Rotationally Symmetric Insert Anchorage for Composite Sandwich Panels
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Solution Overview
Problem
Current methods for anchoring components in composite sandwich panels are labor-intensive, inefficient, and prone to damage due to the need for various tools and precise alignment, especially under high loads and vibrations in aerospace applications.
Innovation Solution
A lightweight support structure with a composite sandwich panel featuring rotationally symmetric cut-outs and inserts that allow for safe and strong anchorage, reducing the need for tools and aids through form-fitting and force-fitting, enabling precise alignment and stabilization of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional auxiliary plate methods are used for insert mounting, then adhesive bonding can be achieved, but the process becomes labor-intensive and time-consuming (up to 48 hours)
Solution Approach 1:
The invention extracts and removes the auxiliary plate from the mounting process entirely. The insert is designed with a tapered portion that directly fits into a corresponding tapered cutout in the sandwich panel, eliminating the need for auxiliary plates and reducing mounting time from 48 hours to a simple insertion operation.
Solution Approach 2:
Instead of using an auxiliary plate to hold the insert during insertion, the invention inverts the approach by designing the insert itself with a tapered geometry that guides it into the cutout. The insert's own structure provides the alignment and insertion function previously requiring external auxiliary tools.
2Manufacturing precision
If auxiliary plates are used during adhesive curing, then insert positioning is maintained, but adhesive leakage can bond the plate to the insert causing damage during removal
Solution Approach 1:
The auxiliary plate is completely removed from the process. The tapered insert fits into a tapered cutout with such precision that no auxiliary plate is needed for positioning or support during adhesive curing, eliminating the source of adhesive leakage problems entirely.
Solution Approach 2:
The cutout is pre-formed with a tapered geometry that matches the insert's tapered portion. This preliminary preparation of the receiving geometry ensures precise alignment and fit before the insert is even introduced, eliminating the need for auxiliary plates to maintain positioning.
3Manufacturing precision
If inserts are precisely aligned with cutouts for accurate mounting, then anchorage precision is improved, but automated assembly becomes impossible or very costly
Solution Approach 1:
The insert and cutout feature asymmetric tapered geometries that naturally guide alignment during insertion. The tapered shape provides self-alignment through geometric constraint alone, eliminating the need for complex alignment mechanisms or precision fixtures required for automated assembly.
Solution Approach 2:
The tapered geometry of the insert and corresponding cutout creates a self-aligning system. During insertion, the tapered surfaces guide the insert into correct alignment automatically without requiring external alignment devices, making the process suitable for automated assembly.
4Manufacturing precision
If hand assembly methods are used for insert mounting, then precise alignment can be achieved, but the process becomes labor-intensive and inefficient
Solution Approach 1:
The tapered insert and cutout geometry creates a self-aligning system that automatically positions the insert correctly during insertion. This eliminates the need for skilled manual alignment operations while maintaining high positioning accuracy, simplifying the operation for any operator.
Solution Approach 2:
The asymmetric tapered geometry provides natural guidance during insertion, ensuring precise alignment through the shape itself rather than requiring skilled manual positioning. The geometry does the alignment work that previously required operator skill and time.
Data Source
AI summary
A lightweight support structure includes a composite sandwich panel having a first face sheet and a lightweight core attached to the face sheet and an essentially rotationally symmetric cut-out extending through the first face sheet and into the lightweight core. The cut-out has an essentially rotationally symmetric inner cut-out and outer cut-out arranged essentially concentric with respect to each other, providing for a support there between. The support has a core support cut from the lightweight core and a support face sheet disc on top, cut from of the first face sheet. A rotationally symmetric insert is fitted into the cut-out for load application and/or anchorage of various components into and onto the sandwich panel.