as being positioned along the bottom surface 652B of the component 614. The second insert 608B also includes at least one notch 642B formed in the first portion 632B. The second locking mechanism 626B of the second insert 608B may be as follows: Figure 1A The locking mechanism 106 discussed in the context of multiple individual elements, or as... Figure 1B The locking mechanism 122, as discussed herein, takes the form of multiple connecting elements, or other configurations as discussed herein, such that it is configured to be coupled to the overhang portion (in... Figure 6B (Shown as 658B). The second insert 608B also includes a second compression mechanism 640B, which is capable of being in a first uncompressed state, changing to a second compressed state in response to the application of a force, and returning to the first uncompressed state in response to the removal of the applied force. The second compression mechanism 640B can be configured in any of the ways discussed herein, including... Figure 1A and Figure 4A and Figure 4BThe compression mechanism discussed herein. The second insert 608B is positioned in the recess 604 such that when the second locking mechanism 626B is secured to the recess 604 via the overhang of the third layer 620, the first surface 654B of the second insert 608B and the first surface 652A of the component 614 are coplanar along the second plane 650B. Multiple engagement regions 628, 630 indicate the locations where the second locking mechanism 626B is engaged with the second layer 618. It should be understood that engagement regions are formed at any location along the overhang of the second layer 618, where a portion of the second locking mechanism 626B is engaged, and two engagement regions 628, 630 are shown for illustrative purposes.

[0075] Figure 6C A cross-sectional view of the cross section BB of component 600 according to various aspects of this disclosure is depicted. Figure 6C The same elements of component 600 are shown and as follows Figure 6A and Figure 6B As shown. Compression mechanisms 640A and 640B are also present. Figure 6C The image shows the device in an uncompressed state. Furthermore, the first surface 654A of the first insert 608A and the surface 652A of the first component 614 are coplanar along the first plane 656A, and the first surface 654B of the second insert 608B and the first surface 652A of the component 614 are coplanar along the second plane 656B. In this example, the first insert 608A is positioned in the first portion 604A of the recess 604, and the second insert 608B is positioned in the second portion 604B of the recess 604. The first insert 608A has a top surface 654A. The overall thickness 644 of the component 614 is... Figure 6C As shown in the figure. The first portion 604A of the groove 604, with a first thickness 644A, is shown to be substantially similar to Figure 6C The second portion 604B has a second thickness 644B. ​​In other examples, the first thickness 644A of the first portion 604A of the groove 604 may be approximately 10% to approximately 75% smaller than the second thickness 644B of the second portion 604B. In still other examples, the first thickness 644A of the first portion 604A of the groove 604 may be approximately 10% to approximately 75% smaller than the second thickness 644B of the second portion 604B. Additionally, Figure 6C A first hole 646A in the first surface 648A of the first insert 608A and a second hole 646B in the first surface 648B of the second insert 608B are shown. Figure 5DConversely, no attachment element is provided in the first hole 646A or the second hole 646B in component 600. In this example, the attachment component can still be attached to the first insert 608A and / or the second insert 608B via each corresponding hole using a magnet, press fit, or other means or combinations thereof. However, in some examples, the attachment element may be provided in one or both of the first hole 646A or the second hole 646B.

[0076] Example methods using inserts

[0077] Figure 7 A flowchart depicts a method 700 of using an insert according to various aspects of this disclosure. At operation 702 in method 700, a component of one of the inserts, such as those discussed above, is positioned in a recess in, for example, an aircraft component (702 - positioning the component in the recess). At operation 702, the compression mechanism of the insert may be in a first uncompressed state. The recess may be formed such that it extends through a first layer (which may include two or more interlayers) and through at least a portion of a second layer positioned adjacent to the first layer. In some examples, the aircraft component may include a third layer on one side of the second layer opposite the first layer. The third layer may include two or more interlayers. The insert may be positioned in the recess such that the insert and the recess are aligned along a common central axis. The recess may be formed at a right angle relative to a first surface of the top layer, the first surface being the outermost top surface of the aircraft component. In other examples, the recess may be formed at an angle relative to the first surface, which is not a right angle. In some examples, the recess may be a blindhold including a bottom surface, such that the recess extends through the first layer and into at least a portion of the second layer. In other examples, the groove may be a through-hole extending through the first, second, and third layers, such that it has a first opening in the first layer and a second opening in the third layer. The groove may be formed with upright sidewalls or with sloping sidewalls, such that the groove tapers toward or away from the top surface. In some examples, at operation 702, multiple inserts may be positioned in one or more grooves. At least one of the top and / or bottom layers of the aircraft component extends a predetermined distance in the opening of the groove to form a cantilever portion. As discussed below, the cantilever portions of each of the first (top) layer and the second (bottom) layer enable a locking mechanism to engage with the groove.

