Self-Locking Mortise and Tenon Joint for Fixture-Free Panel Assembly
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Solution Overview
Problem
Existing mortise and tenon joint assemblies in aircraft panel structures require additional fixtures, fasteners, and adhesive materials for assembly, increasing production costs, labor, and weight, which also prolongs assembly time and affects fuel efficiency.
Innovation Solution
A self-locking joint design for composite sandwich panels featuring mortise openings with self-locking end portions and tenon extensions with flexible members that interlock, eliminating the need for additional assembly tools by using a honeycomb core and CNC-cutting for precise fit and secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fixtures, fasteners, adhesive tape, and clamp devices are used to hold mortise and tenon joint assemblies together, then the joint assembly can be properly assembled and held together, but the labor, materials, and tooling costs increase, and the assembly time increases
Solution Approach 1:
The tenon tab is designed with flexible material that allows it to automatically lock into the mortise opening without requiring external fixtures, fasteners, or clamp devices. The flexible material enables the tenon tab to flex during insertion and then lock securely in place through its own elastic properties, making the assembly self-sufficient and eliminating the need for additional assembly tools.
Solution Approach 2:
The tenon tab is made from flexible material with specific elastic properties that change its physical state during assembly. The material's flexibility parameter allows it to deform during insertion and then recover to lock securely, enabling the joint to assemble itself without external fixtures while maintaining reliable connection.
2Reliability
If additional fixtures, fasteners, adhesive tape, and clamp devices are used to hold mortise and tenon joint assemblies together, then the joint assembly can be properly assembled, but the overall weight of the joint assembly and aircraft panel structures increases
Solution Approach 1:
The tenon tab uses its own flexible material properties to achieve secure locking without requiring additional fasteners, fixtures, or adhesive materials. This self-servicing mechanism eliminates the weight of all additional components while maintaining joint stability through the elastic locking action of the flexible tenon tab.
Solution Approach 2:
The invention extracts and eliminates the need for additional fixtures, fasteners, adhesive tape, and clamp devices from the traditional mortise and tenon joint assembly. By removing these unnecessary components and replacing them with a flexible tenon tab that performs all locking functions independently, the overall weight is reduced while maintaining joint reliability.
3Device complexity
If traditional mortise and tenon joint assemblies are used without self-locking features, then the joint can be assembled with simple components, but additional fixtures and fasteners are required that increase production costs and assembly time
Solution Approach 1:
The flexible tenon tab performs the complete locking function using only its own material properties, eliminating the need for separate fixtures, fasteners, or adhesive materials. This self-servicing design simplifies the overall assembly while reducing production costs by eliminating multiple components and their associated installation and removal 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 solution reduces production costs, assembly time, and weight by providing a secure, fixture-free assembly method for aircraft panel structures, enhancing manufacturing efficiency and fuel efficiency.
Implementation Method 1
the flexible self-locking members are designed to have sufficient flexibility and/or deformability that enable them to flex or deform when the tenon extension is inserted into a corresponding mortise opening and that enable them to expand back to their original positions once the flexible self-locking members interlock with the respective self-locking end portions
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
There is provided in an embodiment a method of fabricating a self-locking joint in a panel structure 44. The method provides a panel structure having at least two face sheets 46a, 46b and a core portion 48 sandwiched therebetween. The method further fabricates in a first portion of the panel structure at least one mortise opening 52 having self-locking end portions 54a, 54b. The method further fabricates on a second portion of the panel structure at least one tenon extension 58 having flexible self-locking members 64a, 64b. The method further interlocks the flexible self-locking members of the at least one tenon extension with the self-locking end portions of the at least one mortise opening to form a self-locking joint in the panel structure.