Screwed inserts for bonding outer panels, sandwich panels including the same, and related methods

Abstract

To support an insert on its interface with one or more skins of a sandwich panel so as to maintain the pull-out strength and the shear strength.SOLUTION: A skin-bonded threaded insert may include a collar (58). The skin-bonded threaded insert may include one or more flanges (60) that engage one or more skins (16, 18) of a sandwich panel (12). The flanges (60) are positioned, e.g., between the two skins (16, 18) or between a core (14) and the skin (18) of the sandwich panel (12) to secure the skin-bonded threaded insert in place within the sandwich panel (12). The skin-bonded threaded insert may be positioned within the sandwich panel (12) without the use of a potting agent and may engage with the skins (16, 18) of the sandwich panel (12), where the pull-out strength and the shear strength thereof do not depend on adherence to the core (14).SELECTED DRAWING: Figure 19

Description

Technical Field

[0001] The present disclosure relates to an insert with an outer plate joint screw, a sandwich panel including the same, and methods related thereto.

Background Art

[0002] Sandwich panels (e.g., those having a core structure sandwiched between two material layers or outer plates) are often used in aircraft manufacturing due to their high specific strength. Depending on the location and use of the sandwich panel within an aircraft, one or more inserts (e.g., circular inserts) may need to be inserted or passed through the panel to attach one or more other structures or fasteners to the sandwich panel. Circular inserts can be used to transmit local loads to the sandwich panel (e.g., via pins, bolts, screws, joints, or other structures), thereby fixing the sandwich panel to another structure, connecting multiple sandwich panels to each other, or attaching one or more external members to the sandwich panel. For example, a circular insert may form a passage for passing a wire bundle from one side of the sandwich panel to the other side. Also, a circular insert may be configured to accommodate fasteners such as pins and bolts so that another panel or member can be fixed to the sandwich panel via the circular insert. In the aerospace industry, such sandwich panels and circular inserts may be used to assemble major and secondary structures inside an aircraft, or to form floorboards, wall panels, galleys, luggage compartments, overhead luggage bins, lavatories, and other structures within the aircraft. Such sandwich panels and circular inserts are also used in other industries.

[0003] Figures 1 and 2 schematically show a conventional circular insert 10 fitted within a sandwich panel 11 in cross-sectional view. The sandwich panel 11 may include a core 13 sandwiched between a first outer panel 15 and a second outer panel 17. The first outer panel 15 and the second outer panel 17 are, for example, rigid or semi-rigid outer panels, and are usually relatively thin compared to the core 13, and the core is generally made of a lightweight material. The conventional circular insert 10 is inserted, for example, into a circular hole 19 formed in the sandwich panel 11, which may be a blind hole 21 (Figure 1) or a through hole 23 (Figure 2). A blind hole 21 extends, for example, through one of the outer panels (e.g., the first outer panel 15) and into the core 13 toward the other outer panel (e.g., the second outer panel 17). A through hole 23, on the other hand, extends through, for example, the first outer panel 15, the second outer panel 17, and the core 13. As shown in Figures 1 and 2, the flange portion 27 of a conventional circular insert 10 is substantially flush with, for example, one or both of the first outer plate 15 and the second outer plate 17. Alternatively, as shown in Figure 3, the flange portion 27 of a conventional circular insert 10 is mounted on top of (for example, on the outer surface of) the first outer plate 15 or the second outer plate 17.

[0004] In conventional methods, an adhesive such as a potting compound or epoxy is injected through a potting hole or opening in the conventional circular insert 10 to fill the gap or space 29 between the conventional circular insert 10 and the core 13 of the sandwich panel 11. Once fully cured, the adhesive fixes the insert in place within the hole 19 of the sandwich panel 11, and once the adhesive has dried, solidified, and / or cured, relative movement of the conventional circular insert 10 with respect to the sandwich panel 11 is substantially prevented, and the conventional insert 10 is held in place within the circular hole 19. (For example, the conventional circular insert 10 is prevented from coming out, rotating, or moving laterally.) In other words, the potting compound fixes the conventional circular insert 10 in place by bonding the interface between the conventional circular insert 10 and the core 13. However, the use of such adhesives is labor-intensive and takes a considerable amount of time to cure, for example, 2 to 6 hours or more. During this time, the conventional circular insert is not stable within the sandwich panel and cannot be subjected to load. This limits the processing volume and overall efficiency in the manufacturing process. In addition, in many cases, the conventional circular insert 10 must be held in place during curing (for example, by applying masking tape to hold the circular insert 10 in place), and even with such measures, the insert may shift during curing.

[0005] In some methods, if excess adhesive is squeezed out around the conventional circular insert 10, this adhesive must be removed from the circular insert 10 so that the secondary component (e.g., a bracket) is substantially flush with the insert and the sandwich panel. Conventional circular inserts 10 and their methods of use and / or installation may result in “high insert” or “low insert” problems, where the conventional circular insert ultimately protrudes too far out of the circular hole (“high”) or is recessed too far into the circular hole (“low”), respectively. (For example, the position of the outer surface of the conventional circular insert 10 may be “high” more than necessary, protruding from the circular hole, or “low” more than necessary, recessed into the circular hole, in either case resulting in the formation of an uneven or non-flush interface between it and the outer panel of the sandwich panel.) Such positional deficiencies may result from misalignment during curing or initial positioning errors, and may hinder the proper positioning of brackets or other secondary components fixed via the conventional circular insert 10. Often, the shear strength in the installed state depends on the insert being flush with the outer panel of the sandwich panel. Expansion forces due to the expansion of the adhesive during curing can also cause defects such as misalignment of the conventional circular insert 10, resulting in visible mark-offs on the opposite side of the sandwich panel, often leading to a defective finished product.

[0006] The conventional method of bonding circular inserts 10 to circular holes in sandwich panels using adhesive can hinder the automation of the manufacturing process. Furthermore, correcting the installation of the wrong type of circular insert 10 can be difficult and time-consuming, especially with conventional adhesive-based methods. Since a single sandwich panel may contain many different types of circular inserts, and some conventional circular inserts fit into circular holes of the same size, installing the wrong insert can occur fairly frequently. Additionally, the adhesives used in conventional methods can degrade even after curing, potentially causing the bond between the circular insert and the adhesive to break due to torque forces, leading to the circular insert 10 falling out of the hole or rotating within the hole in the sandwich panel. In other words, the pull-out strength of conventionally installed circular inserts depends on the potting agent. These challenges in conventional circular inserts 10 and their installation methods in sandwich panels remain ongoing problems across various industries. [Overview of the project]

[0007] The inserts and related methods for use in sandwich panels disclosed herein (e.g., methods for mounting one or more inserts to a sandwich panel) can solve one or more problems in conventional circular inserts and related methods. For example, some of the inserts according to this disclosure can be retained inside the sandwich panel without the use of an adhesive potting agent, can be cured at a predetermined location inside the sandwich panel at the same time as the sandwich panel is cured (thus reducing or eliminating manufacturing process steps), and / or can be supported at the interface with one or more outer panels of the sandwich panel (rather than the interface with the core of the sandwich panel) to maintain pull-out strength and shear strength.

[0008] One embodiment of an insert according to the present disclosure includes a body configured to extend longitudinally from a first cross-section to a second cross-section through at least a portion of the core of a sandwich panel, a hole extending longitudinally in at least a portion of the body, and a collar sized relative to the first enlarged portion of the hole such that its outer surface friction-fits with the first enlarged portion. The outer circumferential surface of the body may be configured to engage with the core of the sandwich panel when the outer panel threaded insert is mounted on the sandwich panel. The hole includes a threaded portion that is threaded to engage with a fastener, and the threaded portion may extend longitudinally along at least a portion of the length of the hole. The threaded portion may have a larger diameter corresponding to the largest diameter of the threaded portion. The hole may also include a first enlarged portion having an enlarged diameter greater than the larger diameter of the threaded portion, and a shelf-like portion formed at the junction between the first enlarged portion and the threaded portion. The collar is configured, for example, to be able to move in a vertical direction relative to the main body, thereby allowing it to move between a raised position and a press-fitted position when attaching the outer panel screw-attached insert to the sandwich panel.

[0009] In another embodiment, the outer panel joining threaded insert may include a body configured to extend longitudinally into the core of the sandwich panel, a longitudinally extending hole in at least a portion of the body, and an enlarged flange having a flange diameter larger than the body diameter of the body. The enlarged flange protrudes radially from the body, for example, at a position along the longitudinal axis of the body, and the position is between a first cross-section of the body and a second cross-section of the body on the opposite side, so that the enlarged flange is longitudinally offset from both the first and second cross-sections. The enlarged flange may be configured to be positioned inside the second outer panel and / or the third outer panel of the sandwich panel.

[0010] Related methods are also disclosed. For example, in one method of attaching a screw-type insert to a sandwich panel, ultrasonic cutting is performed to form the first outer panel of the sandwich panel, the core of the sandwich panel is placed on the first outer panel such that the first surface of the core faces the first outer panel, a hole is formed in the core of the sandwich panel, the screw-type insert is inserted into the hole, the second outer panel of the sandwich panel is placed on the second surface of the core such that the collar of the screw-type insert is positioned above the outer surface of the second outer panel, and the first outer panel, the core, and the second outer panel are all compressed with the screw-type insert in the hole. When inserting the screw-type insert into the hole, at least a part of the body of the screw-type insert is placed inside the hole, and the collar of the screw-type insert is positioned in an elevated state such that the collar is positioned above the second surface of the core, and the second surface of the core is on the opposite side of the first surface of the core. The second outer plate includes, for example, a through hole that penetrates the second outer plate, and when the second outer plate is placed on the core, the collar protrudes from the through hole. By compressing the first outer plate, the core, and the second outer plate together, the collar is translated vertically relative to the main body, and the collar is moved between an elevated position and a press-fitted position. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic cross-sectional view of a conventional insert that is positioned in a blind hole formed in a sandwich panel and is flush with the outer panel of the sandwich panel. [Figure 2] This is a schematic cross-sectional view of a conventional insert that is placed in a through-hole formed in a sandwich panel and is flush with the outer panel of the sandwich panel. [Figure 3] This is a schematic cross-sectional view of a conventional insert positioned in a sandwich panel. [Figure 4]This is a schematic perspective view of an exemplary and non-exclusive example of an apparatus that may include one or more sandwich panels containing one or more inserts as provided in this disclosure. [Figure 5] This is a schematic diagram of an exemplary and non-exclusive system according to the present disclosure, including one or more threaded inserts for bonding outer panels inserted into a sandwich panel. [Figure 6] This is a cross-sectional perspective view showing one embodiment of the threaded insert for outer panel bonding according to this disclosure, installed in a hole in a sandwich panel, with the collar of the insert in the raised position. [Figure 7] Figure 6 is a cross-sectional perspective view showing the outer panel joining threaded insert with the collar in the press-fit position. [Figure 8] This is a perspective view of one embodiment of a threaded insert for joining outer panels according to the present disclosure. [Figure 9] This is a perspective view of one embodiment of a threaded insert for joining outer panels according to the present disclosure. [Figure 10] This is a cross-sectional perspective view of one embodiment of a threaded insert for joining the outer panel according to the present disclosure, which is fitted into a hole in a sandwich panel. [Figure 11] This is a cross-sectional perspective view of one embodiment of an outer panel fastening threaded insert according to the present disclosure, which is fitted into a hole in a sandwich panel and through which a fastener is inserted. [Figure 12] This is a cross-sectional perspective view of one embodiment of a threaded insert for joining the outer panel according to the present disclosure, which is fitted into a hole in a sandwich panel. [Figure 13] This is a perspective view of one embodiment of a threaded insert for joining outer panels according to the present disclosure. [Figure 14] This is a cross-sectional perspective view of one embodiment of a threaded insert for joining the outer panel according to the present disclosure, which is fitted into a hole in a sandwich panel. [Figure 15] A side view of one embodiment of an outer panel joining threaded insert according to the present disclosure. [Figure 16] This is a partially exploded side view of one embodiment of the system of the present disclosure, including the threaded insert for joining the outer panel according to the present disclosure. [Figure 17]A cross-sectional view of an example of an outer panel joining threaded insert according to the present disclosure, mounted within a hole of a sandwich panel. [Figure 18] A side view of an example of an outer panel joining threaded insert having a second insert component according to the present disclosure. [Figure 19] A cross-sectional perspective view of an example of an outer panel joining threaded insert according to the present disclosure, mounted within a hole of a sandwich panel. [Figure 20] A cross-sectional perspective view of an example of an outer panel joining threaded insert according to the present disclosure. [Figure 21] A side view of the outer panel joining threaded insert of FIG. 20. [Figure 22] A diagram representing the process flow of an example of a method for mounting an outer panel joining threaded insert within a hole of a sandwich panel. [Figure 23] A schematic flowchart representing a method for mounting an outer panel joining threaded insert of the present disclosure within a sandwich panel according to the present disclosure. [Figure 24] A schematic flowchart representing a method for mounting an outer panel joining threaded insert of the present disclosure within a sandwich panel according to the present disclosure. [Figure 25] An upper perspective view of an example of a composite part produced by the method of the present disclosure.

Mode for Carrying Out the Invention

[0012] Referring to FIG. 4, one or more inserts 50 according to the present disclosure are attached to, for example, a sandwich panel. Such a sandwich panel is useful in many different applications due to, among other things, its high specific strength. For example, such a sandwich panel including one or more inserts 50 is useful in the aerospace industry, automotive industry, electronics industry, construction industry, military industry, recreation industry, and / or motorsports industry. In FIG. 4, an example of an apparatus 28 generally including one or more sandwich panels 12 and inserts 50 is shown in the form of an aircraft 30. The aircraft 30 can take any suitable form, and for example, civilian aircraft, military aircraft, or any other suitable aircraft are included therein. Although FIG. 4 shows an aircraft 30 in the form of a fixed-wing aircraft, other types and forms of aircraft are also within the scope of the aircraft 30 according to the present disclosure, and this includes (but is not limited to) rotary-wing aircraft and helicopters.

