Composite Sandwich Panel Insert Anchorage via Symmetric Cut-outs
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Solution Overview
Problem
Current methods for anchoring components in composite sandwich panels are labor-intensive, inefficient, and prone to adhesive errors, making it difficult to achieve safe and strong load application, especially under dynamic conditions like those experienced in aerospace applications.
Innovation Solution
A composite sandwich panel design featuring rotationally symmetric cut-outs and inserts that allow for form-fitting and force-fitting, reducing the need for tools and aids, with a method that includes cutting concentric inner and outer cut-outs in the panel to create a support structure for stable insert placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If inserts are mounted using auxiliary plates and adhesive bonding, then anchorage strength is improved, but production time increases to up to 48 hours and process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the sandwich panel at the desired insert locations before assembly. These recesses are created by removing core material and face sheet portions, allowing inserts to be directly received and secured with adhesive without requiring auxiliary plates or lengthy curing processes. The preparatory recess formation enables rapid insert installation while maintaining strong anchorage.
2Reliability
If inserts are mounted using auxiliary plates and adhesive, then anchorage reliability is improved, but risk of adhesive leakage and insert damage increases
Solution Approach 1:
The patent extracts the auxiliary plate from the mounting process entirely. By creating recesses that directly receive inserts within the sandwich panel structure, the method eliminates the need for separate auxiliary plates. This removal of the auxiliary component prevents adhesive leakage issues and eliminates the risk of insert stress or damage during plate removal, while still achieving reliable anchorage through direct adhesive bonding in the recesses.
3Manufacturing precision
If precise alignment of inserts with cut-outs is required, then anchorage precision is improved, but automation becomes impossible or very costly
Solution Approach 1:
The patent applies self-service through self-aligning features integrated into the insert and recess design. The recesses include alignment surfaces and the inserts incorporate corresponding alignment elements such as protrusions or tapered portions. When inserts are inserted into the recesses, these features automatically guide and position the inserts with high precision without requiring external alignment tools or complex automated positioning systems, enabling cost-effective automation.
4Strength
If labor-intensive production processes with various tools are used, then anchorage quality is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges multiple manufacturing operations into integrated steps. The recess formation process combines core material removal and face sheet portion removal in a single preparatory operation. The insert installation combines positioning, alignment, and adhesive bonding in one action. This consolidation of steps into fewer integrated operations maintains high anchorage quality while dramatically simplifying the manufacturing process and reducing the number of tools required.
Data Source
Figure 1~2B
Figure 2C~3A
Figure 3B~3C
AI summary
A lightweight support structure (1) comprising a composite sandwich panel (5) having a first face sheet (10) and a lightweight core (15) attached to the face sheet (10) and an essentially rotationally symmetric cut-out (30) extending through the first face sheet (10) and into said lightweight core (15), the cut-out (30) comprising an essentially rotationally symmetric inner cut-out (31) and an essentially rotationally symmetric outer cut-out (32) arranged essentially concentric with respect to each other, providing for a support (40) inbetween, said support (40) comprising a core support (41) cut from said lightweight core (15) and a support face sheet disc (42) on top, cut from of said first face sheet (10), wherein a rotationally symmetric insert (50) is fitted into said cut-out (30) for load application and/or anchorage of various components into, respectively onto the composite sandwich panel (5).