Sandwich Panel Corner Joint With Trimmed Friction Inserts
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Solution Overview
Problem
Existing methods for connecting sandwich panels in aircraft interiors, such as those used in luggage compartments, lavatories, and galleys, face challenges in achieving strong, lightweight, and visually appealing joints that require minimal manual effort and reduce weight compared to conventional bonding and screwing techniques.
Innovation Solution
The use of friction inserts, which are integrated into the sandwich panels and trimmed to form a stable connection point, allowing for a screw connection at the end face that is mechanically strong and visually concealed, using a fastener to connect the panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bonding or screwing techniques are used to connect sandwich panels, then joint strength is achieved, but weight increases and visual appeal decreases
Solution Approach 1:
The connection system is segmented into separate functional components: friction inserts embedded in the sandwich panels and a separate fastener. This allows the connection function to be distributed and optimized independently from the panel structures themselves, enabling lightweight design while maintaining strength.
Solution Approach 2:
Friction inserts act as intermediary elements between the sandwich panels and the fastener. These inserts provide a mechanical interface that enables strong connections without requiring heavy bonding materials or visible screw holes in the panel faces, thus reducing weight while maintaining joint strength.
2Strength
If conventional bonding or screwing techniques are used, then joint strength is achieved, but manual effort increases
Solution Approach 1:
The friction inserts are self-contained within the sandwich panels, providing automatic mechanical engagement when the fastener is applied. The system performs part of the connection function automatically through the pre-positioned inserts, reducing the manual effort required during assembly compared to conventional bonding or screwing techniques.
3Shape
If friction inserts are trimmed to form connection points, then visual appeal and geometric precision are improved, but manufacturing complexity increases
Solution Approach 1:
The friction inserts are positioned and trimmed to precise geometries during the sandwich panel manufacturing process, before final assembly. This preliminary preparation ensures geometric precision and visual appeal are built into the panels themselves, while the complexity is managed during production rather than during final assembly operations.
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 method provides a lightweight, stable, and visually appealing connection between sandwich panels, reducing manual effort and weight compared to traditional methods, while enabling recyclability and maintaining geometric precision.
Implementation Method 1
The friction insert (16a, 16b) is inserted into the sandwich panel (4a, 4b) by rotation around a central axis (18a, 18b) and application of axial pressure
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A sandwich assembly (2) for an interior (40) of an aircraft (42) comprises two sandwich panels (4a,b) with friction inserts (16a,b), wherein the first sandwich panel (4a) together with its friction insert (16a) is trimmed along a cross-sectional surface (8a) from a raw state (RZ) to a finished state (FZ) to form an end face (10a), wherein in an assembly state (MZ) the first sandwich panel (4a) rests with its end face (10a) against a first flat side (12a) of the second sandwich panel (4b), and the sandwich panels (4a,b) are fastened to one another by means of a mechanical connecting element (28) which mechanically connects the friction inserts (16a,b) to each other. A component (44) for an aircraft (42) comprises the sandwich assembly (2).In a method for producing the sandwich assembly (2) or the component (44), the first sandwich panel (4a) is provided in the raw state (RZ), the first friction insert (16a) is inserted, and the first sandwich panel (4a) including the friction insert (16a) is trimmed to the finished state (FZ) at the cut surface (8a) to form the end face (10a), the second sandwich panel (4b) is provided, and the second friction insert (16b) is inserted into it, and to create the assembly state (MZ), the first sandwich panel (4a) is placed with its end face (10a) against the first flat side (12b) of the second sandwich panel (4b), and the sandwich panels (4a,b) are fastened to each other by means of the connecting element (28) by mechanically connecting the friction inserts (16a,b) to each other by means of the connecting element (28).