Honeycomb Panel Fastener Integration via Intumescent Adhesive
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Solution Overview
Problem
Existing methods for fabricating honeycomb structured panels with fastener elements for vehicle cabins, such as aircraft floors, require multiple fabrication steps, leading to lengthy processes and potential weakening of the panel structure, while also facing challenges in uniformly distributing sealant mixtures and controlling heating times for adhesion.
Innovation Solution
A method that integrates the fabrication of honeycomb panels with fastener elements in a single process by cutting out orifices in the outer walls and core, applying intumescent adhesive, and polymerizing the assembly under vacuum, eliminating the need for sealant mixtures and reducing tooling complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastener elements are incorporated in a second fabrication step after panel assembly, then the panel structure is not weakened during core placement, but the fabrication process becomes lengthy and requires multiple steps
Solution Approach 1:
The method applies preliminary action by cutting orifices in the outer walls and core, and positioning fastener elements within the core during the first fabrication step before the adhesive sets. This allows fastener elements to be incorporated during the initial panel assembly rather than requiring a separate second fabrication step, thereby reducing total fabrication time while maintaining structural integrity through proper adhesive distribution.
2Reliability
If sealant mixture is injected to fill space between fastener element and core, then adhesion is improved, but uniform distribution of sealant is difficult to achieve
Solution Approach 1:
The method applies preliminary action by pre-coating the fastener element with adhesive before insertion into the core, and by pre-positioning the fastener element within the core during the first fabrication step. This eliminates the need for subsequent sealant injection, ensuring uniform adhesive distribution from the outset and improving both adhesion reliability and manufacturing precision.
Solution Approach 2:
The method substitutes the mechanical injection process of sealant mixtures with a controlled adhesive coating application process. By applying adhesive as a coating before fastener insertion rather than injecting sealant afterward, the system replaces a difficult-to-control mechanical injection process with a more precise coating process, achieving uniform distribution and reliable adhesion.
3Strength
If heating is applied to polymerize adhesive, then bonding strength is improved, but heating time control becomes critical and complex
Solution Approach 1:
The method applies parameter changes by optimizing the adhesive formulation to achieve proper polymerization and bonding strength through controlled heating parameters. By carefully selecting and controlling heating temperature and duration parameters during the first fabrication step, the method achieves reliable adhesive bonding without requiring complex heating control systems, balancing bonding strength with system simplicity.
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
This approach allows for the efficient and robust incorporation of fastener elements within the panel during fabrication, reducing fabrication time and ensuring the panel's structural integrity while avoiding the risks associated with multiple steps and sealant distribution issues.
Implementation Method 1
The assembly is polymerized while hot so as to secure the core to the bottom and top outer walls on either side thereof
Implementation Method 2
sucking out the particles that remain in the cavities of the core that open out into said stripped-out space
Data Source
AI summary
A method of fabricating a panel (1) comprising a core (10) made of honeycomb material provided with a plurality of cells (13) and encased by top and bottom outer walls (20, 30), which method comprises, during a preparation stage (P1): fabricating the top outer wall (20); fabricating the bottom outer wall (30); fabricating said core (10), and perforating one internal orifice (11) per fastener element (50) in said core (10) so as to provide a space (12) for receiving said fastener element (50); and then coating at least one layer of a film of an intumescent adhesive (60) on a connection side wall (51) of said fastener element (50) that is to be connected to said core (10). After performing an assembly stage on a bench (70), the assembly comprising the top outer wall (20), the core (10) provided with said fastener element (50), and the bottom outer wall (30) is polymerized in order to obtain said panel (1) provided with said fastener element (50).