[0013] The apparatus 28 (e.g., an aircraft 30) includes, for example, one or more structures 32 formed by one or more sandwich panels 12, where one or more of the sandwich panels are, for example, composite panels. Referring to Figure 5, each sandwich panel 12 includes a core 14 formed of a relatively lightweight material, such as a plurality of elongated cells typically having a hexagonal or rectangular cross-section. Such a core 14 is also referred to as a honeycomb core, but other shapes and configurations such as corrugated structures and / or foamed materials can also be employed. The core 14 may include open-cell structures and / or closed-cell structures. The core 14 can be formed from foam, aluminum, Nomex® (aramid), carbon, Korex, Kevlar®, glass fiber, polyethersulfone, polyvinyl chloride, polyurethane, polyethylene foam, polystyrene foam, balsa wood, syntactic foam, honeycomb structures, polymer honeycomb, thermoplastic honeycomb, stainless steel, polycarbonate, and / or polypropylene. The sandwich panel 12 includes at least two outer panels, with a first outer panel 16 provided on one side of the core 14 and a second outer panel 18 provided on the other side of the core 14, forming a layered sandwich structure. That is, the first outer panel 16 is on the opposite side of the second outer panel 18, and the core 14 is located between the first outer panel 16 and the second outer panel 18. The outer panels 16 and 18 are generally rigid, and the core 14 extends between these outer panels. The first outer panel 16 and the second outer panel 18 can be formed from glass fiber reinforced polymer laminates, carbon fiber reinforced polymer laminates, thermosetting polymers, epoxy, metal sheets, carbon, aramid, aluminum, steel, plywood, balsa, teak, and / or hardwood. The first outer panel 16 and the second outer panel 18 may be formed from the same material or from different materials, depending on the embodiment. In some embodiments, one or more additional outer panels 16' may be connected to the first outer panel 16 and / or the second outer panel 18. Some composite sandwich panels 12 are formed by multiple first outer panels 16 and / or multiple second outer panels 18 fixed to each other, without using a core.

[0014] Referring again to Figure 4, the structure 32 may include one or more sandwich panels 12, joints formed between two or more sandwich panels 12, and / or three-dimensional structures formed using one or more sandwich panels 12. Exemplary and non-exclusive examples include aircraft structures such as wings 34, fuselage 36, horizontal stabilizers 38, overhead luggage racks 40, vertical stabilizers 42, and engine housings 44. However, other components of the aircraft 30 may also include structures 32, such as sandwich panels 12 and / or joints between two or more sandwich panels 12. Other applications of the sandwich panels 12 and one or more inserts 50 within the aircraft 30 include floor panels, interior walls, food handling galley assemblies, control surfaces, passenger storage racks, thrust vectoring assemblies, capsule panels, ablative shields for the nose cone, instrument enclosures and shelves, and bulkhead panels. In other industries, the apparatus 28 (including one or more sandwich panels 12 and inserts 50) includes, for example, space satellites, electronic radome structures, transport vehicles, transport containers, shelters, large antennas or disk reflectors, refrigeration panels, high-speed transport floor panels, marine electronic deck shelters, cargo pallets, automobile bodies, building curtain walls, partitions, divider panels, expandable hospital shelters, and / or internal structures of assemblies.

[0015] Figure 5 shows a schematic diagram of a system 100 including one or more outer panel screw-type inserts 50 (also referred to herein simply as “inserts 50”) that can be fitted into each hole 20 of a sandwich panel 12. In the figure, elements that are likely to be included in a given embodiment are shown with solid lines, and elements that are optional in a given embodiment are shown with dashed lines. However, elements shown with solid lines are not essential to all embodiments of the present disclosure, and elements shown with solid lines may be omitted from a particular embodiment without departing from the scope of the present disclosure. In the cross-sectional view of the sandwich panel 12 in Figure 5, only one insert 50 and one hole 20 are shown (and for clarity, the insert 50 is shown separated from the hole 20 in the exploded view), but the sandwich panel 12 typically includes multiple such holes 20, each capable of accommodating one insert 50 for fitting. Generally, the insert 50 of this disclosure includes a body 52 and a hole 54 extending longitudinally (for example, along a longitudinal axis 56) in at least a portion of the body 52. ​​Various examples of the insert 50 (or system 100 including it) may include one or more collars 58, one or more enlarged flanges 60, coatings 46, one or more threaded floating nuts 64, one or more adhesive packs 66, one or more notched flanges 68, thread locks 69, and / or second insert parts 70, as will be described below in relation to various embodiments of the insert 50. As will be described below in relation to various embodiments, the collar 58 is used, for example, for indexing and / or aligning the parts of the sandwich panel 12 and / or the insert 50. In addition to or instead of this, the collar 58 is configured to fix or hold the insert in place in a predetermined position within a precision-machined hole in the outer plate of the sandwich panel 12 while the sandwich panel 12 is curing with the insert 50 in place.

[0016] The insert 50 is typically configured to house a secondary member 48 within a hole 54, and the secondary member 48 is configured to transmit local loads to the sandwich panel 12 via the outer panel screw insert 50. For example, the secondary member 48 is a fastener that is inserted and / or threaded through the hole 54 of the insert 50 for purposes such as securing another member to the sandwich panel 12 via the insert 50. In some examples, the secondary member 48 is screwed into the insert 50, for example, via internal threads in the insert 50. The hole 54 is, for example, a blind hole or a through hole. For example, one or more parts of the hole 54 are threaded. For example, one or more parts of the hole 54 have a different diameter from one or more other parts of the hole 54.

[0017] One or more surfaces of the insert 50 may be coated with a coating 46, such as a thermosetting resin coating 46. For example, at least a portion of the first cross section 72, the second cross section 74, and / or the outer peripheral surface 76 may be coated with a thermosetting resin coating 46. In some examples, such a coating 46 is configured to flow during the curing of the sandwich panel 12, thereby strengthening and / or facilitating the bonding of the insert 50 into the holes 20 of the sandwich panel 12. That is, the coating 46 at least partially adheres the insert 50 to a predetermined position within the sandwich panel 12. In addition to or instead of this, the coating 46 may be configured to address thickness inconsistencies in the sandwich panel 12 or defects inside the holes 20 and / or the core 14. For example, the coating 46 may be configured to reconnect hexagonal open bubbles in the core 14 due to the formation of holes 20, or to compensate for thickness inconsistencies throughout the sandwich panel 12. In some examples, at least a portion of the collar 58 is also coated with the coating 46. In some examples, the coating 46 contains a phenolic resin.

[0018] In addition to or instead of this, knurling may be applied to one or more surfaces of the insert 50. For example, knurling may be applied to at least a portion of the first cross section 72, the second cross section 74, and / or the outer peripheral surface 76 of the main body 52. ​​In addition to or instead of this, knurling may be applied to at least a portion of the collar 58, for example, the outer surface, top surface, and / or bottom surface of the collar 58.

[0019] In addition to or instead of this, one or more surfaces of the insert 50 may be threaded. For example, at least a portion of the outer circumferential surface 76 may include male threads 67, or the first enlarged diameter portion 80 within the hole 54 may be threaded, or part or all of the hole 54 may be threaded. (This is referred to herein as the threaded portion 78.)

[0020] The insert 50 is configured to bond to the first outer panel 16, the second outer panel 18, and the core 14 of the sandwich panel 12, while simultaneously bonding them to each other and to the holes 20 of the sandwich panel 12. In some examples, the insert 50 is configured to bond to the holes 20 without using additional potting agents as used in conventional inserts. Thus, the system 100 is more efficient and cost-effective than conventional methods of potting inserts in predetermined positions within the sandwich panel. In various embodiments, the system 100 may have the advantages of reducing processing steps, eliminating curing steps, reducing or eliminating post-processing steps, improving the problem of achieving a flush surface, and increasing the strength of the inserted state.

[0021] In various embodiments of System 100, the sandwich panel 12 includes, for example, a first panel hole 22 penetrating the first outer panel 16, which is at least substantially concentric with a hole 20, and when an insert 50 is placed in the hole 20, it is at least substantially concentric with a hole 54 of the insert 50. In addition to or instead, the sandwich panel 12 includes, for example, a second panel hole 24 penetrating the second outer panel 18, which is at least substantially concentric with a hole 20, and when an insert 50 is placed in the hole 20, it is at least substantially concentric with a hole 54 of the insert 50. That is, in some examples, the hole 54 of the insert 50 and the hole 20 are longitudinally extending through holes, so that the secondary member 48 penetrates the entire thickness 26 of the sandwich panel 12. In other examples, the hole 54 and / or the hole 20 may be a stop hole that extends longitudinally only to a portion of the thickness 26 of the sandwich panel 12.

[0022] The first outer panel 16 has a first outer panel inner surface 101 facing the core 14 and a first outer panel outer surface 102 opposite to the first outer panel inner surface 101. Similarly, the second outer panel 18 has a second outer panel inner surface 104 facing the core 14 and a second outer panel outer surface 106 opposite to the second outer panel inner surface 104. As is best seen in Figure 5, the core 14 is sandwiched between the first outer panel inner surface 101 and the second outer panel inner surface 104, and holes 20 are formed in the first outer panel 16 and / or the second outer panel 18, extending into and / or through the core 14. For example, in some systems 100, the holes 20 are formed in the first outer panel 16 and extend into the interior of the core 14 toward the second outer panel 18. In addition to or instead of this, in some systems 100, the holes 20 are formed in the second outer panel 18 and extend into the interior of the core 14 toward the first outer panel 16. The sandwich panel 12 includes at least one hole 20, but often includes multiple holes 20, in which case each hole 20 extends from the first outer panel 16 and / or the second outer panel 18 into the interior of the core 14. The system 100 may also include multiple inserts 50, in which case each of the multiple inserts 50 is fitted into a corresponding hole 20 among the multiple holes 20.

[0023] Core 14 may include foam, aluminum, Nomex® (aramid), carbon, Korex, Kevlar®, glass fiber, polyethersulfone, polyvinyl chloride, polyurethane, polyethylene foam, polystyrene foam, balsa wood, syntactic foam, honeycomb structure, polymer honeycomb, thermoplastic honeycomb, stainless steel, polycarbonate, polypropylene, and / or any other suitable material. The first outer casing 16 and the second outer casing 18 may, in various embodiments, include, for example, glass fiber reinforced polymer laminates, carbon fiber reinforced polymer laminates, thermosetting polymers, epoxy, metal sheets, carbon, aramid, aluminum, steel, plywood, balsa, teak wood, and / or hardwood. In some embodiments, the first outer casing 16 and the second outer casing 18 may be formed from the same material, while in other embodiments, the first outer casing 16 and the second outer casing 18 may be formed from different materials. Each of the first outer panel 16 and the second outer panel 18 can be formed from one or more layers of such materials, for example, from a laminate of layers of one or more of the above materials. Therefore, the sandwich panel 12 is, for example, a composite panel.

[0024] In various embodiments of System 100 and related methods, the first outer plate 16, the second outer plate 18, and / or core 14 are subjected to precision cutting, such as ultrasonic cutting. Unlike conventional methods, the precision cutting in this disclosure may be performed before, rather than after, panel joining. That is, the first outer plate 16, the second outer plate 18, and / or core 14 may be precision-cut by ultrasonic cutting before the layers are joined together to form the sandwich panel 12. In some examples, ultrasonic cutting makes it possible to position the insert 50 of this disclosure before the sandwich panel 12 is joined, and thus the insert 50 can be mounted as part of the layup of the sandwich panel 12. This improved method eliminates the need for the usual post-processing steps and / or time-consuming potting curing steps associated with conventional insert mounting.

[0025] In embodiments of system 100 including an adhesive pack 66, the adhesive pack is, for example, connected to the insert 50 and / or positioned within the hole 20. For example, system 100 includes an adhesive pack 66 positioned between the body 52 of the insert 50 and the core 14 of the sandwich panel 12, such that the adhesive pack 66 conforms to and / or surrounds at least a portion of the body 52 when the insert 50 is positioned within the hole 20. In some embodiments, system 100 may include an adhesive pack 66 that is already positioned within the hole 20 when the insert 50 is fitted into the hole 20. (For example, the adhesive pack 66 may be configured to be placed within the hole 20 of the sandwich panel 12 before the insert 50 is placed within the hole 20.) In various embodiments, the adhesive pack 66 is positioned, for example, adjacent to the first cross-section 72 of the body 52 of the insert 50, the outer peripheral surface 76 of the body 52 of the insert 50, and / or the second cross-section 74 of the body 52 of the insert 50. The adhesive pack 66 is configured to cure, for example, during the curing of the sandwich panel 12, so that when the sandwich panel 12 and the insert 50 are compressed together, the insertion of the insert 50 puts pressure on the adhesive pack 66, causing adhesive to be released from the adhesive pack 66, which flows into the hole 20 and around the insert 50, helping to bond the insert 50 to its predetermined position in the hole 20. In some examples, the adhesive pack 66 is, for example, a two-part epoxy adhesive pack 66. In some systems 100, multiple adhesive packs 66 may be used, for example, one or more adhesive packs 66 placed in each of one or more of the holes 20 of the sandwich panel 12.

[0026] Referring to Figures 7 to 21, these figures illustrate exemplary and non-exclusive embodiments of insert 50 (and / or system 100 including it). Where necessary, the reference numerals used in the schematic diagram of Figure 5 are used to indicate the corresponding parts in Figures 7 to 21. However, the embodiments in Figures 7 to 21 are non-exclusive and do not limit insert 50 to the embodiments illustrated in Figures 7 to 21. That is, insert 50 is not limited to the specific embodiments shown in Figures 7 to 21 and may include any number of different aspects, configurations, features, characteristics, etc., illustrated and described with reference to the schematic diagram of Figure 5 and / or the embodiments and variations thereof in Figures 7 to 21, without requiring the inclusion of all such aspects, configurations, features, characteristics, etc. For simplicity, each of the aforementioned components, parts, parts, aspects, regions, etc., or their variations will not be described, illustrated, and / or referenced again in relation to Figures 7 to 21, but the adoption of the aforementioned features, variations, etc., is within the scope of this disclosure.

[0027] Figures 6 and 7 show a cutaway view of an example of an insert 50 fitted into a hole 20 of a sandwich panel 12. In the example in Figures 6 and 7, the body 52 of the insert 50 penetrates the core 14 in the longitudinal direction (along the longitudinal axis 56), but in various other embodiments, the body 52 may extend longitudinally through only a portion of the core 14, rather than penetrating the entire thickness of the core 14 as in this embodiment. The body 52 of the insert 50 extends longitudinally from a first cross section 72 to a second cross section 74. When the insert 50 is fitted into a hole 20 of the sandwich panel 12, the outer circumferential surface 76 of the body 52 engages with the core 14. The hole 54 extends longitudinally through at least a portion of the body 52. ​​In this embodiment, the hole 54 extends longitudinally from the second cross section 74 toward the first cross section 72, but does not penetrate the body 52. In other embodiments of the insert 50, the hole 54 may penetrate the body 52 or extend partway from the first cross section 72 toward the second cross section 74.

