Honeycomb Panel Insert With Floating Nut and Integrated Closed End
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Solution Overview
Problem
Existing honeycomb core panel inserts for commercial aircraft require complex alignment and separate end caps for securing fasteners, which complicates assembly and reduces structural integrity due to the presence of a cap as the weakest element.
Innovation Solution
A clam-shell like housing formed of two identical halves with snap-fit engagement and integrated potting holes, eliminating the need for a separate cap and enhancing structural strength by maximizing material distribution in critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate end cap is used to close the distal end of the bore, then the housing can be assembled, but the structural strength is reduced due to the cap being the weakest element
Solution Approach 1:
The patent combines the housing and end cap into a single integrated clam-shell like structure formed by joining two identical halves. This eliminates the separate end cap component, removes the weakest element from the assembly, and maximizes material distribution in critical areas while maintaining the closed bore structure.
2Ease of operation
If traditional fastener inserts are used requiring alignment of screw with female threads, then the fastening function is achieved, but the assembly process becomes complicated
Solution Approach 1:
The patent employs a floating nut mechanism where the female threaded portion can move dynamically within the housing to self-align with the male threaded screw. This dynamic adjustment eliminates the need for precise pre-alignment during assembly, simplifying the operation and reducing assembly time while ensuring proper engagement.
3Ease of manufacture
If two identical halves are joined to form the housing, then manufacturing efficiency is improved through single die set, but the housing structure becomes more complex
Solution Approach 1:
The patent divides the housing into two identical halves that can be manufactured separately using a single injection mold die set, improving manufacturing efficiency. The halves are then joined through snap-fit engagement of pegs and holes to form the complete clam-shell like structure, balancing manufacturing benefits with structural requirements.
Data Source
AI summary
A honeycomb sandwich panel insert includes a housing defined by two identical halves which when joined together form a distal flange having opposed potting holes, and a central internal bore, integrally formed laterally extending member when joined forms a tight closed distal end of said bore. The honeycomb sandwich panel insert further includes a nut disposed within the internal bore of the housing and configured to float therein.