[0078] At operation 704, after the insert has been positioned in the recess at operation 702, a force is applied to the insert (704 - applying force to the component). In one example, the force is applied along a shared axis to the top surface of the insert (e.g., the first surface of the first portion). As discussed above, the force applied at operation 704 is sufficient to bring the compression mechanism into a second compressed state. When in the compressed state, the locking mechanism is forced below the top (and / or bottom) layer of the aircraft panel (or other component having the recess and overhang portion as discussed above), such that the overhang portion of the top or bottom layer covers the locking mechanism.

[0079] At operation 706, the force applied at operation 704 is removed, causing the compression mechanism to unfold in the opposite direction to the applied force and return to the first uncompressed state. Returning to the first uncompressed state causes the locking mechanism to also move toward the overhanging portion of the groove in the opposite direction to the applied force (706 – removal of the applied force). At operation 708, in response to the removal of the force at operation 706, the locking mechanism is forced toward the overhanging portion of the top (or bottom) layer and "engages" (connects) to the groove (708 – engages the component to the groove). In other words, the locking mechanism engages with the groove via the top (or bottom) portion extending into the opening (overhanging portion) of the groove, thereby securing the insert to the component.

[0080] In some examples, method 700 may repeat operations 702-708 such that the second insert is positioned in another opening of the through-hole recess, and the recess thus contains two inserts, one attached to the top layer and one attached to the bottom layer. In other examples, method 700 may repeat operations 702-708 to attach additional inserts to other recesses of the component, which may be formed on the same or different surfaces of the component.

[0081] In some examples, after operation 708, at operation 710, one or more notches in the insert are used as access points to place various potting materials into at least a portion of the recess (710 - placing potting material into the recess). This may occur, for example, if the insert is used to secure heavy components, or depending on one or more materials of the insert, the top or bottom layer, or other factors applicable to the intended application of the insert.

[0082] Therefore, using the inserts and assembly methods discussed herein, one or more inserts can be securely attached to one or more components such that the inserts and components are coplanar, and thus ready for the assembly of additional elements to the components via the inserts. The self-aligning inserts become level (coplanar) with the component surfaces, reducing the need for further finishing and adjustment operations, and improving the speed and quality of assembly operations.

[0083] Reference has been made to various aspects in this disclosure. However, it should be understood that this disclosure is not limited to the aspects specifically described. Rather, any combination of the features and elements above, whether or not related to different aspects, is contemplated to implement and practice the teachings provided herein. Furthermore, when elements of an aspect are described in the form of “at least one of A and B,” it will be understood that element A is exclusively included, element B is exclusively included, and aspects including both elements A and B are contemplated. Moreover, while certain aspects may achieve advantages over other possible solutions and / or over the prior art, whether a particular advantage is achieved by a given aspect does not limit this disclosure. Therefore, the aspects, features, aspects, and advantages disclosed herein are illustrative only and should not be considered elements or limitations of the appended claims unless expressly stated in the claims. Similarly, references to “the invention” should not be construed as a generalization of any inventive subject matter disclosed herein and should not be considered elements or limitations of the appended claims unless expressly stated in the claims.

[0084] As those skilled in the art will understand, the aspects described herein may be embodied as a system, method, or computer program product. Therefore, aspects may take the form of entirely hardware aspects, entirely software aspects (including firmware, resident software, microcode, etc.), or aspects combining software and hardware aspects, which are collectively referred to herein as “circuit,” “module,” or “system.” Furthermore, the aspects described herein may take the form of a computer program product embodied in one or more computer-readable storage media having computer-readable program code embodied thereon.

[0085] Program code embodied on a computer-readable storage medium may be transmitted using any suitable medium, including but not limited to wireless, wired, fiber optic cable, RF, or any suitable combination thereof.