[0028] In the embodiments shown in Figures 6 and 7, the insert 50 includes a threaded portion 78 (although in other embodiments the insert 50 may not be threaded), a first enlarged portion 80, and a shelf portion 82 inside the hole 54. The threaded portion 78 is threaded to engage with, for example, the threaded portion of a fastener (e.g., fastener 48). The threaded portion 78 extends longitudinally along at least a portion of the length 84 of the hole 54. As understood in the art, the threaded portion 78 has, for example, a large diameter and a small diameter, the large diameter corresponding to the maximum diameter 86 of the threaded portion. The first enlarged portion 80 generally has a first enlarged diameter 88 that is larger than the maximum diameter 86 of the threaded portion 78. The shelf portion 82 is formed at the junction between the first enlarged portion 80 and the threaded portion 78. That is, the shelf portion 82 represents the change in the diameter of the hole 54 between the maximum diameter 86 of the threaded portion 78 and the first enlarged diameter 88 of the first enlarged portion 80. However, other embodiments of the insert 50 may include a hole 54 that does not include one or more of these elements.

[0029] The embodiment of the insert 50 shown in Figures 6-7 further includes a collar 58, which is sized relative to the first enlarged portion 80 such that, for example, the outer surface 90 of the collar 58 friction-fits or press-fits with the first enlarged portion 80. Thus, the collar 58 can be used to position and / or align the components of the sandwich panel 12 and / or the insert 50 relative to each other. For example, in some examples, the second outer plate 18 is positioned relative to the core 14 and the first outer plate 16 via the collar 58, because the insert 50 is placed in the hole 20 of the sandwich panel 12 before the second outer plate 18 is placed on the core 14 (for example, before the sandwich panel 12 is fully assembled). In addition to or instead of this, the collar 58 may be configured to fix or hold the insert 50 in place in the precision-machined hole in the outer plate of the sandwich panel 12 while the insert 50 is positioned and the sandwich panel 12 is curing.

[0030] The collar 58 is configured to be able to translate vertically relative to the main body 52, thereby allowing the collar 58 to move between an elevated position (Figure 6) and a press-fit position (Figure 7). Such vertical translational movement can occur when inserting the insert 50 into the sandwich panel 12. In some examples, the insert 50 is placed in the hole 20 to compress the sandwich panel 12, hardening and fixing the layers of the sandwich panel 12 together. At the same time, the insert 50 is also press-fitted, causing the collar 58 to translate vertically toward the center of the core 14. That is, the collar 58 is configured to move to the press-fit position when the sandwich panel 12 is compressed, thereby compressing both the sandwich panel 12 and the insert 50 together.

[0031] In some examples, as shown in Figure 6, in the raised position, the lower surface 92 of the collar 58 is positioned opposite and spaced apart from the shelf portion 82. The lower surface 92 is spaced apart from the shelf portion 82 by a collar displacement distance 94. In the press-fit position shown in Figure 7, the lower surface 92 of the collar 58 is closer to the shelf portion 82 than when it is in the raised position. In some examples, in the press-fit position, the lower surface 92 contacts, presses against, or engages with the shelf portion 82, for example. In addition, or alternatively, the collar displacement distance 94 is smaller in the press-fit position than in the raised position. In some examples, the outer surface 90 of the collar 58 is threaded. In addition, or alternatively, the collar 58 is threaded on the inside. In some examples, the collar 58 is configured to act as a thread locker for locking the insert 50 in a predetermined position within the sandwich panel 12, for example.

[0032] When the collar 58 is in the press-fit position (Figure 7), the upper surface 96 of the collar 58 is at least substantially flush with (or slightly subflush with) the second outer plate 18, and the upper surface 96 of the collar 58 is on the opposite side of the lower surface 92 of the collar 58. On the other hand, in the raised position (Figure 6), the upper surface 96 of the collar 58 is, for example, above the second outer plate 18, and the upper surface 96 and at least a portion of the collar 58 protrude from the surface of the second outer plate 18. The collar 58 has countersunk holes in the portion adjacent to the upper surface 96 to facilitate engagement with, for example, a fastener (e.g., a secondary member 48).

[0033] As shown in Figures 6 and 7, in some embodiments, the insert 50 is inserted into the sandwich panel 12 such that, for example, the first cross section 72 of the body 52 of the insert 50 engages with the first outer plate 16. For example, the first cross section 72 is in contact with, connected to, and / or adjacent to the first outer plate 16, specifically, for example, the inner surface 101 of the first outer plate 16 facing the core 14. Similarly, the second cross section 74 is in contact with, connected to, and / or adjacent to the second outer plate 18, specifically, for example, the inner surface 104 of the second outer plate 18 facing the core 14. Thus, in this embodiment, the insert 50 extends at least substantially from the first outer plate 16 to the second outer plate 18, and therefore extends at least substantially along the entire thickness of the core 14 in the longitudinal direction. In other embodiments, the insert 50 extends longitudinally through only a portion of the thickness of the core 14, so that the first cross section 72 and / or the second cross section 74 engage with the core 14 rather than the outer panels 16, 18, respectively. The first cross section 72, the second cross section 74, and the outer circumferential surface 76 engage with the corresponding portion of the sandwich panel 12, respectively, even if there is a coating 46 on one or more of these surfaces. That is, the first cross section 72, the second cross section 74, and the outer circumferential surface 76 are said to be engaged with the corresponding portion of the sandwich panel 12 even if they are not in direct physical contact with the corresponding portion of the sandwich panel 12, for example, due to the interposition of the coating 46.

[0034] In the embodiments shown in Figures 6 and 7, the coating 46 is applied to the first cross-section 72, the second cross-section 74, and the outer peripheral surface 76 of the main body 52. ​​However, in some embodiments, the coating 46 may be applied to some of these surfaces, and / or to only a portion of one or more of these surfaces. In some examples, the coating 46 is applied to at least a portion of the collar 58 (e.g., the outer surface 90 of the collar 58, the lower surface 92 of the collar 58, and / or the upper surface 96 of the collar 58). For example, the collar 58 may be positioned inside the first enlarged diameter portion 80 of the hole 54 at the time the insert 50 is coated with the coating 46, such that the coating 46 is applied to at least a portion of the collar 58 as well. In some embodiments, the coating 46 may be applied to at least a portion of the collar 58 before it is positioned inside the first enlarged diameter portion 80 of the insert 50.

[0035] Figure 8 is a perspective view of one embodiment of the insert 50 with the collar 58 in the raised position, shown away from the sandwich panel. In this embodiment, the first cross section 72, the second cross section 74, and the outer peripheral surface 76 of the main body 52 are all covered with coating 46. The collar 58 is not shown to have coating 46, but in some embodiments, at least a portion of the collar 58 may be coated with coating 46. Figure 9 shows another embodiment of the insert 50 with the collar 58 in the raised position. In this embodiment, the first cross section 72 and the second cross section 74 of the main body 52 are knurled 108. In other examples, in addition to or instead of this, the outer peripheral surface 76 may be knurled 108, and in some examples, at least a portion of the collar 58 may be knurled 108.

[0036] Figure 10 is a cutaway perspective view of an insert 50 of another embodiment inserted into a hole 20 of a sandwich panel 12. Similar to the insert 50 shown in Figures 6-7, the insert 50 of this embodiment includes a collar 58 and a first enlarged portion 80 formed inside the body 52. ​​Furthermore, the insert 50 of this embodiment includes a second enlarged portion 110 inside the hole 54. The second enlarged portion 110 has a second enlarged diameter 112 that is larger than the maximum diameter 86 (Figure 6) of the hole 54. In some examples, the second enlarged diameter 112 is at least substantially equal to, for example, the first enlarged diameter 88 (Figure 6) of the first enlarged portion 80. In other examples, the second enlarged diameter 112 is either smaller than or larger than the first enlarged diameter 88. In this embodiment, the hole 54 also includes a second shelf portion 114, which is formed at the junction between the second enlarged portion 110 and the threaded portion 78 of the hole 54.

[0037] The insert 50 of this embodiment further includes a second collar 116, which is sized relative to the second enlarged portion 110 such that its second outer surface 118 friction-fits with the second enlarged portion 110 of the hole 54. Thus, similar to the collar 58 (sometimes referred to as the first collar 58), the second collar 116 may be configured to move between a second raised position and a second press-fit position when, for example, the insert 50 is mounted on the sandwich panel 12. In the second raised position, the second lower surface 120 of the second collar 116 is positioned away from the second shelf portion 114, and in the second press-fit position (shown in Figure 10), the second lower surface 120 of the second collar 116 is closer to the second shelf portion 114 than when it is in the second raised position. For example, when the second collar 116 is in the second press-fit position, the second lower surface 120 engages with, presses against, connects to, and / or is adjacent to the second shelf portion 114 of the hole 54. The second collar 116 is configured to move to the second press-fit position, for example, when the sandwich panel 12 is compressed, thereby compressing the sandwich panel 12 and the insert 50 (including the collar 58 and the second collar 116) together. In some examples, when the second collar 116 is in the press-fit position, the second upper surface 122 is at least substantially flush with (or slightly lower than) the first outer plate 16, as shown in Figure 10. When the second collar 116 is in the raised position, the second upper surface 122 is, for example, above the first outer plate 16.

[0038] The second collar 116 may be configured to be located inside the second enlarged diameter portion 110 when the coating 46 is attached, bonded, or applied to the insert 50. In some examples, the coating 46 is applied, for example, to the second outer surface 118, the second lower surface 120, and / or the second upper surface 122 of the second collar 116. In addition to or instead of this, the second outer surface 118, the second lower surface 120, and / or the second upper surface 122 of the second collar 116 may be knurled. In addition to or instead of this, the second collar 116 may include a threaded portion, similar to the first collar 58, for example, the second outer surface 118 may be threaded and / or the inside may be threaded.

[0039] Figure 11 shows an insert 50 of another embodiment positioned inside the sandwich panel 12. In this embodiment, the hole 54 includes a first enlarged portion 80 and a second enlarged portion 110, and the insert 50 includes a first collar 58 and a second collar 116. Furthermore, as shown in the embodiment of Figure 11, the second enlarged portion 110 has a smaller diameter than, for example, the first enlarged portion 80, but the diameter of the second enlarged portion 110 is still larger than the diameter of the hole 54 (which may not be threaded). The insert 50 is shown in Figure 11 in the press-fit position, in which the upper surface 96 of the collar 58 is at least substantially flush with the second outer plate 18 (e.g., the outer surface 106 of the second outer plate), and the second upper surface 122 of the second collar 116 is at least substantially flush with the first outer plate 16 (e.g., the outer surface 102 of the first outer plate). The embodiment of the insert 50 in Figure 11 also includes a secondary member 48, which is in the form of a fastener 48 inserted through a hole 54 of the insert 50. As shown, the head 126 of the fastener 48 engages with, for example, a collar 58, while the shaft 128 of the fastener 48 engages with, for example, the hole 54 (for example, with the threaded portion 78 of the hole 54 if the hole 54 is threaded, or simply inserted through the hole 54), and / or engages with a second collar 116 (and / or a threaded floating nut 64 as shown in Figure 12).

[0040] Figure 12 shows another embodiment of the insert 50, which includes a first enlarged diameter portion 80 and a second enlarged diameter portion 110, in which a collar 58 is located. In this embodiment, a portion of the threaded floating nut 64 is located inside the threaded portion 78 of the hole 54, and the flange 130 of the threaded floating nut 64 is located inside the second enlarged diameter portion 110. Thus, a portion of the hole 54 is sized and shaped to accommodate and enclose the threaded floating nut 64. The nut bottom surface 124 of the threaded floating nut 64 is, for example, at least substantially flush with, adjacent to, and / or engaged with, the insert 50, and the threaded floating nut 64 is housed, for example, inside the insert 50.

[0041] Figures 13 to 17 show embodiments of the insert 50 including an expanding flange 60 that projects radially outward from the body 52 of the insert 50 (for example, from the outer circumferential surface 76 of the body 52). In various embodiments of the insert 50, the expanding flange 60 can be positioned at any location along the length of the body 52 (for example, along the longitudinal axis 56). In some examples, the expanding flange 60 is positioned, for example, in or near the second cross-section 74 of the body 52. ​​In the embodiments shown in Figures 13 to 15, the expanding flange 60 defines the second cross-section 74. Similarly, in some examples, the expanding flange 60 may be positioned in or near the first cross-section 72 of the body 52 to define the first cross-section 72. In various other embodiments, the expanding flange 60 may be positioned between the first cross-section 72 and the second cross-section 74, as shown in the embodiments of Figures 16 to 17, in which case the expanding flange 60 is longitudinally offset from both the first and second cross-sections. Depending on the embodiment, the insert 50 may include two or more flanges 60 projecting radially outward from the outer circumferential surface 76, or it may include only one enlarged flange 60. The flange thickness 132 of the enlarged flange 60 is, for example, less than, greater than, or substantially equal to the second thickness 134 of the first enlarged portion 80. In some examples, the flange thickness 132 is at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, and / or at least 80% of the second thickness 134 of the first enlarged portion 80.

[0042] As with other embodiments of the insert 50, in various embodiments of the insert 50 including the enlarged flange 60, one or more surfaces of the body 52 and / or collar 58 may be coated 46 (Figure 13) and / or knurled 108 (Figure 15). As shown in Figure 14, in some examples, the body 52 is sized relative to the sandwich panel 12 so as not to extend across the entire core 14, for example, from the first outer plate 16 to the second outer plate 18. For example, the enlarged flange 60 is positioned to engage with the core 14 and the second outer plate 18 in Figure 14. In other examples, the enlarged flange 60 may be positioned to engage with the core 14 and the first outer plate 16. As is best seen in Figure 15, the flange diameter 138 of the enlarged flange 60 is larger than the body diameter 140 of the body 52. In various embodiments, the flange diameter 138 may be substantially constant along the flange thickness 132, for example, or it may vary along the flange thickness 132, for example, in the case of a tapered or chamfered enlarged flange 60.

[0043] In some examples, the enlarged flange 60 may be configured to be sandwiched between the two outer plates of the sandwich panel 12, as shown in Figure 16 in a partially disassembled state and in Figure 17 in an assembled state. In the system 100 of this embodiment, the sandwich panel 12 includes a first outer plate 16, a core 14, a second outer plate 18 opposite the first outer plate 16, and a third outer plate 136. The second outer plate 18 is sandwiched between the third outer plate 136 and the core 14. When the sandwich panel 12 is assembled and the insert 50 is placed in the hole 20 of the sandwich panel 12 (Figure 17), the enlarged flange 60 is located inside the third outer plate 136 (for example, between the third outer plate 136 and the core 14), and is located between the second outer plate 18 and the third outer plate 136, as shown. In other examples, the enlarged flange 60 may be positioned inside both the third outer plate 136 and the second outer plate 18, for example, the enlarged flange 60 may be positioned between the second outer plate 18 and the first outer plate 16. Thus, in these embodiments, the insert 50 is bonded below the third outer plate 136 and held in the hole 20 not by a potting agent placed in the hole 20, but by co-bonding with the second outer plate 18 and / or the third outer plate 136. As is best seen in Figure 17, for example, the first cross section 72 engages with the core 14, and therefore the body 52 does not extend across the entire thickness of the sandwich panel 12, but in other examples, the insert 50 may extend through the thickness of the core 14. The outer circumferential surface 76 typically engages with the core 14 when the insert 50 is mounted in the sandwich panel 12. The second cross-section 74 may protrude from the third outer plate 136, or it may be substantially flush with the third outer plate 136, resulting in less interference when attaching fasteners compared to the structure where the entire enlarged flange 60 is visible.

