Lattice Potted-In Inserts for Stronger Sandwich Panel Bonding
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Solution Overview
Problem
Current potted-in inserts for sandwich panels lack sufficient bonding strength and weight rating to securely attach heavy objects, due to smooth tubular shafts and potential air pockets during installation.
Innovation Solution
A potted-in insert with a lattice structure between its ends, featuring interconnected unit cells with voids to enhance bonding with the potting compound, produced using additive manufacturing to ensure robust attachment to sandwich panels.
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 bonding strength with the potting compound is insufficient
Solution Approach 1:
The patent applies a lattice structure with interconnected struts and voids to the potted-in insert shaft. This porous configuration allows the potting compound to penetrate deeply into the insert structure, creating extensive bonding surfaces throughout the lattice framework rather than just on the outer surface, thereby significantly enhancing bonding strength.
Solution Approach 2:
The patent transitions from a traditional solid or smooth-tubular shaft to a three-dimensional lattice structure. This dimensional transformation creates multiple levels of bonding interfaces at different depths and orientations, allowing the potting compound to bond in three dimensions throughout the insert volume rather than merely on a two-dimensional surface.
2Strength
If a traditional potted-in insert is used, then the installation process is simple, but the weight rating is too low for securing heavy objects
Solution Approach 1:
The lattice structure's porous framework provides mechanical interlocking with the potting compound while maintaining structural integrity. The interconnected struts distribute loads throughout the entire insert body, enabling the assembly to support heavier weights compared to solid or smooth-tubular designs.
Solution Approach 2:
The patent creates a composite bonding system where the lattice structure (insert material) works in conjunction with the potting compound to form an integrated load-bearing assembly. This composite approach combines the structural framework of the lattice with the bonding and filling properties of the potting compound to achieve high weight ratings.
3Reliability
If the potting compound does not entirely fill the cavity surrounding the tubular shaft, then the installation is faster, but air pockets occur that reduce bonding quality
Solution Approach 1:
The lattice structure's open cellular framework acts as a capillary network that actively draws in and guides the potting compound during injection. The porous geometry ensures complete filling of the insert structure, eliminating air pockets and voids that would compromise bonding quality, while the structured flow path maintains efficient installation speed.
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 increases bond strength and weight rating, allowing for secure attachment of heavy objects by ensuring complete filling and embedding of the potting compound, reducing the likelihood of insert movement and enhancing installation reliability.
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 voids are sufficiently large to receive therethrough a potting compound.
Data Source
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.