Honeycomb Panel Fastener With Snap-In Load Attachment
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Solution Overview
Problem
Honeycomb cored sandwich panels face challenges in carrying concentrated unit loading due to their inherent structural limitations, with existing fastening techniques being heavy, difficult to implement, non-customizable, and requiring special training, while also compromising the panel's weight benefits and core material integrity.
Innovation Solution
A snap-in honeycomb panel fastener system that includes an insert pillar, clip, base plate, support ring, spring, prong ring, retainer latch, and top insert, which locks into place easily and minimizes added weight, featuring a design that prevents rotation and ensures easy assembly and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid sectional fillers (epoxy or wooden blocks) are used to create mounting points, then structural load attachment is achieved, but the panel weight increases and core material is removed weakening the panel
Solution Approach 1:
The fastener is divided into multiple components: a hollow cylindrical body, a separate conical frustum insert, and a fastening element. This segmentation allows the hollow body to maintain panel weight benefits while the insert provides structural attachment capability when needed.
Solution Approach 2:
The fastener uses composite construction combining a hollow cylindrical body (maintaining honeycomb structure) with a conical frustum insert (providing attachment). This composite approach achieves structural attachment without requiring solid fillers that would compromise panel weight.
2Strength
If threaded inserts pressed into place with epoxy are used, then fastening capability is achieved, but the fastener is heavy and requires the insert to be held until epoxy sets
Solution Approach 1:
The invention replaces the epoxy chemical bonding system with a mechanical expansion system. The conical frustum insert expands mechanically within the hollow body to create friction-based anchoring, eliminating the need for epoxy and the associated installation complexity of holding inserts until curing.
3Strength
If mechanical fasteners with conical flanges are used, then attachment is achieved, but the fasteners are heavy and require special training to install properly
Solution Approach 1:
Instead of deforming the panel skin around the fastener (traditional approach), the invention inverts the approach by having the fastener body deform the honeycomb core material around itself during insertion. The hollow cylindrical body is inserted first, then the conical frustum expandstod deform and anchor within it, reversing the traditional deformation sequence and reducing installation complexity.
4Ease of operation
If panel apertures are bored through skin and core for fastener installation, then fastening is enabled, but the panel's structural integrity and weight benefits are compromised
Solution Approach 1:
The fastener creates a localized attachment zone within the honeycomb core rather than requiring extensive material removal. The hollow cylindrical body and conical frustum insert concentrate the fastening function in a small local region, preserving the overall panel structural integrity and weight benefits while enabling fastening at the specific location needed.
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 fastener system effectively addresses the limitations of previous methods by providing easy installation, reduced weight addition, and improved stress distribution, while maintaining the panel's structural integrity and weight benefits.
Implementation Method 1
a spring between the base plate and the top insert, which when compressed in an axial direction, causes deformation away from the axis of the spring
Data Source
AI summary
A fastener for attachment to a panel, having an inner skin and an outer skin, via a panel aperture in the outer skin. The fastener including an insert pillar, a base plate, a spring, and a top insert arranged and configured to allow longitudinal compression of the spring resulting in movement and deflection of components to promote ease of use, security, and durability.