Ballistic-Resistant Panel Insert Assembly for Honeycomb Fastening
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Solution Overview
Problem
Existing panel attachment systems for aircraft honeycomb panels face issues with structural integrity, ease of installation, and safety due to limited structural capabilities and vulnerability to ballistic penetration, particularly at fastener locations, which compromise the integrity and security of aircraft components.
Innovation Solution
A ballistic-resistant panel insert and fastener system featuring a two-piece housing with a helical thread insert and diamond-etched plug body, combined with ballistic-resistant shields to enhance structural integrity and protect against ballistic penetration, utilizing materials like Kevlar or graphene for increased strength and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard fasteners are used to attach components to honeycomb panels, then installation is simple and cost-effective, but structural integrity and ballistic resistance are compromised
Solution Approach 1:
The fastener system is divided into separate components: a panel insert that attaches to the honeycomb panel and a fastener that attaches to the component. This segmentation allows each component to be optimized independently - the insert provides ballistic resistance while the fastener provides secure attachment, resolving the contradiction between strength and complexity.
Solution Approach 2:
The panel insert is constructed from composite materials including ballistic-resistant materials (such as aramid fibers or ultra-high molecular weight polyethylene) combined with structural materials. This composite construction provides both the required structural integrity and ballistic resistance without excessive complexity.
2Reliability
If ballistic-resistant materials are incorporated into the fastener system, then safety and ballistic resistance are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The ballistic-resistant panel insert is pre-manufactured and pre-attached to the honeycomb panel before final component assembly. This preliminary action allows the complex ballistic-resistant component to be manufactured separately using optimized processes, then simply inserted into the panel, reducing overall manufacturing complexity while maintaining high reliability.
3Strength
If floating inserts are used instead of through inserts, then panel structural integrity is maintained, but installation difficulty and epoxy waste increase
Solution Approach 1:
The floating insert design allows the insert to self-align and self-secure within the drilled hole through its floating mechanism. The insert automatically positions itself and secures without requiring precise epoxy application or complex installation procedures, maintaining panel integrity while simplifying installation and reducing epoxy waste.
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
The system provides improved structural integrity, ease of installation, and enhanced safety by reducing the risk of ballistic penetration, thereby enhancing the reliability and strength of aircraft components while reducing costs and assembly errors.
Implementation Method 1
a helical thread insert and diamond-etched plug body
Implementation Method 2
diamond-etched plug body
Implementation Method 3
utilizing materials like Kevlar or graphene for increased strength and safety
Data Source
AI summary
A ballistic resistant fastener having a ballistic resistant face plate includes a plurality of layers of aramid synthetic fibers or carbon nanotubes, a plug body having a threaded body bore extending into the body, a helical thread insert within the plug body, a bolt engaging the helical thread insert, and a bottom cup having a cup sidewall attached to the body.