Flanged Panel Insert Carrier for High Pullout Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional panel inserts in spacecraft and satellite buses are prone to pullout failures, leading to costly repairs or replacements, and limit design flexibility due to their destructive removal and low load capacity, necessitating excessive use and increased weight, which complicates design changes and manufacturing.
Innovation Solution
The introduction of panel insert carriers with flanged ends and standardized thread patterns allows for universal mounting of various panel inserts, enhancing pull-out resistance and enabling repeated removal and insertion to accommodate changing design requirements, supporting multiple types and sizes of fasteners and components without panel redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional panel inserts are used for mounting components to panels, then mounting capability is provided, but pullout failure occurs frequently leading to panel destruction and costly repairs
Solution Approach 1:
The system divides the mounting function into two separate components: a reusable carrier that remains permanently installed in the panel, and removable panel inserts that can be extracted and replaced. This segmentation prevents damage to the panel and carrier when inserts are removed or replaced, eliminating the need for costly panel repairs while maintaining reliable mounting capability.
Solution Approach 2:
The carrier acts as an intermediary component between the panel and the panel inserts. It provides a standardized interface that accepts various inserts while protecting the panel from damage during insert installation and removal. The carrier's internal threading and structural design distribute loads to prevent panel material failure, thereby improving reliability without compromising repairability.
2Adaptability or versatility
If conventional panel inserts are used to accommodate design changes, then mounting is provided, but design flexibility is limited due to destructive removal requirements
Solution Approach 1:
The system enables dynamic reconfiguration of panel mountings by allowing inserts to be easily removed and replaced without damaging the carrier or panel. Design changes can be accommodated by simply swapping inserts rather than removing and reinstalling entire panel assemblies, providing adaptability while maintaining manufacturing simplicity through standardized carrier designs.
Solution Approach 2:
The carrier is designed with universal compatibility to accept multiple types and sizes of panel inserts through a standardized interface. This multi-functionality allows a single carrier design to support various mounting configurations and design changes, enhancing adaptability without requiring custom-manufactured carriers for each application.
3Reliability
If more panel inserts are used to mitigate pullout failure, then reliability is improved, but weight and cost increase
Solution Approach 1:
The solution extracts the weak link (the panel insert-material interface) from the load path by introducing a carrier that remains permanently installed in the panel. The carrier's flanged ends and internal structure distribute mounting loads across a larger area of the panel, preventing pullout failure without requiring multiple inserts. This reduces the total number of inserts needed, thereby reducing weight while maintaining or improving reliability.
Data Source
AI summary
Provided herein are various enhancements for panel inserts which can provide for mounting of threaded fasteners or other mounting members into various panels. In one example, a panel insert carrier comprises a barrel having flanged ends. The barrel comprising an axial bore therein having a threaded surface configured to removably accept a threaded insert. At least one of the flanged ends comprises an aperture for injection of potting around an exterior of the barrel when inserted into a bore hole of a panel.