Adjustable-Height Threaded Inserts for Flush Sandwich Panel Mounting
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Solution Overview
Problem
Conventional round inserts for sandwich panels in aircraft and other industries face challenges due to size variations and inaccuracies in installation, leading to scrap and rework costs, and prior adjustable-height inserts are not suitable for flush installations.
Innovation Solution
The development of threaded adjustable-height inserts comprising a first and second insert part with a threaded engagement mechanism, allowing for adjustable height and flush installation without requiring access to both sides of the sandwich panel, using a combination of sliding and rotational adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional round inserts are used with fixed heights, then manufacturing is simplified, but dozens of different sizes are needed to accommodate variations in sandwich panel sizes and bore depths
Solution Approach 1:
The insert incorporates an adjustable height mechanism that allows the insert to dynamically change its height to match different bore depths. The second insert part can be selectively positioned at different heights relative to the first insert part, enabling a single insert design to accommodate multiple panel thicknesses and bore depths without requiring dozens of different sized inserts.
Solution Approach 2:
The adjustable-height insert design enables a single universal insert to perform the function of multiple fixed-height inserts. By allowing height adjustment, one insert design can serve multiple applications across different sandwich panel configurations, reducing the total number of insert sizes needed from dozens to a manageable few.
2Adaptability or versatility
If prior adjustable-height inserts with external flanges are used, then adaptability to different depths is achieved, but flush installation is not possible
Solution Approach 1:
The insert uses a dynamic adjustment mechanism where the second insert part can be selectively positioned at different heights relative to the first insert part. This allows the insert to be adjusted to achieve flush installation with the sandwich panel surface while maintaining adaptability to different bore depths. The adjustable mechanism enables precise height control to ensure the insert surface aligns flush with the panel.
3Reliability
If conventional inserts require access to both sides of the panel for installation, then secure bonding is achieved, but one-sided installation becomes difficult
Solution Approach 1:
The insert is divided into two separate insert parts that can be independently positioned and adjusted. The first insert part can be inserted through one side of the sandwich panel, and the second insert part can be selectively positioned relative to it. This segmentation allows the insert to be installed and adjusted from one side of the panel while maintaining secure bonding through the adhesive material in the gap between the insert and the panel core.
Data Source
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AI summary
A threaded adjustable-height insert may be installed in a bore of a sandwich panel, such that the insert may be configured to transfer a load to the sandwich panel. The threaded 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 overall height of the threaded adjustable-height insert may be adjusted by longitudinally sliding the second insert part with respect to the first insert part and rotating the second insert part with respect to the first insert part. Presently disclosed threaded adjustable-height inserts may be configured for flush installation in a sandwich panel. Methods of installing such threaded adjustable-height inserts and adjusting the height of the same are also disclosed.