Honeycomb Panel Insert Sealing to Reduce Filler Weight
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Solution Overview
Problem
The existing methods for fixing inserts in honeycomb sandwich panels result in excessive filler quantity, leading to increased weight, as the filler fills gaps between the panel components.
Innovation Solution
A panel processing method that involves using a sealer to close the gap between the bottom plate and the honeycomb core, preventing filler from accumulating below the plate, thereby reducing the required filler quantity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insert hole is filled with filler to fix the insert, then the insert is securely fixed to the honeycomb sandwich panel, but the quantity of filler increases leading to increased weight
Solution Approach 1:
The insert hole filling process is segmented into two distinct stages: first, a sealing material is applied to seal the gap between the insert and hole wall; second, filler is injected to fill the remaining cavity. This segmentation allows precise control over filler quantity while ensuring secure fixation, thereby reducing overall weight without compromising fixation reliability.
Solution Approach 2:
The gap sealing action is performed as a preliminary step before filler injection. By pre-sealing the gap between the insert and hole wall with sealing material, the system prevents filler leakage and ensures that subsequent filler injection fills only the necessary cavity space, thereby minimizing filler quantity and panel weight while maintaining fixation reliability.
2Strength
If a large quantity of filler is used to fill the insert hole, then the insert is firmly fixed, but the honeycomb sandwich panel becomes heavy
Solution Approach 1:
Different materials with distinct properties are applied to different locations within the insert hole: sealing material is applied locally to the gap between the insert and hole wall to provide sealing and initial bonding, while filler is injected into the central cavity to provide structural support. This local differentiation optimizes both fixation strength and weight reduction by using each material only where it is most effective.
Solution Approach 2:
The solution employs a composite approach by combining sealing material and filler in a single insert hole filling process. The sealing material provides adhesion and gap sealing, while the filler provides structural strength and rigidity. This composite material strategy achieves superior fixation strength with reduced overall material quantity, thereby reducing panel weight.
3Device complexity
If the gap between the bottom plate and honeycomb core is left open, then the structure is simpler, but the filler accumulates below the plate increasing weight
Solution Approach 1:
The gap sealing is performed as a preliminary action before filler injection by applying sealing material to the gap between the bottom plate and honeycomb core. This preliminary sealing prevents filler from accumulating below the plate, thereby eliminating the need for complex post-processing while achieving weight reduction through precise filler placement.
4Ease of manufacture
If manual sealing method is used to close the gap, then the process is simple, but the operation is difficult and time-consuming
Solution Approach 1:
A pushing plate is introduced as an intermediary tool to facilitate the sealing material application process. The pushing plate enables uniform and controlled application of sealing material into the gap between the bottom plate and honeycomb core, simplifying the operation while significantly improving efficiency by eliminating the need for difficult manual sealing operations.
Data Source
Figure 1
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AI summary
First, a bottom plate (111) is placed on a bottom portion of an embedding hole (103) formed in a honeycomb core (101). Subsequently, a sealer (113) for closing a gap between a side portion of the bottom plate (111) and a wall surface of the honeycomb core (101) is applied to an upper surface of the bottom plate (111). Then, a pushing plate (112) is pressed against the sealer (113). Consequently, the sealer (113) protrudes into the gap, so that the gap is closed with the sealer (113).