Honeycomb Composite Insert Venting for Overlay Pressure Equalization
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Solution Overview
Problem
Trapped air within composite structure assemblies, such as those with honeycomb cores, causes pressure imbalances that lead to distortion of overlays during flight, creating hazards and obstructions due to the difference in air pressure between the trapped air and external pressure.
Innovation Solution
A fastener assembly with a receptacle and base that includes a channel and vent opening, allowing air to escape and equalize pressure, comprising a receptacle with a sidewall defining a channel extending from a first opening to a second opening, and a base connected to the second opening, with a fastener having a head and shaft that secures the assembly while forming a flow path through the vent opening, channel, and base bore to reduce internal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hole is sealed air tight with the fastener bracket and overlay during installation, then the composite structure assembly is securely installed and sealed, but air pressure imbalance causes overlay distortion during flight
Solution Approach 1:
The patent applies a porous sealant material that allows trapped air to slowly escape through the sealed hole while maintaining an effective air tight seal against external pressure. The porous structure enables selective permeability - blocking external air ingress while allowing internal trapped air to vent, thereby preventing pressure buildup and overlay distortion during flight.
Solution Approach 2:
The patent introduces a porous sealant as an intermediary substance between the fastener bracket and overlay that mediates the conflicting requirements of seal integrity and pressure equalization. This intermediary material creates a selective barrier that maintains structural sealing while permitting controlled air escape, resolving the contradiction between sealed integrity and overlay flatness.
2Object-affected harmful factors
If the overlay is adhered to seal closed the hole, then the composite structure assembly is protected, but the overlay bulges and creates hazards during flight
Solution Approach 1:
The porous sealant material allows trapped air to escape through the sealed hole, preventing pressure-induced overlay bulging that creates walking hazards. Simultaneously, the same porous structure maintains effective sealing against external factors, thus eliminating the contradiction between protection and hazard prevention.
3Shape
If pressure equalization is achieved, then overlay distortion is prevented, but the seal must allow air passage which compromises air tightness
Solution Approach 1:
The porous sealant creates a selective barrier that appears solid and maintains air tight sealing against external pressure, while its porous internal structure allows trapped air molecules to slowly diffuse and escape. This enables simultaneous achievement of overlay flatness through pressure equalization and seal integrity against external factors.
Solution Approach 2:
The sealant exhibits different functional qualities at different scales - at the macro level it appears solid and maintains air tight sealing, while at the micro level its porous structure allows air passage. This local quality differentiation enables the seal to simultaneously prevent external air ingress while allowing internal air escape.
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
The solution effectively balances air pressures, preventing overlay distortion and maintaining a flattened position during flight by allowing trapped air to escape, thus mitigating hazards and obstructions.
Implementation Method 1
the air pressure exerted against the overlay from outside of the composite structure assembly is reduced relative to the air pressure that is trapped within the air tight sealed hole. The relatively higher air pressure within the hole causes the overlay to be deformed and bulge
Data Source
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AI summary
A fastener assembly (10) includes a base (12) which defines a bore (14) which extends through the base. The fastener assembly further includes a receptacle (16) wherein the receptacle includes a sidewall (18) wherein the sidewall defines a channel (20) which extends through the receptacle. The channel extends from a first opening (22) defined by the sidewall to a second opening (24) defined by the sidewall and the sidewall is connected to the base wherein the second opening aligns with the bore of the base. The sidewall of the receptacle defines a vent opening (26) which extends through the sidewall. The receptacle and the base define a flow path through the vent opening of the sidewall, through the channel of the receptacle, through the second opening of the sidewall of the receptacle and through the bore of the base.