[0044] Similar to other embodiments of the insert 50, a coating such as a thermosetting resin coating (e.g., coating 46) may be provided on at least a portion of the insert 50, such as the second cross section 74, the first cross section 72, and / or the enlarged flange 60. In addition to or instead of this, a resin or adhesive may be added to the edge of the enlarged flange 60 to fill the gap 142 between the enlarged flange 60 and the outer panels 136, 18. In some examples, a donut-shaped member 144 pre-impregnated with thermosetting resin may be arranged to surround the main body 52, and the donut-shaped member 144 is configured to join the insert 50 to a predetermined position in the hole 20 of the sandwich panel 12. The donut-shaped member 144 extends radially outward from the main body 52, for example, along the bottom surface 146 of the enlarged flange 60. For example, the donut-shaped member 144 extends to cover at least 75% of the bottom surface 146 of the enlarged flange 60. By using the coating 46, the resin impregnated into the donut-shaped member 144, the outer panels 18 and 136, and / or other adhesives or resins that have been applied, injected, or inserted, the insert 50 can be joined to the second outer panel 18 and the third outer panel 136 when the sandwich panel 12 has hardened.

[0045] In some examples, the bottom surface 146 of the enlarged flange 60 is chamfered, for example, as shown in Figures 16-17. The bottom surface 146 usually engages with the second outer plate 18, but in various embodiments of the insert 50, the bottom surface 146 may also engage with other parts of the sandwich panel 12. The top surface 148 of the enlarged flange 60 (opposite the bottom surface 146) may engage with the third outer plate 136, as is best seen in Figure 17. The top surface 148 is, for example, at least substantially parallel to the second cross section 74 and / or at least substantially perpendicular to the longitudinal axis of the body 52.

[0046] In some examples, the second outer panel 18 includes a recess 168 corresponding to the bottom surface 146 of the enlarged flange 60, and is configured such that the enlarged flange 60 fits into the recess 168 when the insert 50 is fitted inside the sandwich panel 12 and the parts are compressed together. In some examples, the recess 168 is pre-formed in the second outer panel 18, for example. In other examples, the recess 168 is formed, for example, during the compression and curing of the sandwich panel 12. When the insert 50 is press-fitted into the hole 20 of the sandwich panel 12, for example, the second cross-section 74 of the insert 50 engages with and / or is at least substantially flush with the third outer panel 136 (e.g., the outer surface 170 of the third outer panel 136).

[0047] Next, referring to Figures 18 and 19, embodiments of the insert 50 including a second insert component 70 are shown in a side view (Figure 18) and a notched perspective view (Figure 19) showing the insert 50 positioned on the sandwich panel 12. In these embodiments, the second insert component 70 is configured to engage with the body 52 of the insert 50 such that at least a portion of the body 52 is located inside the housing portion 150 of the second insert component 70. Such engagement between the body 52 and the second insert component 70 is selectively adjustable so as to adjust the overall height 152 of the insert 50. (For example, the overall height 152 corresponds to the total height of the body 52 and the second insert component 70 when they are engaged.) For example, by configuring a male screw 67 provided on the outer circumferential surface 76 of the body 52 to engage with a female screw 154 in the housing portion 150 of the second insert component 70, the position of the body 52 along the longitudinal axis of the insert 50 relative to the second insert component 70 can be adjusted. In other words, the male thread 67 and the female thread 154 of the second insert component 70 enable selective longitudinal translation of the body 52 relative to the second insert component 70. In some examples, the enlarged flange 60 is configured to act as a stopper to restrict the translational movement of the body 52 relative to the second insert component 70, for example, so that the overall height 152 is minimized when the second insert component 70 contacts the enlarged flange 60. In addition to or instead of this, when the first cross section 72 of the body 52 engages with or contacts the inner surface 162 within the housing 150 of the second insert component 70, the body 52 does not substantially move any further longitudinally within the housing 150, so the inner surface 162 of the second insert component 70 can act as a stopper to restrict the translational movement of the body 52 relative to the second insert component 70. In other words, the inner surface 162 can be configured to restrict the vertical translational movement of the main body 52 relative to the second insert component 70, for example, when compressing the sandwich panel 12 and the insert 50 with the insert 50 placed in the hole 20 of the sandwich panel 12.

[0048] The second insert component 70 includes a second outer surface 156 configured to engage with the core 14 of the sandwich panel 12. The second insert component 70 includes a panel engagement cross section 158, which is typically configured to engage with the first outer panel 16 or the second outer panel 18, but in some examples it may engage with the core 14. In the embodiment shown in Figure 19, the panel engagement cross section 158 is shown engaged with the first outer panel 16. The second insert component 70 also includes an insert-facing cross section 160 opposite to the panel engagement cross section 158. In some examples the insert-facing cross section 160 may contact or engage with the body 52 (e.g., the enlarged flange 60 of the body 52) when the overall height 152 is at its minimum, but typically there is a space between the insert-facing cross section 160 and the enlarged flange 60 (or other faces or elements of the body 52). As shown in Figures 18 and 19, the insert-facing cross-section 160 typically faces a part of the main body 52, for example, the bottom surface 146 of the enlarged flange 60.

[0049] Figure 18 shows an embodiment of insert 50 in which knurling 108 is applied to the second cross section 74 of the main body 52 and the panel engagement cross section 158 of the second insert component 70, and Figure 19 shows an embodiment of insert 50 in which coating 46 is applied to the second insert component 70 and the main body 52, but modifications are also included within the scope of this disclosure. In the embodiment of Figure 19, the coating 46 is applied to the second outer surface 156, the panel engagement cross section 158, the insert opposing cross section 160, and the female thread 154, but in other embodiments, the coating 46 may be applied to some of these surfaces and / or only to portions of one or more of these surfaces.

[0050] In some examples, the second insert component 70 is configured to engage with the main body 52 such that, when the sandwich panel 12 is compressed (for example, when the first outer plate 16, core 14, and second outer plate 18 are compressed together to form the sandwich panel 12), the main body 52 moves longitudinally relative to the second insert component 70, thereby reducing the overall height 152. For example, by appropriately setting the size and shape of the male thread 67 of the main body 52 and the female thread 154 of the second insert component 70 relative to each other, the main body 52 can be configured to move ratchet-like along the female thread 154 and move longitudinally relative to the second insert component 70, thereby reducing the overall height 152, when the sandwich panel 12 and insert 50 are compressed with sufficient force.

[0051] Figures 20-21 show an embodiment of an insert 50 having a notched flange 68 and an enlarged flange 60. In this embodiment, the enlarged flange 60 is positioned adjacent to the second cross-section 74 of the body 52, but does not define or form the second cross-section 74 in this embodiment. As shown in these figures, the enlarged flange 60 may be a stepped two-diameter enlarged flange 60, and can be configured, for example, to increase the overall strength of the enlarged flange 60 and / or the insert 50. In this embodiment, the notched flange 68 forms the first cross-section 72. However, in other embodiments, the notched flange 68 may be located near (e.g., adjacent to) the first cross-section 72, or at other positions along the length of the insert 50. The notched flange 68 includes a plurality of notches 164. Each notch 164 is configured, for example, to contain adhesive for bonding the insert 50 to a predetermined position in a hole in a sandwich panel. In some examples, such adhesives or resins are configured to flow, for example, through the notches 164 to fix the inserts 50 in place within the holes of the sandwich panel. As is best seen in Figure 21, in some examples, the notch flange diameter 166 of the notch flange 68 is smaller than, for example, the first enlargement diameter 88 of the enlargement flange 60. In other examples, the notch flange diameter 166 is at least substantially equal to, or greater than, the first enlargement diameter 88.

[0052] The embodiments in Figures 20-21 are shown without the collar 58, but the embodiments of the insert 50 shown in Figures 20-21 or their variations may include the collar 58. Similarly, the embodiments in Figures 20-21 do not include the knurling 108 or coating 46 as shown, but in other embodiments including the notched flange 68, one or more surfaces of the insert 50 may be knurled 108 and / or coated 46. In a specific example, the top surface 148 of the enlarged flange 60 is coated or resin is applied. Also, the hole 54 of the insert 50 in this embodiment is shown as a blind hole 54 that does not penetrate the entire insert, but in other embodiments, the hole 54 may penetrate the entire insert 50, including the notched flange 68. The hole 54 may also include a female thread (e.g., threaded portion 78). The insert 50 in Figures 20-21 is shown as a single, integrated structure, but in various embodiments, two or more body parts may be joined together to form the insert.

[0053] Figure 22 illustrates the processing flow of an exemplary and non-exclusive embodiment of the method according to the present disclosure. In Figure 22, at 200, the first outer panel 16 of the sandwich panel 12 is prepared, for example, by precision cutting and positioning for assembly. Next, at 202, the core 14 is precision cut and positioned relative to the first outer panel 16, so that the core 14 is positioned such that its first surface 172 faces and engages with the first outer panel 16. Next, at 204, the insert 50 is placed in the hole 20 of the sandwich panel 12. The insert 50 (e.g., collar 58) typically protrudes from the second surface 174 opposite the first surface 172 of the core 14. At 206, the second outer panel 18 is precision cut and positioned relative to the core 14, so that the second outer panel 18 engages with the second surface 174 of the core 14. At this stage, the collar 58 of the insert 50 is in the raised position, above the second surface 174 of the core 14 and the second outer panel 18. In step 208, the sandwich panel 12 is compressed and hardened, thereby pressing the collar 58 into the press-fit position so that it is flush with the second outer panel 18. In this way, all the components of the sandwich panel 12 (e.g., the first outer panel 16, the core 14, and the second outer panel 18) and the insert 50 are joined without pre-hardening the insert in place with a potting agent. In conventional methods, the components of the sandwich panel are first joined together, then the panel is cut and holes / perforations are cut within the panel, and then the insert is installed and hardened with a potting agent. Therefore, the method and procedure of this disclosure can improve the efficiency of the processing flow compared to conventional methods.

[0054] Figures 23 and 24 schematically illustrate flowcharts of exemplary and non-exclusive embodiments of the methods described herein. In Figures 23 and 24, some steps are shown in dashed boxes, indicating that these steps are, for example, optional or may correspond to any version of the methods described herein. On the other hand, not all methods described herein must include steps shown in solid boxes. The methods and steps shown in Figures 23 and 24 are not limiting, and other methods and steps are also within the scope of this disclosure, including methods with more and fewer steps than those shown herein, as can be seen from the description herein.

[0055] Figure 23 shows a method 300 for attaching an outer panel screw-type insert (e.g., insert 50) to a sandwich panel (e.g., sandwich panel 12). In the above method 300, in 302, a first outer panel of the sandwich panel (e.g., first outer panel 16) is prepared, which may include precision cutting of the first outer panel, ultrasonic cutting of the first outer panel, shaping of the first outer panel, and / or drilling one or more holes in the first outer panel. In 304, holes are formed in the core (e.g., holes 20 are formed in core 14). This can be done before or after placing the core on the first outer panel in 306. That is, holes can be formed in the core in 304 before fixing, placing, or positioning the core on any of the outer panels. In some examples, forming holes in 304 includes precision cutting of the core. In 306, the core of the sandwich panel is placed on the first outer panel such that the first surface of the core faces the first outer panel. In 308, at least a portion of the insert is inserted into the hole or positioned within the hole. For example, at least a portion of the insert's body (e.g., body 52) is positioned within the hole of the sandwich panel. The insert's collar (e.g., collar 58) may be positioned above the second surface of the core opposite the first surface of the core facing the first outer plate. In 310, the second outer plate of the sandwich panel (e.g., second outer plate 18) is positioned on the second surface of the core, with the collar positioned above the second outer plate through a through-hole (e.g., through-hole 54) in the second outer plate. In 312, with at least a portion of the insert positioned within the hole 20, the first outer plate, core, and second outer plate are compressed together, thereby translating the collar longitudinally relative to the body and moving the collar between an elevated position and a press-fit position. Compressing the sandwich panel and insert in 312 also includes curing the sandwich panel and the insert in a predetermined position within the hole of the sandwich panel. This allows the insert to be bonded to the sandwich panel without the need for potting.

[0056] In some examples, the compression of the sandwich panel at 312 causes the lower surface of the collar to approach and / or contact the shelf-like portion within the enlarged diameter of the insert body. As a result of such longitudinal translational movement of the collar during the compression of the sandwich panel at 312, the upper surface of the collar also becomes at least substantially flush with the compressed second outer plate, for example, due to the longitudinal translational movement of the collar.

[0057] Method 300 may also include preparing a second outer plate in 314. This step may include precision cutting of the second outer plate, ultrasonic cutting of the second outer plate, shaping of the second outer plate, and / or drilling one or more holes in the second outer plate. Some methods 300 also include coating at least a portion of the insert (e.g., with a thermosetting resin) and / or knurling at least a portion of the insert in 316 before placing the insert in the hole in 308.

[0058] In some methods 300, an adhesive pack (e.g., adhesive pack 66) configured to cure during the curing of the sandwich panel may be placed in the holes of the sandwich panel in 318, which is typically done before placing the insert in the holes in 308. For example, placing the adhesive pack in 318 may include placing the adhesive pack between the body and core of the insert in the holes of the sandwich panel. In some examples, placing the adhesive pack in 318 includes placing the adhesive pack adjacent to a first cross-section of the insert, placing the adhesive pack adjacent to the outer circumferential surface of the body of the insert, and / or placing the adhesive pack in the holes of the sandwich panel.

[0059] Next, referring to Figure 24, the method 400 for mounting an insert within a sandwich panel may include, in 402, placing at least a portion of the insert (e.g., insert 50) into a hole in the sandwich panel that extends to at least a portion of the core. In 404, the enlarged flange (e.g., enlarged flange 60) of the insert is overlapped, for example, with the second outer panel and / or third outer panel of the sandwich panel. Finally, in 406, the sandwich panel and the insert are compressed and cured together, and the curing of the sandwich panel bonds the insert to the second and third outer panels of the sandwich panel. In some examples, overlapping the outer panels in 404 may involve, for example, first placing the insert into the hole and then placing one or more outer panels on top of a portion of the insert. In other examples, overlapping the outer panels in 404 includes lifting and separating at least a portion of the third outer panel from the second panel, inserting an insert into the hole, and then repositioning the third outer panel on the enlarged flange of the insert and the second panel, thereby sandwiching the enlarged flange between the second and third outer panels of the sandwich panel. In some examples, in 404, substantially the entire top surface of the enlarged flange is covered by or overlapped with the second and / or third panels. Compressing and hardening the sandwich panel in 406 may include moving the second cross section of the insert from a state where it is above the third outer panel to a state where it is at least substantially flush with the third outer panel.

