Two-Part Threaded Insert Structure for Stronger Composite Panels
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Solution Overview
Problem
Current methods for installing threaded inserts in composite panels result in limited pull-out strength and poor force transfer due to the lack of panel skin coverage on the external face of the insert, and require additional processing steps and materials, including the potential for potting compound entering the threaded hole, which can render it unusable.
Innovation Solution
A composite panel design featuring a two-part insert where the first insert piece is bonded to both the core and the panel skins, with the second insert piece attached via a mechanical interlock, such as a screw fit or snap-fit, to create a threaded hole for fasteners, eliminating the need for potting compound and ensuring better attachment and force transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cavity is formed through the panel skin to install the threaded insert, then the insert can be housed in the core, but the pull-out strength is limited and force transfer is poor
Solution Approach 1:
The threaded insert is divided into two separate pieces: a first insert piece that fits within the cavity in the core, and a second insert piece that extends through the panel skin. This segmentation allows the first piece to be securely housed in the core while the second piece provides external engagement, thereby improving pull-out strength without requiring complex processing.
Solution Approach 2:
The threaded insert transitions from a single-piece design to a two-piece design that extends in multiple dimensions - the first piece within the core cavity and the second piece through the panel skin to the external face. This dimensional extension improves force transfer and pull-out strength by distributing loads across both the core and panel skin.
2Reliability
If potting compound is used to secure the insert, then the insert can be bonded to the core, but the compound may enter the threaded hole and require reworking
Solution Approach 1:
The threaded hole is extracted from the insert piece that is potted in the core, and instead provided on a separate second insert piece that extends through the panel skin. This extraction prevents potting compound from entering and blocking the threaded hole, eliminating the need for reworking while maintaining reliable attachment.
Solution Approach 2:
The second insert piece acts as an intermediary element that provides the threaded hole function separately from the potted first insert piece. This mediator approach allows the bonding function and threading function to be performed by separate components, preventing contamination of the threaded hole while ensuring reliable attachment.
3Ease of operation
If the cavity extends through the panel skin, then the insert can be accessed from both sides, but the external face of the insert lacks panel skin coverage
Solution Approach 1:
The insert is segmented into two pieces positioned at different locations - the first piece within the core cavity and the second piece extending through the panel skin to the external face. This segmentation allows the external face of the second piece to be covered by panel skin, improving force transfer while maintaining accessibility through the through-aperture.
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 design enhances the pull-out strength and force transfer of the threaded insert by bonding it securely to both panel skins, reduces processing complexity, and prevents bonding material from entering the threaded hole, making the insert more reliable and efficient to use.
Implementation Method 1
a first bonding material bonds the first panel skin to the core and the first bonding material bonds the first panel skin to the first face of the first insert piece
Data Source
Figure 1~2b
Figure 2c~2d
Figure 3
AI summary
A composite panel (200) comprising a first panel skin (202), a second panel skin (203) and a core (201) arranged between the first panel skin (202) and the second panel skin (203). The composite panel (200) having a threaded insert for receiving a fastener, the threaded insert arranged within a cavity of the core (201) of the composite panel (200).