Sandwich Insert Installation With Controlled Potting Volume
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Solution Overview
Problem
Installing inserts in sandwich structures, such as honeycomb structures, is challenging due to the difficulty in controlling the volume of potting mass used for stabilization, often resulting in excessive weight and uneven distribution.
Innovation Solution
A method involving a hollow body that restricts the filling room for potting mass within the core element, ensuring precise distribution and containment, with features like compressible and self-expandable designs, and 3D-printed structures to simplify installation and maintain precise control over potting mass volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the hole is widened in the core element to accommodate the insert, then the insert can be installed in the sandwich structure, but the potting mass distributes uncontrollably to destroyed chambers resulting in excessive weight
Solution Approach 1:
A hollow body is introduced as an intermediary component between the insert and the potting mass. This hollow body acts as a containment structure that directs the potting mass only to the necessary filling room around the insert, preventing it from spreading to destroyed chambers. The hollow body thus mediates between the insert installation requirement and the weight control requirement.
Solution Approach 2:
The hollow body is designed with a flexible membrane wall that can be compressed during insertion through the sandwich structure and then expands to its original shape inside the core element. This flexible shell structure allows for easy installation while maintaining the containment function to control potting mass distribution and minimize weight.
2Manufacturing precision
If the hollow body is made rigid to maintain shape, then the filling room is well-defined, but the installation process becomes complex requiring precise positioning
Solution Approach 1:
The hollow body transitions from a compressed dynamic state during insertion to an expanded static state during operation. This dynamic characteristic allows the hollow body to be easily inserted in a compact form and then automatically expand to define the filling room precisely, eliminating the need for complex positioning mechanisms.
Solution Approach 2:
The hollow body performs self-positioning and self-shaping through its elastic expansion after insertion. Once inserted in the compressed state, the hollow body automatically expands to its original shape, defining the filling room boundaries without requiring external positioning tools or complex installation procedures.
3Reliability
If more potting mass is used to ensure complete filling, then the insert is well-stabilized, but the weight of the sandwich structure increases significantly
Solution Approach 1:
The hollow body serves as a mediator that ensures complete and controlled filling of the filling room with potting mass. By containing the potting mass within the hollow body boundaries, it ensures that the insert is fully stabilized while preventing excess potting mass from spreading to unnecessary areas, thus controlling the weight.
Solution Approach 2:
The invention replaces the mechanical judgment of visual inspection for complete filling with a physical containment system. The hollow body provides a defined filling room that ensures complete filling by its geometric boundaries, eliminating the need for excessive potting mass and complex monitoring mechanisms.
Data Source
Figure 1a~2b
Figure 3a~4c
Figure 5a~5f
AI summary
Disclosed is a method for placing an insert (12) in a sandwich structure (16) such as a honeycomb structure, wherein a potting mass filling room (33) is provided in a sandwich hole having a room wall preventing penetration of the honeycomb chambers, a sandwich structure and a hollow body forming the filling room.