[0060] Method 400 may also include one or more steps in Method 300 of Figure 23, such as preparing the first outer panel of the sandwich panel in 302, placing the core on the first outer panel in 306, and / or forming holes in the core in 304. In addition to or instead of these, Method 400 may include placing the adhesive pack in 318, and / or coating the insert and / or knurling the insert in 316.

[0061] Figure 25 shows an exploded view of an example of a part 500 manufactured by methods 300 and / or 400 of the present disclosure. Typical machining processes for forming composite parts may involve waterjet cutting of hardened plies or panels, which can result in fiber fraying and rounded edges. Alternatively, cutters and drill presses may be used on materials such as hardened Kevlar panels, which can result in excessive dust and wear of drill bits and cutters. In methods 300 and 400 of the present disclosure, individual plies 502 are cut by ultrasonic cutting and then laminated to form a part 500. For example, the plies 502 are cut with a numerically controlled ultrasonic knife or cutting machine to create holes 504. The cut plies 502 are then laminated in a specific order, for example, to form the desired features and cross-section of the part 500. Laminating the plies 502 can be understood as being similar to additive manufacturing techniques such as laminate manufacturing. In some examples, the plies 502 are aligned using tools, frames, pins, etc., and then the laminate of plies 502 is cured. Metal parts, reinforcing materials, inserts 50, and / or other detail elements may be embedded between the plies 502 of the laminate and cured together.

[0062] Non-exclusive embodiments of the gist of this disclosure are described in the appendices listed below.

[0063] A1. A threaded insert (50) for joining a panel (12) configured to be fitted into a hole (20) in the sandwich panel (12), wherein the sandwich panel (12) includes a first panel (16), a second panel (18) opposite the first panel (16), and a core (14) between them, and the threaded insert (50) for joining the panel (12) is configured to be fitted into a hole (20) in the sandwich panel (12), wherein the sandwich panel (12) includes a first panel (16), a second panel (18) opposite the first panel (16), and a core (14) between them, The sandwich panel (12) includes a body (52) configured to extend longitudinally from a first cross-section (72) to a second cross-section (74) through at least a portion of the core (14) of the sandwich panel (12), wherein the outer circumferential surface (76) of the body (52) is configured to engage with the core (14) of the sandwich panel (12) when the outer panel joining threaded insert (50) is mounted on the sandwich panel (12). The outer panel screw insert further includes a hole (54) extending vertically in at least a portion of the main body (52), the hole (54) being It includes a threaded portion (78) that is threaded to engage with a fastener (48), the threaded portion (78) extending longitudinally along at least a portion of the length (84) of the hole (54), and the threaded portion (78) having a large diameter corresponding to the maximum diameter (86) of the threaded portion (78), The hole further comprises a first enlarged diameter portion (80) having an enlarged diameter (88) larger than the large diameter of the threaded portion (78), It includes a shelf-like portion (82) formed at the joint between the first enlarged diameter portion (80) and the threaded portion (78), The outer panel joining threaded insert further includes a collar (58) sized to the first enlarged diameter portion (80) of the hole (54) such that its outer surface (90) frictionally fits with the first enlarged diameter portion (80), the collar (58) being configured to be vertically translatably movable relative to the body (52), thereby allowing the outer panel joining threaded insert (50) to move between a raised position and a press-fit position when the outer panel joining threaded insert (50) is mounted on the sandwich panel (12).

[0064] A1.1. The first cross-section (72) of the main body (52) is an outer panel joining screw insert (50) as described in Appendix A1, which engages with the first outer panel (16).

[0065] A1.2. The second cross-section (74) of the main body (52) is an outer panel joining screw insert (50) as described in Appendix A1 or A1.1, which engages with the second outer panel (18).

[0066] A1.3. The first cross-section (72) of the main body (52) is an outer plate joining screw insert (50) as described in any of appendices A1 to A1.2, which engages with the core (14).

[0067] A1.4. The second cross-section (74) of the main body (52) is an outer plate joining screw insert (50) as described in any of appendices A1 to A1.2, which engages with the core (14).

[0068] A1.5. In the raised position, the lower surface (92) of the collar (58) is facing the shelf-like portion (82) of the hole (54) and is located at a distance of collar displacement distance (94) from the shelf-like portion, as described in any of Appendix A1 to A1.4, for the outer panel joining screw insert (50).

[0069] A1.6. In the press-fit position, the collar displacement distance (94) is smaller than when the collar (58) is in the raised position, and therefore the lower surface (92) of the collar (58) is closer to the shelf-like portion (82) when the collar (58) is in the press-fit position than when the collar (58) is in the raised position, as described in Appendix A1.5, with threaded insert (50) for outer panel joining.

[0070] A1.7. In the press-fit position, the lower surface (92) of the collar (58) engages with the shelf-shaped portion (82) of the hole (54), the outer panel joining threaded insert (50) as described in any of Appendix A1 to A1.6.

[0071] A2. The outer panel joining threaded insert (50) according to any of the appendices A1 to A1.7, wherein the first cross-section (72), the second cross-section (74), and / or the outer peripheral surface (76) of the main body (52) are coated (46) with a thermosetting resin.

[0072] A2.1. The outer panel joining threaded insert (50) as described in Appendix A2, wherein the thermosetting resin (46) flows during the curing of the sandwich panel (12) to join the outer panel joining threaded insert (50) into the sandwich panel (12).

[0073] A2.2. The thermosetting resin (46) is configured to accommodate the non-uniformity of the thickness of the sandwich panel (12) in the outer panel joining threaded insert (50) as described in Appendix A2 or A2.1.

[0074] A3. The outer panel joining threaded insert (50) according to any of the appendices A1 to A2.2, wherein the outer panel joining threaded insert (50) is configured to house a secondary member (48) in the hole (54), and the secondary member (48) is configured to transmit a local load to the sandwich panel (12) via the outer panel joining threaded insert (50).

[0075] A4. The outer panel joining threaded insert (50) described in any of the appendices A1 to A3, wherein the threaded portion (78) is configured to accommodate a fastener (48) in the hole (54).

[0076] A5. The aforementioned hole (54) is a blind hole (54), an outer panel joining screw insert (50) as described in any of appendices A1 to A4.

[0077] A6. The hole (54) is a through hole (54), as described in any of the appendices A1 to A4, for the outer panel joining screw insert (50).

[0078] A7. The outer surface (90) of the collar (58) is threaded, as described in any of the appendices A1 to A6, for the outer panel joining threaded insert (50).

[0079] A8. The collar (58) is an external panel joining threaded insert (50) as described in any of appendices A1 to A7, with the inside threaded.

[0080] A9. The outer panel fastening threaded insert (50) according to any of the appendices A1 to A8, wherein the collar (58) is configured to act as a thread lock (69) for locking the outer panel fastening threaded insert (50) in a predetermined position within the sandwich panel (12).

[0081] A10. A threaded insert (50) for exterior panel bonding as described in any of appendices A1 to A9, further including a thread locker (69).

[0082] A11. The outer panel joining threaded insert (50) according to any of the appendices A1 to A10, wherein the collar (58) is positioned inside the first enlarged diameter portion (80) of the hole (54) at the time the outer panel joining threaded insert (50) is covered with a thermosetting resin coating (46).

[0083] A12. The collar (58) is an outer panel joining screw insert (50) as described in any of the appendices A1 to A11, wherein the outer surface (90), top surface (96), and / or bottom surface (92) of the collar (58) are coated with a thermosetting resin coating (46).

[0084] A13. The thermosetting resin is a phenolic resin, as described in any of appendices A1 to A12, for the outer panel joining threaded insert (50).

[0085] A14. The outer panel joining threaded insert (50) described in any of appendices A1 to A13, wherein the first cross-section (72), the second cross-section (74), and / or the outer peripheral surface (76) of the main body (52) are knurled.

[0086] A15. The outer surface (90) of the collar (58) is knurled, and the outer panel joining screw insert (50) is as described in any of the appendices A1 to A14.

[0087] A16. The lower surface (92) of the collar (58) is an outer plate joining screw insert (50) as described in any of appendices A1 to A15, which is pressed against the shelf-shaped portion (82) when the collar (58) is in the press-fit position.

[0088] A17. The collar (58) is configured to move to the press-fit position when the sandwich panel (12) is compressed, thereby compressing both the sandwich panel (12) and the outer panel joining threaded insert (50) as described in any of the appendices A1 to A16.

[0089] A18. The upper surface (96) of the collar (58) is at least substantially flush with the second outer panel (18) when the collar (58) is in the press-fit position, and the upper surface (96) of the collar (58) is on the opposite side of the lower surface (92) of the collar (58), the outer panel joining threaded insert (50) as described in any of the appendices A1 to A17.

[0090] A19. The upper surface (96) of the collar (58) is above the second outer panel (18) when the collar (58) is in the raised position, and is an outer panel joining screw insert (50) as described in any of the appendices A1 to A18.

[0091] A20. The outer panel joining threaded insert (50) described in any of the appendices A1 to A19, wherein the outer panel joining threaded insert (50) is configured to be joined into the hole (20) of the sandwich panel (12) at the same time as joining the first outer panel (16), the second outer panel (18), and the core (14) of the sandwich panel (12).

[0092] A21. The outer panel joining threaded insert (50) according to any of the appendices A1 to A20, wherein the outer panel joining threaded insert (50) is configured to be joined into the hole (20) of the sandwich panel (12) without the use of additional potting agent.

[0093] A22. The outer plate joining threaded insert (50) according to any of the appendices A1 to A21, wherein the hole (54) further includes a second enlarged diameter portion (110) having a second enlarged diameter (112) larger than the large diameter of the threaded portion (78).

[0094] A22.1. The outer plate joining threaded insert (50) described in Appendix A22, wherein the second enlarged diameter (112) is substantially equal to the enlarged diameter (88) of the first enlarged diameter portion (80).

[0095] A22.2. The outer plate joining threaded insert (50) according to any of the appendices A22 to A22.1, wherein the hole (54) includes a second shelf-like portion (114) formed at the second joint between the second enlarged diameter portion (110) and the threaded portion (78).

[0096] A22.3. The outer panel joining threaded insert (50) according to any of the appendices A22 to A22.2, further comprising a second collar (116), wherein the second collar (116) is sized relative to the second enlarged diameter portion (110) such that the second outer surface (118) of the second collar (116) frictionally fits with the second enlarged diameter portion (110) of the hole (54), and the second collar (116) is configured to move between a second raised position and a second press-fit position when the outer panel joining threaded insert (50) is mounted on the sandwich panel (12), wherein in the second raised position, the second lower surface (120) of the second collar (116) is spaced apart from the second shelf portion (114) of the hole (54), and in the second press-fit position, the second lower surface (120) of the second collar (116) engages with the second shelf portion (114) of the hole (54).

[0097] A22.4. The second outer surface (118) of the second collar (116) is threaded, as is the case for the outer panel joining threaded insert (50) described in any of the appendices A22 to A22.3.

[0098] A22.5. The second collar (116) is an external panel joining threaded insert (50) as described in any of appendices A22 to A22.4, with internal threading.

[0099] A22.6. The second collar (116) is configured to be positioned inside the second enlarged portion (110) of the hole (54) when the outer panel joining threaded insert (50) is covered with a thermosetting resin, as described in any of appendices A22 to A22.5.

[0100] A22.7. The second collar (116) is a screw-type insert (50) for outer panel bonding as described in any of the appendices A22 to A22.6, wherein the second outer surface (118), second upper surface (122), and / or second lower surface (120) of the second collar (116) are coated with a thermosetting resin.

[0101] A22.8. The second outer surface (118) of the second collar (116) is knurled, and is an outer panel joining threaded insert (50) as described in any of appendices A22 to A22.7.

[0102] A22.9. The second lower surface (120) of the second collar (116) is an outer plate joining threaded insert (50) as described in any of appendices A22 to A22.8, which is pressed against the second shelf-like portion (114) when the second collar (116) is in the second press-fit position.

[0103] A22.10. The second collar (116) is configured to move to a second press-fit position when the sandwich panel (12) is compressed, so that the sandwich panel (12) and the outer panel joining threaded insert (50) are compressed together, as described in any of appendices A22 to A22.9.

[0104] A22.11. The second upper surface (122) of the second collar (116) is flush with the first outer panel (16) when the second collar (116) is in the press-fit position, as described in any of the appendices A22 to A22.10, for the outer panel joining threaded insert (50).

[0105] A22.12. The second upper surface (122) of the second collar (116) is a screw-attached insert (50) for joining the outer panel, as described in any of appendices A22 to A22.11, which is positioned above the first outer panel (16) when the second collar (116) is in the raised position.

[0106] A23. The outer panel joining threaded insert (50) according to any of the appendices A1 to A22.12, further comprising a threaded floating nut (64) disposed in the hole (54) of the outer panel joining threaded insert (50).

[0107] A23.1. A threaded insert (50) for exterior panel bonding as described in Appendix A23, wherein a portion of the hole (54) is sized and shaped to accommodate and enclose the threaded floating nut (64).

[0108] A24. The collar (58) is a screw-type insert (50) for joining outer panels as described in any of the appendices A1 to A23.1, wherein a countersunk hole is machined in the portion adjacent to the upper surface (96) of the collar (58) to facilitate engagement with the fastener (48).

[0109] A25. The main body (52) further includes an enlarged flange (60) projecting radially outward from the outer circumferential surface (76), and is an outer plate joining threaded insert (50) as described in any of appendices A1 to A24.

[0110] A26. The enlarged flange (60) has a thickness of at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, and / or at least 80% of the second thickness (134) of the first enlarged portion (80), as described in Appendix A25, with threaded insert (50) for outer plate joining.

[0111] A27. The enlarged flange (60) is an outer plate joining threaded insert (50) as described in any of appendices A25 to A26, which defines the first cross-section (72).

[0112] A28. The enlarged flange (60) is an outer plate joining threaded insert (50) as described in any of appendices A25 to A26, which defines the second cross-section (74).

[0113] A29. An outer plate joining screw insert (50) according to any of the appendices A1 to A28, wherein a male screw (67) is provided on at least a portion of the outer circumferential surface (76) of the main body (52).

[0114] A30. The outer panel joining threaded insert (50) according to any of the appendices A1 to A29, further comprising a second insert component (70) configured to engage with the main body (52), wherein at least a portion of the main body (52) is located inside the housing (150) of the second insert component (70) when the main body (52) engages with the second insert component (70), and the engagement between the main body (52) and the second insert component (70) is selectively adjustable so as to adjust the overall height (152) of the main body (52) including the second insert component (70).