[0086] Computer program code used to perform the operations of aspects of this disclosure may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, Smalltalk, C++, etc., and conventional procedural programming languages ​​such as the "C" programming language or similar programming languages. The program code may be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter case, the remote computer may be connected to the user's computer via any type of network, including local area networks (LANs) or wide area networks (WANs), or may be connected to an external computer (e.g., via the Internet through an Internet service provider).

[0087] This document describes aspects of the present disclosure with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to aspects of the present disclosure. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, executable via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / actions specified in the blocks of the flowchart illustrations and / or block diagrams.

[0088] These computer program instructions may also be stored in a computer-readable medium that can instruct a computer, other programmable data processing device or other apparatus to operate in a particular manner, such that the instructions stored in the computer-readable medium produce an article of writing which includes instructions that implement functions / actions specified in the frames of flowcharts and / or block diagrams.

[0089] Computer program instructions may also be loaded onto a computer, other programmable data processing apparatus or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer-implemented process, such that the instructions, which execute on the computer, other programmable data processing apparatus or other device, provide for implementing the functions / actions specified in the frames of flowcharts and / or block diagrams.

[0090] The flowcharts and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various aspects of this disclosure. In this regard, each box in a flowchart or block diagram may represent a module, segment, or portion of code that includes one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions marked in the boxes may occur outside the order indicated in the figures. For example, two boxes shown consecutively may actually be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order or out of order, depending on the functions involved. It should also be noted that each box in the block diagrams and / or flowcharts, and combinations of boxes in the block diagrams and / or flowcharts, may be implemented by a system based on dedicated hardware, or a combination of dedicated hardware and computer instructions, that performs the specified function or action.

[0091] Furthermore, this disclosure includes embodiments based on the following examples:

[0092] A component, comprising:

[0093] Central axis (116);

[0094] A first portion (102) having a first surface (102A);

[0095] A second portion (108) having a second surface (108A);

[0096] A connector portion (126) extending between the first portion (102) and the second portion (108);

[0097] A hole (104) is formed in the first part (102) along the central axis (116);

[0098] A locking mechanism (106) integrally formed with the component, the locking mechanism (106) being offset from the first surface (102A) by an offset distance (564); and

[0099] The compression mechanism (110) is connected to the second part (108).

[0100] The component of Example 1 also includes a locking mechanism (106) comprising a plurality of flaps (106A), each of the plurality of flaps (106A) extending between a first portion (102) and a second portion (108).

[0101] The components of Example 1 or 2, wherein the first part (102), the second part (108), the connector part (126) and the locking mechanism (106) are each formed of the same material, which includes polymers, metals, composite materials, ceramics or combinations thereof.

[0102] The component of any one of Examples 1 to 3, wherein the compression mechanism (110) is formed of a polymer, metal, composite material, ceramic or a combination thereof.

[0103] The component of Example 4, wherein the hole (104) includes an attachment element (566).

[0104] The component of any of Examples 1 to 5 further includes a first outer diameter (204) of the first part (102) that is substantially similar to the second outer diameter (310) of the second part (108).

[0105] The component of Example 6, wherein the outer diameter (314) of the connector portion (126) is smaller than the first outer diameter (204) and smaller than the second outer diameter (310).

[0106] The component of Example 2, wherein each of the plurality of flaps of the locking mechanism (106) is at an angle (α) of about 10 degrees to about 80 degrees relative to the first surface (102A) of the first part (102).

[0107] The component of any of Examples 1 to 6 also includes an offset distance (564) of about 0.020 inches to about 0.050 inches.

[0108] A component, comprising:

[0109] Insert (100B), the insert having:

[0110] Central axis (116);

[0111] A first portion (102) having a first surface (102A);

[0112] A second portion (108) having a second surface (108A);

[0113] A connector portion (126) extending between the first portion (102) and the second portion (108);

[0114] A hole (104) is formed in the first part (102) along the central axis (116);

[0115] A locking mechanism (122) circumferentially positioned around the insert (100B) includes a plurality of flaps (124) extending from the first shared element (118) and positioned at an offset distance (564) from the first surface (102A) of the first portion (102); and

[0116] The compression mechanism (110) is connected to the second part (108).

[0117] The components of Example 10 also include a first shared element (118) coupled to a first outer surface (102B) of the first portion (102).

[0118] The components of Example 10 or 11 also include a locking mechanism (122) having a second shared element (120).

