Adjustable-Height Insert for Flush Installation in Sandwich Panels
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Solution Overview
Problem
Conventional round inserts for sandwich panels in aircraft and other industries require multiple sizes due to size variations, leading to installation errors and shortages, and existing adjustable-height inserts are not suitable for flush installations.
Innovation Solution
The development of adjustable-height inserts comprising a first and second insert part with a selectively adjustable overall height, allowing for flush installation without requiring access to both sides of the sandwich panel, achieved through an interference fit and radially-extending projections that engage the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fixed-size inserts are used, then installation is simple, but multiple sizes are needed due to panel size variations, leading to installation errors and shortages
Solution Approach 1:
The insert design incorporates a compressible core that allows the insert to dynamically adjust its dimensions. The core can be compressed radially and/or axially to fit inserts of different sizes into a single standardized bore, eliminating the need for multiple insert sizes while maintaining adaptability to panel size variations
Solution Approach 2:
The insert utilizes changes in physical parameters of the core material, specifically its compressibility. By applying compression forces, the core's volume and shape parameters change, allowing the insert to conform to different bore sizes. This parameter change enables a single insert design to replace multiple fixed-size inserts
2Length of moving object
If adjustable-height inserts with flange are used, then height adjustment is possible, but the insert is not flush with the panel surface
Solution Approach 1:
The compressible core allows the insert's height to be dynamically adjusted during installation. By controlling the degree of compression, the insert can be made flush with the panel surface while maintaining the necessary height for proper fastener engagement and load transfer
Solution Approach 2:
The insert design applies different properties to different parts: the core is made compressible for height adjustment, while the outer shell and fastener engagement features maintain their structural integrity. This local differentiation allows height adjustment without compromising the flush installation requirement
3Manufacturing precision
If access to both sides of the panel is required for installation, then precise positioning is possible, but installation complexity increases
Solution Approach 1:
The insert is pre-compressed to a reduced size before insertion, allowing it to be installed through a single-sided access point. After insertion, the compressible core expands to its final dimensions, ensuring precise positioning and proper engagement without requiring access to both sides of the panel
Solution Approach 2:
The compressible core allows the insert to be nested within a smaller volume during installation, then expand to its full size after insertion. This nesting capability enables single-sided installation while maintaining the precision and engagement requirements of the final installed state
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and efficient installation of inserts in various sizes without the need for multiple sizes, reducing scrap and rework costs, and allowing for tool-less installation in a wide range of applications.
Implementation Method 1
the second insert part is configured to be selectively operatively positioned with respect to the first insert part such that the second inner surface of the second neck engages the first outer surface of the first neck with an interference fit
Data Source
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AI summary
A two-part adjustable-height insert may be installed in a bore of a sandwich panel, such that the adjustable-height insert may be configured to transfer a load to the sandwich panel. The adjustable-height insert may include a first insert part and a second insert part that may be selectively operatively positioned with respect to each other. The adjustable-height insert may be configured such that an interference fit between the first insert part and the second insert part may be engaged by moving a second flange of the second insert part towards a first flange of the first insert part, which may thereby reduce the overall height of the adjustable-height insert to a selected height. Presently disclosed adjustable-height inserts may be configured for flush installation in a sandwich panel. Methods of installing such adjustable-height inserts and adjusting the height of the same are also disclosed.