[0115] A30.1. The outer panel joining threaded insert (50) as described in Appendix A30, wherein the second insert component (70) includes a second outer surface (156) configured to engage with the core (14) of the sandwich panel (12), a panel engaging cross section (158) configured to engage with the first outer panel (16) or the second outer panel (18) of the sandwich panel (12), and an insert opposing cross section (160) configured to engage with the body (52).

[0116] A31. The second insert component (70) is the outer plate joining threaded insert (50) as described in Appendix A30 or A30.1, which includes a female thread (154) for engaging with the outer circumferential surface (76) of the main body (52).

[0117] A32. The enlarged flange (60) of the main body (52) is configured to act as a fastener, and the overall height (152) is minimized when the second insert component (70) contacts the enlarged flange (60), as described in any of appendices A30 to A31, with threaded insert (50) for outer plate joining.

[0118] A33. The second insert component (70) is an outer panel joining threaded insert (50) as described in any of appendices A30 to A32, which is coated with a thermosetting resin.

[0119] A33.1. The outer panel joining threaded insert (50) as described in Appendix A33, wherein at least a portion of the second outer peripheral surface (156) of the second insert component (70), at least a portion of the insert-facing cross section (160) of the second insert component (70), and / or at least a portion of the panel engagement cross section (158) of the second insert component (70) is coated with a thermosetting resin.

[0120] A34. A threaded insert (50) for exterior panel joining as described in any of the appendices A30 to A33.1, wherein at least a portion of the second outer peripheral surface (156) of the second insert component (70), at least a portion of the insert-facing cross section (160) of the second insert component (70), and / or at least a portion of the panel engagement cross section (158) of the second insert component (70) is knurled.

[0121] A35. The outer panel joining screw insert (50) described in any of appendices A30 to A34, wherein the second insert component (70) engages with the main body (52) such that the main body (52) is translated vertically relative to the second insert component (70) by compressing the sandwich panel (12) and the collar (58), thereby reducing the overall height (152).

[0122] A36. The outer panel joining threaded insert (50) according to any of appendices A30 to A35, wherein the housing (150) includes an inner surface (162) configured to restrict the vertical translational movement of the main body (52) relative to the second insert component (70) when the sandwich panel (12) is compressed.

[0123] A37. The first cross-section (72) of the main body (52) engages with the inner surface (162) of the housing portion (150) of the second insert component (70) when the sandwich panel (12) is compressed, and is an outer panel joining screw insert (50) as described in any of appendices A30 to A36.

[0124] A38. The female thread (154) of the second insert component (70) is configured to engage with the body (52) such that when the sandwich panel (12) is compressed with sufficient force, the body (52) moves along the female thread (154) in a ratchet manner, thereby causing the body (52) to translate vertically relative to the second insert component (70) and reducing the overall height (152), as described in any of appendices A30 to A37.

[0125] B1. An outer panel joining screw insert (50) as described in any of Appendix A1 to A38, A system (100) comprising the sandwich panel (12), wherein the outer panel screw-type insert (50) is positioned, at least in part, within the hole (20) of the sandwich panel (12).

[0126] B2. The system (100) described in Appendix B1, wherein the outer panel joining screw insert (50) is configured such that when the collar (58) is in the raised position, the upper surface (96) of the collar (58) is higher than the second outer panel (18) of the sandwich panel (12), and the upper surface (96) of the collar (58) is on the opposite side of the lower surface (92) of the collar.

[0127] B3. The system (100) described in Appendix B1 or B2, wherein the outer panel joining threaded insert (50) is configured such that when the collar (58) is in the press-fit position, the upper surface (96) of the collar (58) is flush with or slightly lower than the second outer panel (18) of the sandwich panel (12).

[0128] B4. The system (100) according to any of the appendices B1 to B3, wherein the sandwich panel (12) includes a first panel hole (22) that penetrates the first outer panel (16), and the first panel hole (22) is at least substantially concentric with the hole (54) of the outer panel screw-attached insert (50).

[0129] B5. The system (100) according to any of the appendices B1 to B4, wherein the sandwich panel (12) includes a second panel hole (24) that penetrates the second outer panel (18), and the second panel hole (24) is at least substantially concentric with the hole (54) of the outer panel screw-attached insert (50).

[0130] B6. The sandwich panel (12) is The first outer panel (16) has an inner surface (101) of the first outer panel and an outer surface (102) of the first outer panel opposite to the inner surface (101), The first outer panel (102) and the second outer panel (106) are facing opposite directions from each other. The sandwich panel further comprises the core (14) sandwiched between the inner surface (101) of the first outer panel (16) and the inner surface (104) of the second outer panel (18), The system (100) according to any of the appendices B1 to B5, comprising the hole (20) formed in at least one of the first outer plate (16) and the second outer plate (18) and extending into the interior of the core (14).

[0131] B7. The system (100) according to any of the appendices B1 to B6, wherein the hole (20) is formed in the first outer plate (16) and extends into the interior of the core (14) toward the second outer plate (18).

[0132] B8. The system (100) according to any of the appendices B1 to B7, wherein the hole (20) is formed in the second outer plate (18) and extends into the interior of the core (14) toward the first outer plate (16).

[0133] B9. The core (14) comprises one or more of the following: foam, aluminum, Nomex® (aramid), carbon, Korex, Kevlar®, glass fiber, polyethersulfone, polyvinyl chloride, polyurethane, polyethylene foam, polystyrene foam, balsa wood, syntactic foam, honeycomb structure, polymer honeycomb, thermoplastic honeycomb, stainless steel, polycarbonate, and polypropylene, as described in any of Appendix B1 to B8, the system (100).

[0134] B10. The first outer panel (16) comprises one or more of the following: a laminate of glass fiber reinforced polymer, a laminate of carbon fiber reinforced polymer, a thermosetting polymer, epoxy, metal sheet, carbon, aramid, aluminum, steel, plywood, balsa, teak, and hardwood, as described in any of the appendices B1 to B9 (100).

[0135] B11. The second outer panel (18) comprises one or more of the following: a laminate of glass fiber reinforced polymer, a laminate of carbon fiber reinforced polymer, a thermosetting polymer, epoxy, metal sheet, carbon, aramid, aluminum, steel, plywood, balsa, teak, and hardwood, according to any of the descriptions in Appendix B1 to B10 (100).

[0136] B12. The sandwich panel (12) is a system (100) as described in any of appendices B1 to B11, including a composite panel.

[0137] B13. The system (100) according to any of the appendices B1 to B12, wherein there are a plurality of holes (20), each (20) of the plurality of holes (20) extending into the interior of the core (14) from at least one of the first outer plate (16) and the second outer plate (18), there are a plurality of outer plate joining threaded inserts (50), each of the plurality of outer plate joining threaded inserts (50) is an outer plate joining threaded insert (50) described in any of appendices A1 to A38, and at least one of the plurality of outer plate joining threaded inserts (50) is fitted into each (20) of the plurality of holes (20).

[0138] B14. The first outer panel (16), the second outer panel (18), and / or the core (14) are precision cut, the system (100) as described in any of appendices B1 to B13.

[0139] B15. The system (100) according to any of the appendices B1 to B14, further comprising an adhesive pack (66) positioned between the body (52) of the outer panel screw insert (50) and the core (14) of the sandwich panel (12), wherein the adhesive pack (66) is configured to cure during the curing of the sandwich panel (12).

[0140] B16. The adhesive pack (66) is a two-part epoxy adhesive pack (66) as described in Appendix B15 (100).

[0141] B17. The system (100) according to any of the appendices B15 to B16, wherein the adhesive pack (66) is positioned adjacent to the first cross-section (72) of the body (52) of the outer panel screw-attached insert (50).

[0142] B18. The adhesive pack (66) is positioned adjacent to the outer peripheral surface (76) of the body (52) of the outer panel screw insert (50), in the system (100) according to any of the appendices B15 to B17.

[0143] B19. The system (100) according to any of the appendices B15 to B18, wherein the adhesive pack (66) is configured to be inserted into the hole (20) of the sandwich panel (12) before the outer panel screw insert (50).

[0144] B20. The system (100) according to any of the appendices B15 to B19, wherein the adhesive pack (66) comprises a plurality of adhesive packs (66) arranged near the outer panel screw insert (50).

[0145] B21. The system (100) according to any of the appendices B1 to B20, wherein the enlarged flange (60) is arranged to engage with the core (14) and the first outer plate (16) of the sandwich panel (12).

[0146] B22. The system (100) according to any of the appendices B1 to B20, wherein the enlarged flange (60) is arranged to engage with the core (14) and the second outer plate (18) of the sandwich panel (12).

[0147] C1. A method (300) for attaching an outer panel joining screw insert (50) to a sandwich panel (12), The first outer panel (16) of the sandwich panel (12) is prepared (302), The core (14) of the sandwich panel (12) is placed on the first outer plate (16) such that the first surface (172) of the core (14) faces the first outer plate (16) (306), A hole (20) is formed (304) in the core (14) of the sandwich panel (12), The outer panel joining screw insert (50) is inserted into the hole (20) (308), so that at least a part of the body (52) of the outer panel joining screw insert (50) is positioned inside the hole (20), and the collar (58) of the outer panel joining screw insert (50) is raised so that the collar (58) is above the second surface (174) of the core (14), and the second surface (174) of the core (14) is on the opposite side of the first surface (172) of the core (14). The second outer panel (18) of the sandwich panel (12) is placed on the second surface (174) of the core (14) (310), such that the collar (58) of the outer panel joining screw insert (50) is positioned above the outer surface of the second outer panel (18), the second outer panel (18) includes a through hole (24) that penetrates through it, and when the second outer panel (18) is placed on the core (14), the collar (58) protrudes from the through hole (24), Method (300): With the outer plate joining threaded insert (50) in the hole (20), the first outer plate (16), the core (14), and the second outer plate (18) are all compressed (312), and this compression (312) causes the collar (58) to translate vertically relative to the main body (52), thereby moving the collar (58) between an elevated position and a press-fit position.

[0148] C2. The method (300) described in Appendix C1, wherein the outer panel joining threaded insert (50) is the outer panel joining threaded insert (50) described in any of Appendix A1 to A38.

[0149] C3. The method according to any of the appendices C1 to C2 (300), wherein in the raised position, the lower surface (92) of the collar (58) is spaced apart from the shelf-like portion (82) of the hole (54), and in the press-fit position, the lower surface (92) of the collar (58) engages with the shelf-like portion (82) of the hole (54).

[0150] C4. The method according to any of the appendices C1 to C3 (300), wherein, when compressing (312), the collar (58) is translated vertically such that the upper surface (96) of the collar (58) is at least substantially flush with the outer surface of the second outer plate (18).

[0151] C5. The method (300) described in any of the appendices C1 to C4, wherein the sandwich panel (12) is cured during the compression (312) such that the first outer panel (16), the second outer panel (18), the core (14), and the outer panel joining threaded insert (50) are all joined during compression.

[0152] C6. The method (300) described in any of the appendices C1 to C5, wherein the sandwich panel (12) and the outer panel screw-attached insert (50) are compressed without using a potting agent or additional adhesive during the compression (312).

[0153] C7. The method according to any one of the appendices C1 to C6 (300), further comprising placing an adhesive pack (66) between the body (52) of the outer panel screw insert (50) and the core (14) of the sandwich panel (12), wherein the adhesive pack (66) is configured to cure during the curing of the sandwich panel (12).

[0154] C8. The adhesive pack (66) is a two-part epoxy adhesive pack (66) as described in Appendix C7 (300).

[0155] C9. The method (300) described in any of the appendices C7 to C8, wherein when arranging (318), the adhesive pack (66) is placed adjacent to the first cross-section (72) of the main body (52) of the outer panel joining screw insert (50).

[0156] C10. The method (300) described in any of the appendices C7 to C9, wherein when arranging (318), the adhesive pack (66) is placed adjacent to the outer peripheral surface (76) of the main body (52) of the outer panel joining screw insert (50).

[0157] C11. The method (300) described in any of the appendices C7 to C10, wherein, when arranging (318), an adhesive pack (66) is placed in the hole (20) of the sandwich panel (12) before inserting the outer panel joining screw insert (50).

[0158] C12. When preparing the first outer plate (16) (302), the method (300) for precisely cutting the first outer plate (16) as described in any of the appendices C1 to C11.

[0159] C13. The method according to any of the appendices C1 to C12 (300), wherein ultrasonic cutting is performed to form the first outer plate (16) when preparing the first outer plate (16) (302).

[0160] C14. The method according to any of the appendices C1 to C13 (300), further comprising preparing the second outer panel (18) (314), wherein the second outer panel (18) is precisely cut when preparing the second outer panel (18) (314).

[0161] C15. The method according to any of the appendices C1 to C14 (300), further comprising preparing the second outer plate (18) (314), wherein the second outer plate (18) is formed by ultrasonic cutting when preparing the second outer plate (18) (314).

[0162] C16. The method (300) described in any of the appendices C1 to C15, wherein the core (14) is precisely cut when forming the hole (20) of the core (14) of the sandwich panel (12) (304).

[0163] C17. The method according to any of the appendices C1 to C16 (300), further comprising coating the outer panel joining threaded insert (50) with phenolic resin (316) before insertion of the outer panel joining threaded insert (50).

[0164] C18. The method according to any of the appendices C1 to C17 (300), further comprising knurling (316) one or more surfaces of the outer plate joining threaded insert (50).

[0165] D1. A threaded insert (50) for joining outer panels, configured to be fitted into a hole (20) in a sandwich panel (12), wherein the sandwich panel (12) includes a first outer panel (16), a second outer panel (18) opposite the first outer panel (16), a third outer panel (136), and a core (14) positioned between the first outer panel (16) and the second outer panel (18), and the threaded insert (50) for joining outer panels is outer panel (136), and a core (14) positioned between the first outer panel (16) and the second outer panel (18), and the threaded insert (50) is configured to be fitted into a hole (20) in a sandwich panel (12), wherein the sandwich panel (12) includes a first outer panel (16), a second outer panel (18) opposite the first outer panel (16), a third outer outer panel (136), and a core (14) positioned between the first outer panel (16) and the second outer panel (18), and the threaded insert (50) is configured to be fitted into a hole (20) in a sandwich panel (12), wherein the sandwich panel (12) includes a first outer panel (16), a second outer panel (18) opposite the first outer panel (16), a third outer outer panel (136), and a core (14) positioned between the first outer panel (16) and the second outer panel (18), The sandwich panel (12) includes a body (52) configured to extend vertically from the core (14), wherein the second cross-section (74) of the body (52) is on the opposite side of the first cross-section (72), The aforementioned screw-attached insert for joining the outer panel further includes a hole (54) extending vertically in at least a portion of the main body (52), A screw-type insert for joining outer panels, comprising a main body (52) and an enlarged flange (60) having a flange diameter (138) larger than the main body diameter, wherein the enlarged flange (60) protrudes radially from the main body (52) at a position along the longitudinal axis (56) of the main body (52), the position being between the first cross section (72) and the second cross section (74), and thus the enlarged flange (60) is longitudinally offset from both the first cross section (72) and the second cross section (74), and the enlarged flange (60) is configured to be positioned inside the second outer panel (18) and / or the third outer panel (136) of the sandwich panel (12).