[0119] The component of Example 12 also includes each of a plurality of flaps (124) extending between a first shared element (118) and a second shared element (120), with a second ring (120) coupled to a second outer surface (108B) of a second portion (108).

[0120] A component of any of Examples 10 to 13, wherein the insert (100B) is formed of a first material and the locking mechanism (122) is formed of a second material, the first material being different from the second material.

[0121] The component of any of Examples 10 to 14, wherein the first outer diameter (204) of the first part (102) is smaller than the second outer diameter (310) of the second part (108).

[0122] The component of any of Examples 10 to 15, wherein each of the plurality of blades (124) is at an angle (α) of about 10 degrees to about 80 degrees relative to the first surface (102A).

[0123] Components of any of Examples 10 to 15 also include:

[0124] A component (506) having a first layer (510) forming a first surface (528) of the component (506) and forming above a second layer (508);

[0125] A groove (504) is formed in the first surface (528) of the component (506), the groove (504) extends into the second layer (508) and is defined by an opening (504A) and a sidewall (516) in the first surface (528), a portion (518) of the first layer (510) extends a predetermined distance in the groove (504) around the opening (504A) of the groove (504), the component (502) is positioned in the groove (504) and is fixed to the groove (504) via a locking mechanism (540) and the connection of the portion (518) of the first layer (510) extending into the groove (504), the first surface (502A) of the insert (502) is coplanar with the first surface (528) of the component (506).

[0126] A method for forming a component, comprising:

[0127] Operation (702) positions the first component in the groove of the second component;

[0128] The first component has:

[0129] Central axis;

[0130] The first portion having a first surface;

[0131] The second part having a second surface;

[0132] The first hole is formed in the first part along the central axis;

[0133] A first locking mechanism extending circumferentially around the first component, the first locking mechanism being offset from the first surface by a first offset distance; and

[0134] The first compression mechanism is connected to the second surface, and the first compression mechanism is in a first uncompressed state.

[0135] A second component having a first layer formed on a second layer, a portion of the first layer extending a first predetermined distance in a first opening of a groove.

[0136] Operation (704) applies force along the central axis of the first component in a first direction to put the first compression mechanism into a second compression state, wherein the central axis of the first component is aligned with the central groove axis of the groove;

[0137] Operation (706) removes the force applied along the central axis in the first direction; and

[0138] Operation (708), in response to removing the force applied in the first direction, engages the first component to the groove, wherein removing the force applied in the first direction returns the first compression mechanism to a first uncompressed state, such that the first locking mechanism is secured to the portion of the first layer extending around the first opening of the groove, and when the first compression mechanism returns to the first uncompressed state, the first surface is coplanar with the first layer of the second component.

[0139] The method in Example 18 also includes:

[0140] Position the third component (702) in a groove in the second component, the groove being a through hole extending along a centerline from a first opening on a first surface of the second component to a second opening on a second surface of the second component, the second surface being opposite to the second surface;

[0141] The third component has:

[0142] The third part having a third surface;

[0143] The fourth part having a fourth surface;

[0144] A second hole is formed in the third part along the central axis;

[0145] A second locking mechanism extending circumferentially around the first component, the second locking mechanism being offset from the third surface by a second offset distance; and

[0146] The second compression mechanism is connected to the fourth surface, and the second compression mechanism is in the first uncompressed state.

[0147] The second component has a third layer formed on the second layer, a portion of which extends a second predetermined distance into the second opening.

[0148] Operation (704) applies force in the second direction along the central axis of the third component to put the second compression mechanism into a second compression state;

[0149] Operation (706) removes the force applied along the central axis in the second direction; and

[0150] Operation (708), in response to removing the force applied along the central axis, engages the third component to the groove, wherein removing the force applied along the central axis returns the second compression mechanism to a first uncompressed state, such that the second locking mechanism is secured to the portion of the third layer extending around the second opening of the groove, wherein when the second compression mechanism returns to the first uncompressed state, the third surface of the third component is coplanar with the third layer of the second component.

[0151] The method of Example 18 or 19 further includes: operation (710) placing a plurality of potting materials into a groove of the second component via a first notch formed in a first surface of the first component.

[0152] While the foregoing addresses aspects of this disclosure, other and additional aspects of this disclosure may be contemplated without departing from its essential scope, which is defined by the appended claims.

