Mechanical Fasteners for Sandwich Panel Assembly
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Solution Overview
Problem
The use of potting compounds in sandwich panel construction for aircraft components is time-consuming and costly, as they require curing time and can shift during the curing process, affecting the aesthetic appearance and requiring additional effort to maintain insert position.
Innovation Solution
A panel apparatus with a double panel construction using mechanical fasteners embedded through the skin layers and into the core material of both panels, eliminating the need for adhesives and allowing immediate use without waiting for the adhesive to cure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting compounds are used to bond inserts to sandwich panels, then the inserts are securely attached, but the curing process adds 2-4 hours to the manufacturing cycle time
Solution Approach 1:
The patent replaces the chemical bonding system (potting compounds requiring curing) with a mechanical fastening system (threaded inserts with locking features). The inserts incorporate anti-loosening mechanisms such as lock nuts, washers, or integrated locking features that provide immediate secure attachment without requiring adhesive curing time, thus eliminating the 2-4 hour waiting period while maintaining reliable insert attachment.
Solution Approach 2:
The inserts are pre-installed into the sandwich panels during the panel manufacturing process before final assembly. This preliminary installation allows the panels to be prepared in advance with secure insert attachment, eliminating the need for separate curing cycles later in the manufacturing process and enabling continuous production flow.
2Strength
If bonding panel joints are used to join sandwich panels, then strong structural connections are achieved, but multiple joints must be clamped and held until curing is complete, limiting work on the panel apparatus
Solution Approach 1:
The patent replaces bonded panel joints with mechanical fastening systems that use bolts, screws, or other removable fasteners to join sandwich panels. These mechanical connections provide strong structural bonds immediately upon fastening, eliminating the need for clamps and curing time. Workers can complete panel assemblies quickly and proceed to the next production step without waiting for adhesive curing, significantly improving manufacturing productivity.
3Productivity
If mechanical fasteners are used instead of adhesives, then cycle times are reduced and immediate installation is possible, but the structural integrity and aesthetic quality must be maintained
Solution Approach 1:
The patent modifies the design parameters of the mechanical fasteners to optimize both structural performance and aesthetic appearance. This includes selecting appropriate fastener materials with suitable strength properties, designing fastener head configurations that distribute loads effectively, and choosing finishes or coatings that match the panel aesthetics. The fastener geometry and material selection are carefully adjusted to achieve the required structural integrity while enabling immediate installation without curing delays.
Data Source
AI summary
A panel apparatus is described that includes a first sandwich panel and a second sandwich panel arranged substantially parallel to each other, and the first sandwich panel and the second sandwich panel each include a core material inserted between at least two skin layers. The panel apparatus also includes at least one mechanical fastener mechanically embedded into the first sandwich panel and the second sandwich panel. The at least one mechanical fastener at least extends through one skin layer and into the core material of the first sandwich panel and at least extends through one skin layer and into the core material of the second sandwich panel, and the at least one mechanical fastener is configured to accept insertion of an item. Methods of assembling the panel apparatus are also described.