Lattice Potted-In Inserts for Stronger Sandwich Panel Bonding
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Solution Overview
Problem
Existing potted-in inserts for sandwich panels have a low weight rating due to poor bonding with the panel, making it difficult to secure heavy objects.
Innovation Solution
A potted-in insert with a lattice structure between its ends and along the shaft, designed to increase the bond strength with the potting compound and the sandwich panel, allowing for heavier objects to be secured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a smooth tubular shaft is used for the potted-in insert, then the manufacturing is simple, but the bond strength with the potting compound is poor
Solution Approach 1:
The insert employs a lattice structure with interconnected struts and nodes that creates a porous framework. This porous structure allows the potting compound to penetrate and bond with the insert at multiple points throughout the lattice, dramatically increasing the bond strength compared to a smooth surface. The porous material enables mechanical interlocking between the compound and insert structure.
Solution Approach 2:
The insert combines a lattice framework with potting compound to create a composite bonding system. The lattice structure provides a scaffold that, when filled and bonded with the potting compound, creates a composite material system with enhanced mechanical properties and bond strength that neither component could achieve alone.
2Strength
If air pockets occur during potting compound injection, then the installation process is simple, but the bond strength is reduced
Solution Approach 1:
The lattice structure's porous nature with interconnected voids allows the potting compound to flow through and fill the entire cavity uniformly. The compound can penetrate through the lattice framework, ensuring complete filling and eliminating air pockets that would otherwise form in a solid shaft configuration.
Solution Approach 2:
The lattice structure transforms the bonding interface from a two-dimensional surface contact (smooth shaft) to a three-dimensional volumetric interaction. The compound bonds throughout the volume of the lattice structure, providing multiple bonding pathways and ensuring complete filling even in complex geometries.
3Strength
If a lattice structure is added to the insert, then the bond strength increases, but the manufacturing complexity increases
Solution Approach 1:
The lattice structure parameters (strut thickness, node configuration, cell size) can be optimized and scaled based on the required bond strength and application requirements. This allows the same basic lattice design to be manufactured at different scales and with varying degrees of complexity to match specific manufacturing capabilities and performance requirements.
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 lattice structure enhances the bond strength between the insert and the potting compound, increasing the weight rating of the insert and enabling the secure attachment of heavier objects to the sandwich panel.
Implementation Method 1
The lattice structure has a plurality of interconnected unit cells each comprising struts connected at nodes to define voids between the struts. The voids are sufficiently large to receive therethrough a potting compound.
Implementation Method 2
The lattice structure enhances the bond strength between the insert and the potting compound
Data Source
Figure 1
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AI summary
Potted-in inserts are provided for use as attachment points for securing objects to sandwich panels. The potted-in inserts comprise a shaft having a first outer diameter, a first end having a second outer diameter that is greater than the first diameter, a second end having a third outer diameter, and an inner bore extending through the first end, the shaft, and the second end. The inner bore having an inner diameter. A lattice structure is between the first end and the second end and in an area adjacent the shaft between the first diameter and the second diameter. The lattice structure is fixed to the first end, the second end, and/or the shaft. The lattice structure has a plurality of interconnected unit cells each comprising struts connected at nodes to define voids between the struts. The voids are sufficiently large to receive therethrough a potting compound.