Air Gap Mounting Insert for Sandwich Panel Dents
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Solution Overview
Problem
Existing methods for inserting and fixing mounting inserts into lightweight sandwich panels often result in unsightly dents on the opposite cover layer due to the transmission of tensile forces through the adhesive, which penetrates the core layer and causes deformation.
Innovation Solution
A method involving a recess in the core layer that does not fully penetrate, with an air gap between the mounting insert and the recess bottom, decoupling the tensile force and preventing deformation, along with a mounting insert design featuring a collar and optional support section for additional anchoring and force redirection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesive fills the entire borehole and penetrates into the honeycomb structure up to the opposite cover layer, then the mounting insert is securely fixed, but tensile forces are transmitted to the opposite cover layer causing dents
Solution Approach 1:
The adhesive bonding process is segmented into two distinct zones: a first region where adhesive fills the space between the mounting insert and borehole wall for secure fixation, and a second region near the opposite cover layer where the adhesive is prevented from penetrating. This segmentation is achieved by controlling adhesive application to stop before reaching the opposite cover layer, or by using a barrier element, thereby breaking the continuous force transmission path that causes dents while maintaining reliable fixation in the first region
Solution Approach 2:
A barrier element or controlled adhesive stop introduces an intermediary that blocks the transmission of tensile forces from the mounting insert through the adhesive to the opposite cover layer. This intermediary prevents the harmful force transmission while allowing the adhesive to perform its primary function of securing the mounting insert in the first region, thus resolving the contradiction between fixation security and dent prevention
2Strength
If adhesive is applied to fully bond the mounting insert, then fixation strength is improved, but the adhesive transmits tensile forces causing deformation of the opposite cover layer
Solution Approach 1:
The adhesive bonding is segmented spatially into a first region with full adhesive bonding for strength, and a second region near the opposite cover layer where adhesive is excluded or blocked. This ensures strong fixation where needed while preventing force transmission that causes deformation, resolving the contradiction between bonding strength and shape preservation
Solution Approach 2:
Different adhesive bonding qualities are applied to different regions: strong complete bonding in the first region for fixation strength, and no bonding or blocked bonding in the second region near the opposite cover layer to prevent deformation. This local differentiation of bonding quality resolves the contradiction between overall strength and local shape preservation
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
Prevents the formation of dents by decoupling the tensile force from the opposite cover layer, maintaining the structural integrity and appearance of the lightweight sandwich panel.
Implementation Method 1
The mounting insert is inserted into the recess and fixed by means of adhesive bonding
Implementation Method 2
an air gap remains between an end face of the recessing section that points towards the bottom of the recess and the bottom of the recess, and where no adhesive is placed into the air gap
Data Source
AI summary
A method for Inserting and fixing a mounting insert into a lightweight sandwich panel. The panel comprises a core layer and two cover layers that are applied to opposing main surfaces of the panel. A recess extends into the depth of the core layer of the panel. The mounting insert is inserted into the recess and is adhesively bonded therein. The bottom of the recess extends to a depth of the core layer material that extends further than the longitudinal extension of the recessing section to be inserted. When adhesively bonding the mounting insert, an air gap remains between an end face of the recessing section and the bottom of the recess. No adhesive is placed into the air gap. The air gap ensures a decoupling so that any applied tensile forces are no longer transferred to the cover layer opposite and the undesired formation of dents is avoided.