[0166] D1.1. The first cross-section (72) of the main body (52) is an outer panel joining screw insert (50) as described in Appendix D1, which engages with the core (14) of the sandwich panel (12).

[0167] D1.2. The outer circumferential surface (76) of the main body (52) is configured to engage with the core (14) of the sandwich panel (12) when the outer panel screw insert (50) is mounted on the sandwich panel (12), as described in Appendix D1 or D1.1.

[0168] D1.3. The enlarged flange (60) is configured to be positioned between the second outer panel (18) and the third outer panel (136) when the outer panel joining threaded insert (50) is installed inside the sandwich panel (12), as described in any of the appendices D1 to D1.2.

[0169] D1.4. The enlarged flange (60) is configured to be positioned between the second outer panel (18) and the first outer panel (16) when the outer panel joining threaded insert (50) is installed inside the sandwich panel (12), thereby the enlarged flange (60) is located inside both the second outer panel (18) and the third outer panel (136), as described in any of the appendices D1 to D1.2.

[0170] D2. The outer panel joining threaded insert (50) according to any one of the appendices D1 to D1.4, wherein at least a portion of the outer panel joining threaded insert (50) is coated with a thermosetting resin (46).

[0171] D2.1. The thermosetting resin coating (46) is provided on the second cross section (74) as an outer panel joining screw insert (50) as described in Appendix D2.

[0172] D2.2. The thermosetting resin coating (46) is provided on the enlarged flange (60) and is an outer plate joining threaded insert (50) as described in Appendix D2.

[0173] D3. The outer panel joining threaded insert (50) according to any of the appendices D1 to D2.2, further comprising a donut-shaped member (144) pre-impregnated with a thermosetting resin, wherein the donut-shaped member (144) is arranged to surround the main body (52), and the donut-shaped member (144) is configured to join the outer panel joining threaded insert (50) to a predetermined position within the hole (20) of the sandwich panel (12).

[0174] D4. The donut-shaped member (144) is an outer plate joining threaded insert (50) as described in Appendix D3, extending radially outward from the main body (52) along the bottom surface (146) of the enlarged flange (60).

[0175] D5. The outer plate joining threaded insert (50) as described in Appendix D4, wherein the donut-shaped member (144) extends to cover at least 75% of the bottom surface (146) of the enlarged flange (60).

[0176] D6. The outer panel joining threaded insert (50) described in any of appendices D1 to D5, wherein the outer panel joining threaded insert (50) is configured to be joined to the second outer panel (18) and the third outer panel (136) when the sandwich panel (12) is cured.

[0177] D7. The enlarged flange (60) is an outer plate joining threaded insert (50) as described in any of the appendices D1 to D6, wherein the bottom surface (146) of the enlarged flange (60) is chamfered.

[0178] D8. The bottom surface (146) of the enlarged flange (60) is configured to engage with the second outer plate (18), a threaded insert (50) for joining the outer plate as described in any of the appendices D1 to D7.

[0179] D9. The top surface (148) of the enlarged flange (60) is configured to engage with the third outer plate (136), the outer plate joining threaded insert (50) as described in any of the appendices D1 to D8.

[0180] D10. The top surface (148) of the enlarged flange (60) is at least substantially parallel to the second cross section (74), the outer plate joining threaded insert (50) as described in any of the appendices D1 to D9.

[0181] D11. The outer panel joining threaded insert (50) according to any of the appendices D1 to D10, wherein the top surface (148) of the enlarged flange (60) is at least substantially perpendicular to the vertical axis (56) of the body (52) of the outer panel joining threaded insert (50).

[0182] D12. The outer panel joining threaded insert (50) according to any of the appendices D1 to D11, further comprising a second insert component (70) configured to engage with the main body (52), wherein at least a portion of the main body (52) is located inside the housing (150) of the second insert component (70) when the main body (52) engages with the second insert component (70), and the engagement between the main body (52) and the second insert component (70) is selectively adjustable so as to adjust the overall height (152) of the main body (52) including the second insert component (70).

[0183] D13. The outer panel joining threaded insert (50) as described in Appendix D12, wherein the second insert component (70) includes a second outer surface (156) configured to engage with the core (14) of the sandwich panel (12), a panel engaging cross section (158) configured to engage with the first outer panel (16) or the second outer panel (18) of the sandwich panel (12), and an insert opposing cross section (160) opposite to the panel engaging cross section (158).

[0184] D13.1. The outer panel joining threaded insert (50) as described in Appendix D13, wherein the panel engaging cross section (158) is configured to engage with the main body (52) when the overall height (152) of the outer panel joining threaded insert (50) is minimized.

[0185] D13.2. The outer panel joining threaded insert (50) described in Appendix D13, wherein the panel engaging cross section (158) is configured to face the enlarged flange (60) of the main body (52).

[0186] D14. The second insert component (70) is an outer plate joining threaded insert (50) as described in any of appendices D12 to D13.1, including a female thread (154) for engaging with the outer circumferential surface (76) of the main body (52).

[0187] D15. The enlarged flange (60) of the main body (52) is configured to act as a fastener, and the overall height (152) is minimized when the second insert component (70) contacts the enlarged flange (60), as described in any of the appendices D12 to D14, with threaded insert (50) for outer plate joining.

[0188] D16. The second insert component (70) is an outer panel joining threaded insert (50) as described in any of appendices D12 to D15, which is coated with a thermosetting resin.

[0189] D17. The outer panel joining threaded insert (50) as described in Appendix D16, wherein at least a portion of the second outer peripheral surface (156) of the second insert component (70), at least a portion of the insert-facing cross section (160) of the second insert component (70), and / or at least a portion of the panel engagement cross section (158) of the second insert component (70) is coated with a thermosetting resin.

[0190] D18. A threaded insert (50) for exterior panel joining as described in any of appendices D12 to D17, wherein at least a portion of the second outer peripheral surface (156) of the second insert component (70), at least a portion of the insert-facing cross section (160) of the second insert component (70), and / or at least a portion of the panel engagement cross section (158) of the second insert component (70) is knurled.

[0191] D19. The outer panel joining screw insert (50) described in any of appendices D12 to D18, wherein the second insert component (70) engages with the main body (52) such that the main body (52) is translated vertically relative to the second insert component (70) by compressing the sandwich panel (12), thereby reducing the overall height (152).

[0192] D20. The outer panel joining threaded insert (50) according to any of the appendices D12 to D19, wherein the housing (150) includes an inner surface (162) configured to restrict the vertical translational movement of the main body (52) relative to the second insert component (70) when the sandwich panel (12) is compressed.

[0193] D21. The first cross-section (72) of the main body (52) engages with the inner surface (162) of the housing portion (150) of the second insert component (70) when the sandwich panel (12) is compressed, and is an outer panel joining screw insert (50) as described in any of appendices D12 to D20.

[0194] D22. The female thread (154) of the second insert component (70) is configured to engage with the body (52) such that when the sandwich panel (12) is compressed with sufficient force, the body (52) moves along the female thread (154) in a ratchet manner, thereby causing the body (52) to translate vertically relative to the second insert component (70) and reducing the overall height (152), as described in any of appendices D12 to D21.

[0195] D23. The outer panel joining threaded insert (50) according to any of appendices D1 to D22, further comprising a notched flange (68), the notched flange (68) being adjacent to or forming the first cross section (72), and the notched flange (68) comprising a plurality of notches (164).

[0196] D24. The outer panel joining threaded insert (50) as described in Appendix D23, wherein the plurality of notches (164) are configured to accommodate adhesive for joining the outer panel joining threaded insert (50) to predetermined positions within the holes (20) of the sandwich panel (12).

[0197] D25. The notched flange diameter (166) of the notched flange (68) is smaller than the flange diameter (138) of the enlarged flange (60), and the outer plate joining threaded insert (50) is as described in any of appendices D23 to D24.

[0198] E1. The outer panel joining screw insert (50) described in any of the appendices D1 to D25, A system (100) comprising the sandwich panel (12), wherein the outer panel screw-type insert (50) is positioned, at least in part, within the hole (20) of the sandwich panel (12).

[0199] E2. The system (100) according to Appendix E1, wherein the sandwich panel (12) includes a first panel hole (22) that penetrates the first outer panel (16), and the first panel hole (22) is at least substantially concentric with the hole (54) of the outer panel screw-attached insert (50).

[0200] E3. The system (100) according to any one of the appendices E1 to E2, wherein the sandwich panel (12) includes a second panel hole (24) that penetrates the second outer panel (18), and the second panel hole (24) is at least substantially concentric with the hole (54) of the outer panel screw-attached insert (50).

[0201] E4. The sandwich panel (12) is The first outer panel (16) has an inner surface (101) of the first outer panel and an outer surface (102) of the first outer panel opposite to the inner surface (101), The first outer panel (102) and the second outer panel (106) are facing opposite directions from each other. The sandwich panel further comprises the core (14) sandwiched between the inner surface (101) of the first outer panel (16) and the inner surface (104) of the second outer panel (18), The system (100) according to any one of appendices E1 to E3, comprising the hole (20) formed in at least one of the first outer plate (16) and the second outer plate (18) and extending into the interior of the core (14).

[0202] E5. The system (100) according to any one of the appendices E1 to E4, wherein the hole (20) is formed in the first outer plate (16) and extends into the interior of the core (14) toward the second outer plate (18).

[0203] E6. The system (100) according to any one of the appendices E1 to E5, wherein the hole (20) is formed in the second outer plate (18) and extends into the interior of the core (14) toward the first outer plate (16).

[0204] E7. The core (14) comprises one or more of the following: foam, aluminum, Nomex® (aramid), carbon, Korex, Kevlar®, glass fiber, polyethersulfone, polyvinyl chloride, polyurethane, polyethylene foam, polystyrene foam, balsa wood, syntactic foam, honeycomb structure, polymer honeycomb, thermoplastic honeycomb, stainless steel, polycarbonate, and polypropylene, as described in any of the appendices E1 to E6, the system (100).

[0205] E8. The first outer panel (16) comprises one or more of the following: a laminate of glass fiber reinforced polymer, a laminate of carbon fiber reinforced polymer, a thermosetting polymer, epoxy, metal sheet, carbon, aramid, aluminum, steel, plywood, balsa, teak, and hardwood, according to any of the appendices E1 to E7 (100).

[0206] E9. The second outer panel (18) comprises one or more of the following: a laminate of glass fiber reinforced polymer, a laminate of carbon fiber reinforced polymer, a thermosetting polymer, epoxy, metal sheet, carbon, aramid, aluminum, steel, plywood, balsa, teak, and hardwood, as described in any of the appendices E1 to E8 (100).

[0207] E10. The sandwich panel (12) is a system (100) as described in any of the appendices E1 to E91, including a composite panel.

[0208] E11. The system (100) according to any of the appendices E1 to E10, wherein there are a plurality of holes (20), each (20) of the plurality of holes (20) extending into the interior of the core (14) from at least one of the first outer plate (16) and the second outer plate (18), there are a plurality of outer plate fastening threaded inserts (50), each of the plurality of outer plate fastening threaded inserts (50) is an outer plate fastening threaded insert (50) described in any of appendices D1 to D25, and at least one of the plurality of outer plate fastening threaded inserts (50) is fitted into each (20) of the plurality of holes (20).

[0209] E12. The first outer panel (16), the second outer panel (18), and / or the core (14) are precision cut, the system (100) as described in any of the appendices E1 to E11.

[0210] E13. The system (100) according to any of the appendices E1 to E12, further comprising the third outer outer plate (136) positioned adjacent to the second outer surface of the second outer plate (18), wherein the enlarged flange (60) of the outer plate joining threaded insert (50) is positioned between the second outer plate (18) and the third outer outer plate (136).

[0211] E14. The system (100) according to any of the appendices E1 to E13, wherein the second outer plate (18) includes a recess corresponding to the bottom surface (146) of the enlarged flange (60) of the outer plate joining threaded insert (50).

[0212] E15. The system (100) according to any of the appendices E1 to E14, wherein the second cross section (74) of the outer panel joining threaded insert (50) engages with and / or is at least substantially flush with the third outer panel (136) of the sandwich panel (12).

[0213] E16. The system (100) according to any one of the appendices E1 to E15, further comprising an adhesive pack (66) positioned between the body (52) of the outer panel screw insert (50) and the core (14) of the sandwich panel (12), wherein the adhesive pack (66) is configured to cure during the curing of the sandwich panel (12).

[0214] E17. The adhesive pack (66) is a two-component epoxy adhesive pack (66) as described in Appendix E16 (100).

[0215] E18. The system (100) according to any one of the appendices E16 to E17, wherein the adhesive pack (66) is positioned adjacent to the first cross-section (72) of the body (52) of the outer panel screw-attached insert (50).

[0216] E19. The adhesive pack (66) is positioned adjacent to the outer peripheral surface (76) of the body (52) of the outer panel screw insert (50) in the system (100) according to any of the appendices E16 to E18.

[0217] E20. The system (100) according to any of the appendices E16 to E19, wherein the adhesive pack (66) is configured to be inserted into the hole (20) of the sandwich panel (12) before the outer panel screw insert (50).

[0218] E21. The system (100) according to any of the appendices E16 to E20, wherein the adhesive pack (66) comprises a plurality of adhesive packs (66) arranged near the outer panel screw insert (50).

[0219] F1. A method (400) for attaching an outer panel screw insert (50) to a sandwich panel (12), wherein the sandwich panel (12) includes a first outer panel (16), a second outer panel (18) opposite the first outer panel (16), a third outer panel (136) adjacent to the second outer panel (18), and a core (14) positioned between the first outer panel (16) and the second outer panel (18), and the method (300) is as follows: The outer plate joining threaded insert (50) is inserted (402) into the hole (20) that extends in at least a portion of the core (14), The enlarged flange (60) of the threaded insert (50) for joining the outer panel is superimposed (404) with the second outer panel (18) and / or the third outer panel (136). A method comprising compressing and hardening (406) the sandwich panel (12) and the outer panel joining screw insert (50) together, thereby joining the outer panel joining screw insert (50) to the second outer panel (18) and the third outer panel (136) by the hardening of the sandwich panel (12).

[0220] F2. The method (400) described in Appendix F1, wherein the outer panel joining threaded insert (50) includes the outer panel joining threaded insert (50) described in any of Appendix D1 to D25.

[0221] F3. The method according to any one of the appendices F1 to F2 (400), further comprising lifting and separating at least a portion of the third outer plate (136) from the second outer plate (18) before inserting the outer plate joining threaded insert (50) (402) into the hole (20).

