Composite Sandwich Panel Fastener Insert Without Adhesive Potting
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Solution Overview
Problem
The existing methods for attaching components to composite sandwich panels, such as using potted fastener inserts, are hindered by long adhesive cure times, increasing production time and cost.
Innovation Solution
A fastener insert that mechanically secures to a composite sandwich panel without potting, featuring a base with a central cavity and a fastener carrier that engages via snap-fit locking features, eliminating the need for adhesive curing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive potting is used to attach fastener inserts to composite sandwich panels, then reliable mechanical attachment is achieved, but production time increases due to long adhesive cure times (90 to 240 minutes)
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive potting) with a mechanical fastening system. The fastener insert includes a base with locking features that mechanically engage with the composite sandwich panel through snap-fit engagement, eliminating the need for adhesive curing time while maintaining secure attachment.
Solution Approach 2:
The fastener insert is divided into separate components: a base portion that engages with the panel and a fastener carrier that attaches to the base. This segmentation allows for pre-assembly of the base with the panel, and subsequent quick attachment of the fastener carrier, thereby reducing overall production time while ensuring reliable connection.
2Strength
If adhesive potting is used to attach fastener inserts, then secure fastening is achieved, but assembly complexity and cost increase due to curing requirements
Solution Approach 1:
The patent replaces the complex chemical process of adhesive application and curing with a simple mechanical snap-fit engagement system. The locking features on the base and fastener carrier engage through straightforward mechanical motion, eliminating the need for controlled curing environments, temperature management, and quality inspection of adhesive bonds.
Solution Approach 2:
The fastener insert design incorporates self-aligning and self-locking features that automatically ensure proper engagement during assembly. The snap-fit mechanism provides inherent feedback when properly engaged, eliminating the need for complex assembly procedures, specialized training, or extensive quality control measures.
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 solution enables quicker and more efficient assembly processes by eliminating the need for adhesive curing, reducing production time and costs while maintaining secure attachment.
Implementation Method 1
The mechanical engagement may be a snap-fit engagement of the first and second locking features. As used herein, components 'snap-fit' to one another when a feature of one resiliently flexes and locks to a feature of the other during movement of one of the components toward the other component
Data Source
AI summary
A fastener insert for securement to a composite sandwich panel at an opening in the composite sandwich panel includes a base and a fastener carrier. The base has a body and a flange integral with the body. The flange extends laterally outward of an outer perimeter of the body. The base defines a central cavity extending entirely through both the body and the flange. The base includes a first locking feature disposed at the central cavity. The fastener carrier is configured to insert into the central cavity of the base. The fastener carrier defines a fastener opening and has a second locking feature configured for mechanical engagement with the first locking feature of the base to retain the fastener carrier to the base. A panel assembly and a method of fastening a component to a composite sandwich panel utilize the fastener insert.