Composite Insert Assembly for Damage-Free Panel Installation

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Solution Overview

Problem

The existing methods for assembling two-part inserts in components, such as those used in airplane panels with supporting cores, are inefficient, difficult to perform, and prone to damaging the panels, especially when installing components in confined spaces like aircraft.

Innovation Solution

A method involving a sleeve element and an insert element, where the sleeve is arranged in a bore of the component, connected with the insert to form a composite element, and an engagement apparatus is used to align and assemble them, introducing a preloaded force to secure the composite element, which can be reproducible and damage-free.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a hammer or stationary press is used to assemble two-part inserts at a component, then the insert can be joined, but the panel with supporting core is easily damaged

Engineering Contradiction:

Improvejoining strengthVSAvoidpanel damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a sleeve element as an intermediary component that fits into a bore of the panel and receives the insert element. This mediator allows the insert to be secured without directly impacting the panel structure, thereby preventing damage while achieving secure joining. The sleeve acts as a buffer between the assembly tools and the delicate panel.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the traditional mechanical system of hammering or pressing directly on the panel with a new mechanical system involving the sleeve element and insert element. The joining force is applied to the insert element within the sleeve rather than directly to the panel, substituting a damaging mechanical action with a protected mechanical action.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If traditional methods are used to assemble inserts in airplane panels, then joining is achieved, but the assembly process is difficult and time-consuming

Engineering Contradiction:

Improvejoining strengthVSAvoidassembly efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent segments the insert into two separate elements: a sleeve element that remains in the panel bore and an insert element that is inserted into the sleeve. This segmentation allows for easier handling and assembly, as each element can be positioned independently without requiring complex tooling or multiple operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements a nested structure where the insert element is placed inside the sleeve element, which itself is positioned in the panel bore. This nesting arrangement simplifies the assembly process by allowing components to be sequentially inserted without requiring disassembly or complex alignment procedures.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Manufacturing precision

If components are installed in confined spaces like aircraft, then the installation must be precise, but traditional assembly methods are not feasible

Engineering Contradiction:

Improveinstallation precisionVSAvoidassembly accessibility

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent applies preliminary action by pre-positioning the sleeve element in the panel bore before inserting the insert element. This preparatory step ensures proper alignment and positioning is established beforehand, allowing for precise final assembly without requiring complex adjustments in confined spaces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces dynamic elements through the engagement apparatus that can be inserted and removed flexibly. The apparatus allows for alignment and securing of the insert element with controlled movement, enabling precise assembly in confined spaces where static tools would be ineffective.

Inventive Principle:

Principle #15Dynamics

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 enables efficient, safe, and fast joining of composite elements, reducing the risk of panel damage and ensuring consistent assembly, even in challenging environments like the aerospace industry, without requiring special tools.

Implementation Method 1

The engagement apparatus introduces a preloaded force into the at least one composite element

Methodology Applied

Scientific EffectPreloaded force: Force

Data Source

PatentUS11073173B2Arranging a composite element at a component

Publication Date: 2021.07.27 ELBE FLUGZEUGWERKE GMBH

AI summary

Disclosed here is a method for arranging at least one composite element at a component. The composite element includes a sleeve element and an insert element. The method involves: arranging the sleeve element in a bore of the component; connecting the sleeve element and the insert element so that a composite element is formed; inserting an engagement apparatus in the composite element, wherein the engagement apparatus aligns and/or assembles the sleeve element and the insert element to each other. Also disclosed here is use of an engagement apparatus and at least one composite element for arranging the composite element at a component. The at least one composite element includes a sleeve element and an insert element. The engagement apparatus aligns and/or assembles the sleeve element and the insert element to each other.