[0222] F4. The method according to Appendix F3 (400), further comprising returning the third outer plate (136) to the second outer plate (18) so that the third outer plate (136) overlaps with the enlarged flange (60) and the enlarged flange (60) is sandwiched between the second outer plate (18) and the third outer plate (136).

[0223] F5. The hole (20) penetrates the second outer plate (18) and the third outer plate (136) as described in any of the appendices F1 to F4 (400).

[0224] F6. The method (400) described in any of the appendices F1 to F5, wherein, when overlapping (404), substantially the entire top surface (148) of the enlarged flange (60) is overlapped with the second outer plate (18).

[0225] F7. The method (400) described in any of the appendices F1 to F6, wherein, when overlapping (404), substantially the entire top surface (148) of the enlarged flange (60) is overlapped with the third outer plate (136).

[0226] F8. Prepare the first outer panel (16) of the sandwich panel (12) (302), The core (14) of the sandwich panel (12) is placed on the first outer plate (16) such that the first surface of the core (14) faces the first outer plate (16) (306), and, The method according to any of the appendices F1 to F7 (400), further comprising forming a hole (20) in the core (14) of the sandwich panel (12) (304).

[0227] F9. The method (400) according to any of the appendices F1 to F8, wherein the second cross section (74) of the outer panel joining threaded insert (50) is above the third outer panel (136), and the method (400) further comprises compressing (312) the first outer panel (16), the core (14), the second outer panel (18), and the third outer panel (136) together with the outer panel joining threaded insert (50) in the hole (20), such that the compression (312) causes the second cross section (74) to be at least substantially flush with the third outer panel (136).

[0228] F10. The method (400) described in Appendix F9, wherein the sandwich panel (12) is cured during the compression (312) such that the first outer panel (16), the second outer panel (18), the third outer panel (136), the core (14), and the outer panel joining threaded insert (50) are all joined together during the compression (312).

[0229] F11. The method according to any of the appendices F1 to F10 (400), further comprising placing an adhesive pack (66) between the body (52) of the outer panel screw insert (50) and the core (14) of the sandwich panel (12), wherein the adhesive pack (66) is configured to cure during the curing of the sandwich panel (12).

[0230] F12. The adhesive pack (66) is a two-component epoxy adhesive pack (66) as described in Appendix F11 (400).

[0231] F13. The method (400) described in any of the appendices F11 to F12, wherein when arranging (318), the adhesive pack (66) is placed adjacent to the first cross-section (72) of the main body (52) of the outer panel joining screw insert (50).

[0232] F14. The method (400) described in any of the appendices F11 to F13, wherein, when arranging (318), the adhesive pack (66) is placed adjacent to the outer peripheral surface (76) of the main body (52) of the outer panel joining screw insert (50).

[0233] F15. The method (400) described in any of the appendices F11 to F14, wherein, when arranging (318), an adhesive pack (66) is placed in the hole (20) of the sandwich panel (12) before inserting the outer panel joining screw insert (50).

[0234] F16. The method (400) described in any of the appendices F1 to F15, further comprising precision cutting the first outer panel (16).

[0235] F17. The method according to any of the appendices F1 to F16 (400), further comprising forming the first outer plate (16) by ultrasonic cutting.

[0236] F18. The method according to any of the appendices F1 to F17 (400), further comprising preparing the second outer panel (18) (314), wherein the second outer panel (18) is precisely cut when preparing the second outer panel (18) (314).

[0237] F19. The method according to any of the appendices F1 to F18 (400), further comprising preparing the second outer plate (18) (314), wherein the second outer plate (18) is formed by ultrasonic cutting when preparing the second outer plate (18).

[0238] F20. The method (400) described in any of the appendices F1 to F19, further comprising precision cutting the core (14).

[0239] F21. The method according to any of the appendices F1 to F20 (400), further comprising coating the outer panel joining threaded insert (50) with phenolic resin (316) before inserting the outer panel joining threaded insert (50).

[0240] F22. The method according to any of the appendices F1 to F21 (400), further comprising knurling (316) one or more surfaces of the outer panel joining threaded insert (50).

[0241] G1. Apparatus (28) comprising at least one system (100) described in any of the appendices B1 to B22 and / or E1 to E21.

[0242] G2. The apparatus (28) is the apparatus (28) described in Appendix G1, which includes one or more of the following: aircraft (30), satellites, antennas, transport vehicles, transport containers, automobiles, and shelters.

[0243] G3. The sandwich panel (12) forms part of one or more of the floor, galley, main internal structure, secondary structure, interior wall, luggage compartment, overhead luggage rack, restroom, capsule panel, nose cone, instrument enclosure, bulkhead panel, curtain wall, partition, and dividing panel of the apparatus (28) as described in any of the appendices G1 to G2.

[0244] H1. To house a secondary member (48) in the hole (54) of the outer panel joining threaded insert (50) and transmit a local load to the sandwich panel (12) via the outer panel joining threaded insert (50), use the outer panel joining threaded insert (50) described in any of the appendices A1 to A38 and / or D1 to D25.

[0245] I1. Use the systems (100) described in any of the appendices B1-B22 and / or E1-E21 to manufacture one or more of the aircraft (30), satellites, antennas, transport vehicles, transport containers, automobiles, and shelters.

[0246] In this specification, when the terms “selective” or “selectively” modify the operation, movement, configuration, or other function of one or more components or elements of the device, it means that such particular operation, movement, configuration, or other function is a direct or indirect result of the user's operation of the device or one or more components.

[0247] In this specification, the terms “adapted” and “configured” mean that an element, component, or other essential part is designed and / or intended to perform a particular function. Therefore, the use of the terms “adapted” and “configured” should not be interpreted as meaning that an element, component, or other essential part is merely “capable” of performing a particular function, but rather that the element, component, and / or other essential part is specifically selected, manufactured, implemented, used, programmed, and / or designed to perform that function. Furthermore, it is within the scope of this disclosure that an element, component, and / or other essential part described as adapted to perform a particular function may, in addition to or instead be described as configured to perform that function, and vice versa. Similarly, an essential part described as configured to perform a particular function may, in addition to or instead be described as operating to perform that function.

[0248] Not all elements of an apparatus or processes of a method disclosed herein are necessary for all apparatuses or methods provided herein. This disclosure includes all novel and non-obvious combinations and partial combinations of the elements and processes disclosed herein. Furthermore, one or more of the elements and processes disclosed herein may constitute an independent gist of an invention separate from the entire disclosed apparatus or method. Accordingly, such a gist of an invention does not need to be associated with any specific apparatus or method expressly disclosed herein, and such a gist of an invention may find useful in apparatuses and / or methods not expressly disclosed herein.

Claims

1. A threaded insert for joining outer panels, configured to be fitted into a hole in a sandwich panel, wherein the sandwich panel includes a first outer panel, a second outer panel opposite the first outer panel, and a core between them, and the threaded insert for joining outer panels is The sandwich panel includes a body configured to extend longitudinally from a first cross-section to a second cross-section through at least a portion of the core of the sandwich panel, the outer circumferential surface of the body is configured to engage with the core of the sandwich panel when the outer panel screw-attached insert is mounted on the sandwich panel, The outer plate joining screw insert further includes a hole extending longitudinally in at least a portion of the main body, the hole being, It includes a threaded portion that is threaded to engage with a fastener, the threaded portion extends longitudinally along at least a portion of the length of the hole, and the threaded portion has a large diameter corresponding to the maximum diameter of the threaded portion, The aforementioned hole further comprises a first enlarged diameter portion having an enlarged diameter larger than the aforementioned large diameter of the threaded portion, It includes a shelf-like portion formed at the joint between the first enlarged diameter portion and the threaded portion, The outer panel joining threaded insert further includes a collar sized to the first enlarged diameter of the hole such that its outer surface frictionally fits with the first enlarged diameter, the collar being configured to be translationally movable in the longitudinal direction relative to the main body, thereby allowing the outer panel joining threaded insert to move between a raised position and a press-fitted position when the outer panel joining threaded insert is mounted to the sandwich panel.

2. The insert with screws for joining outer panels according to claim 1, wherein the first cross-section of the main body engages with the first outer panel.

3. In the raised position, the lower surface of the collar is facing the shelf-like portion of the hole and is located at a distance from the shelf-like portion by a collar displacement distance, as described in claim 1, with an outer panel joining screw insert.

4. In the press-fit position, the collar displacement distance is smaller than when the collar is in the raised position, and therefore the lower surface of the collar is closer to the shelf-like portion when the collar is in the press-fit position than when the collar is in the raised position, as described in claim 3, an outer plate joining screw insert.

5. The outer panel joining threaded insert according to claim 1, wherein the first cross-section, the second cross-section, and the outer peripheral surface of the main body are coated with a thermosetting resin, and the thermosetting resin flows during the curing of the sandwich panel to join the outer panel joining threaded insert within the sandwich panel.

6. The outer panel joining screw insert according to claim 1, wherein the first and second cross-sectional surfaces of the main body are knurled.

7. The collar is configured to move to the press-fit position when the sandwich panel is compressed, thereby compressing the sandwich panel and the outer panel screw-attached insert together, as described in claim 1.

8. The upper surface of the collar is at least substantially flush with the second outer plate when the collar is in the press-fit position, and the upper surface of the collar is on the opposite side of the lower surface of the collar. The upper surface of the collar is located above the second outer panel when the collar is in the raised position, as described in claim 1, with an outer panel joining screw insert.

9. The outer panel joining screw insert according to claim 1, wherein the outer panel joining screw insert is configured to be joined into the hole of the sandwich panel at the same time as joining the first outer panel, the second outer panel, and the core of the sandwich panel.

10. The outer panel joining threaded insert according to claim 1, wherein the hole further includes a second enlarged diameter portion having a second enlarged diameter larger than the large diameter of the threaded portion, the hole includes a second shelf-like portion formed at a second joint between the second enlarged diameter portion and the threaded portion, the outer panel joining threaded insert further includes a second collar, the second collar being sized relative to the second enlarged diameter portion such that the second outer surface of the second collar friction-fits with the second enlarged diameter portion of the hole, the second collar being configured to move between a second raised position and a second press-fit position when the outer panel joining threaded insert is mounted on the sandwich panel, the second lower surface of the second collar being spaced apart from the second shelf-like portion of the hole, and the second lower surface of the second collar engaging with the second shelf-like portion of the hole.

11. The outer panel joining threaded insert according to claim 1, further comprising a threaded floating nut disposed in the hole of the outer panel joining threaded insert.

12. The main body further includes an enlarged flange projecting radially outward from the outer circumferential surface, the enlarged flange defining the first cross-section, as described in claim 1, an outer plate joining threaded insert.

13. The outer panel joining threaded insert according to any one of claims 1 to 12, further comprising a second insert component configured to engage with the main body, wherein at least a portion of the main body is located inside the housing of the second insert component when the main body engages with the second insert component, the engagement between the main body and the second insert component is selectively adjustable to adjust the overall height of the main body including the second insert component, and the second insert component includes a second outer surface configured to engage with the core of the sandwich panel, a panel engaging cross section configured to engage with the first or second outer panel of the sandwich panel, and an insert-facing cross section configured to engage with the main body.

14. The insert with screws for joining outer panels according to claim 13, wherein the second insert component includes a female thread for engaging with the outer circumferential surface of the main body, the second insert component is configured to engage with the main body such that the main body is translated longitudinally relative to the second insert component by compressing the sandwich panel and the collar, thereby reducing the overall height, and the female thread of the second insert component is configured to engage with the main body such that when the sandwich panel is compressed with sufficient force, the main body moves along the female thread in a ratchet manner, thereby translating longitudinally relative to the second insert component, thereby reducing the overall height.

15. A method for attaching an outer panel fastening screw insert to a sandwich panel, The first outer panel of the sandwich panel is prepared, and in doing so, ultrasonic cutting is performed to form the first outer panel. The core of the sandwich panel is placed on the first outer panel such that the first surface of the core faces the first outer panel. A hole is formed in the core of the sandwich panel. Insert the outer panel joining screw insert into the hole, positioning at least a portion of the body of the outer panel joining screw insert inside the hole, and position the collar of the outer panel joining screw insert in an elevated state where the collar is above the second surface of the core, the second surface of the core being on the opposite side of the first surface of the core. The second outer panel of the sandwich panel is placed on the second surface of the core, such that the collar of the screw-attached insert for joining the outer panel is positioned above the outer surface of the second outer panel, the second outer panel includes a through hole that penetrates the second outer panel, and when the second outer panel is placed on the core, the collar protrudes from the through hole. A method comprising compressing the first outer plate, the core, and the second outer plate together while the outer plate joining screw insert is in the hole, thereby translating the collar vertically relative to the main body by this compression, and moving the collar between an elevated position and a press-fit position.

16. The method according to claim 15, further comprising placing an adhesive pack between the body of the outer panel screw insert and the core of the sandwich panel, wherein the adhesive pack is configured to cure during the curing of the sandwich panel.

17. A threaded insert for joining outer panels, configured to be fitted into a hole in a sandwich panel, wherein the sandwich panel includes a first outer panel, a second outer panel opposite the first outer panel, a third outer panel, and a core positioned between the first and second outer panels, and the threaded insert for joining outer panels is configured to be fitted into a hole in a sandwich panel, the sandwich panel includes a first outer panel, a second outer panel opposite the first outer panel, a third outer panel, and a core positioned between the first and second outer panels, The sandwich panel includes a body configured to extend vertically from the core, wherein the second cross-section of the body is on the opposite side of the first cross-section. The aforementioned screw-attached insert for joining the outer panel further comprises a hole extending vertically in at least a portion of the main body, A threaded insert for joining outer panels, comprising an enlarged flange having a flange diameter larger than the body diameter of the body, wherein the enlarged flange protrudes radially from the body at a position along the longitudinal axis of the body, the position being between the first cross-section and the second cross-section, and the enlarged flange being configured to be positioned inside the second outer panel and / or the third outer panel of the sandwich panel.

18. The outer panel joining threaded insert according to claim 17, wherein the enlarged flange is configured to be positioned between the second outer panel and the third outer panel when the outer panel joining threaded insert is installed inside the sandwich panel.

19. The outer panel joining threaded insert according to claim 17, wherein the enlarged flange is configured to be positioned between the second outer panel and the first outer panel when the outer panel joining threaded insert is installed inside the sandwich panel, so that the enlarged flange is located inside both the second outer panel and the third outer panel.

20. The outer panel threaded insert according to any one of claims 17 to 19, further comprising a notched flange, the notched flange forming the first cross section, the notched flange comprising a plurality of notches, the plurality of notches configured to accommodate adhesive for bonding the outer panel threaded insert at predetermined positions in the holes of the sandwich panel, and the notched flange diameter of the notched flange being smaller than the flange diameter of the enlarged flange.

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