Claims

1. A method for forming a component, wherein, The method includes: Position the first component in the groove of the second component; The first component has: Central axis; The first portion having a first surface; The second part having a second surface; A first hole is formed in the first portion along the central axis; A first locking mechanism extending circumferentially around the first component, the first locking mechanism being offset from the first surface by a first offset distance; and A first compression mechanism is connected to the second surface, and the first compression mechanism is in a first uncompressed state. The second component has a first layer formed on the second layer, a portion of which extends a first predetermined distance in the first opening of the groove. A force is applied along the central axis of the first component in a first direction to put the first compression mechanism into a second compression state, wherein the central axis of the first component is aligned with the central groove axis of the groove; Remove the force applied along the central axis in the first direction; and In response to the removal of the force applied in the first direction, the first component is coupled to the groove, wherein removing the force applied in the first direction causes the first compression mechanism to return to the first uncompressed state, such that the first locking mechanism is secured to the portion of the first layer extending around the first opening of the groove, and when the first compression mechanism returns to the first uncompressed state, the first surface is coplanar with the first layer of the second component.

2. The method according to claim 1, further comprising: The third component is positioned in the groove of the second component, the groove being a through hole extending along the central axis from a first opening on the first surface of the second component to a second opening on the second surface of the second component, the first surface of the second component being opposite to the second surface of the second component; The third component has: The third part has a third surface; The fourth part has a fourth surface; A second hole is formed in the third portion along the central axis; A second locking mechanism extends circumferentially around the first component, and the second locking mechanism is offset from the third surface by a second offset distance; as well as A second compression mechanism is connected to the fourth surface, and the second compression mechanism is in a first uncompressed state. The second component has a third layer formed on the second layer, a portion of which extends a second predetermined distance into the second opening. A force is applied in the second direction along the central axis of the third component, causing the second compression mechanism to be in a second compression state; Remove the force applied along the central axis in the second direction; as well as In response to the removal of the force applied along the central axis, the third component is coupled to the groove, wherein removing the force applied along the central axis causes the second compression mechanism to return to the first uncompressed state, such that the second locking mechanism is secured to the portion of the third layer extending around the second opening of the groove, and when the second compression mechanism returns to the first uncompressed state, the third surface of the third component is coplanar with the third layer of the second component.

3. The method according to claim 1, further comprising: Various potting materials are placed into the groove of the second component via a first recess formed in the first surface of the first component.

4. The method according to claim 1, wherein, The first component also includes a connector portion extending between the first portion and the second portion.

5. The method according to claim 1, wherein, The first locking mechanism includes a plurality of flaps, each of which extends between the first portion and the second portion.

6. The method according to claim 4, wherein, The first part, the second part, the connector part, and the locking mechanism are each formed of the same material, including polymers, metals, composite materials, ceramics, or combinations thereof.

7. The method according to claim 1, wherein, The first compression mechanism is formed of a polymer, metal, composite material, ceramic, or a combination thereof.

8. The method according to claim 1, wherein, The first hole includes an attachment element.

9. The method according to claim 4, wherein, The first outer diameter of the first part is substantially similar to the second outer diameter of the second part.

10. The method according to claim 9, wherein, The outer diameter of the connector portion is smaller than the first outer diameter and smaller than the second outer diameter.

11. The method according to claim 5, wherein, Each of the plurality of flaps of the locking mechanism is at an angle (α) of 10 to 80 degrees relative to the first surface of the first portion.

12. The method according to claim 1, wherein, The first offset distance is 0.020 inches to 0.050 inches.

13. The method according to claim 1, wherein, The groove extends into the second layer and is defined by the opening and sidewalls in the first surface.

14. The method according to claim 3, wherein, The various potting materials include thermosetting materials.

15. The method according to claim 3, wherein, The various potting materials include thermosetting materials, metals, alloys, composite materials, or combinations thereof.

16. The method according to claim 1, wherein, The second component is an aircraft component.

17. The method according to claim 16, wherein, The aircraft component is the panel on the aircraft fuselage.

18. The method according to claim 16, wherein, The aircraft components are internal parts of the cabin.

19. The method according to claim 16, wherein, The aircraft component is the wing.

20. The method according to claim 16, wherein, The aircraft component is the engine.

21. The method according to claim 15, wherein, The thermosetting material is epoxy resin.

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