Composite Edge Insert for Trim Attachment
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Solution Overview
Problem
Existing methods for attaching objects to composite objects with honeycomb or foam cores often result in misalignment, increased weight, and reduced structural integrity, and require additional processing time and effort, while bonding trim to these objects is time-consuming and inefficient.
Innovation Solution
An insert with a structure and attachment features is positioned within a hollow portion of the composite object, spanning its thickness, and adhesively bonded to ensure precise alignment and attachment of additional objects or trim without compromising the structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bracket is installed at the edge of the composite object to attach another object, then the attachment function is achieved, but the shape of the outer surfaces is changed in an undesired manner and the evenness is compromised
Solution Approach 1:
The patent introduces a bracket as an intermediary component that attaches to the composite object at its edge rather than directly modifying the outer surfaces. The bracket spans across the edge and provides attachment points for additional objects, thereby achieving the attachment function while preserving the original shape and evenness of the outer surfaces of the composite object.
2Ease of operation
If a cylindrical insert is used to install a fastener at the edge of the composite object, then the attachment is achieved, but the hole formed in the core layer is rougher than desired requiring additional processing
Solution Approach 1:
The patent employs a cylindrical insert that is pre-installed into a hole formed in the core layer of the composite object. The insert serves as a preliminary preparation that facilitates subsequent fastener installation. By using the insert as an intermediate step, the system achieves easier fastener installation while the insert itself is designed to maintain sufficient alignment precision without requiring excessive additional processing of the hole.
3Ease of operation
If a cylindrical insert is used to attach a fastener to the composite object, then the attachment function is achieved, but the overall weight of the composite object increases more than desired
Solution Approach 1:
The patent utilizes a cylindrical insert that serves as a temporary or sacrificial component during the attachment process. The insert is designed to be relatively lightweight and simple in structure, providing the necessary attachment function while minimizing weight addition. In some implementations, the insert may be designed to remain as part of the final assembly with acceptable weight characteristics, or it may be designed as a disposable component that facilitates attachment without requiring long-term structural integrity.
4Ease of operation
If a hole is formed within the core layer of material to install a fastener, then the attachment is achieved, but the structural integrity of the core layer is reduced
Solution Approach 1:
The patent introduces a cylindrical insert as an intermediary component that is installed into a hole in the core layer. The insert serves as a mediator between the hole and the fastener, distributing loads and reinforcing the area around the hole. This intermediary structure helps maintain the structural integrity of the core layer while still enabling fastener installation, as the insert provides additional material strength around the hole perimeter and distributes mechanical loads more effectively than a bare hole would.
5Object-affected harmful factors
If trim is bonded to the edge of the composite object to cover exposed honeycomb material, then the edge protection is achieved, but the bonding process is more time-consuming than desired
Solution Approach 1:
The patent introduces a retainer as an intermediary component that is bonded to the edge of the composite object, which then receives and holds the trim member. The retainer serves as a mediator between the composite object and the trim, providing a dedicated attachment structure that simplifies the overall process. The retainer can be designed with features such as clips, slots, or interference fits that enable quick and easy installation of the trim member without requiring time-consuming bonding operations, while still achieving comprehensive edge protection and trim retention.
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
This method allows for efficient and precise attachment of objects to composite materials without compromising structural integrity, reducing processing time and weight, and enabling quick installation of trim without full bonding.
Implementation Method 1
adhesively bonded to ensure precise alignment and attachment
Data Source
AI summary
A method and apparatus for associating an edge of a first object with a second object using an insert. In one illustrative embodiment, an apparatus comprises a structure and a number of attachment features associated with the structure. The structure is configured to be inserted within a hollow portion of the first object at an edge of the first object. The structure is further configured to span an entire thickness of the first object at the edge of the first object. The number of attachment features is configured for use in attaching the second object to the structure to attach the second object to the edge of the first object.