Two-Part Threaded Insert Structure for Stronger Composite Panels
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Solution Overview
Problem
Current methods for installing threaded inserts in composite panels result in limited pull-out strength and poor force transfer due to the lack of panel skin coverage on the external face of the insert, and require additional processing steps and materials, such as potting compounds that can enter the threaded holes, making the process inefficient.
Innovation Solution
A composite panel design featuring a two-part insert where the first insert piece is bonded to both panel skins and the core, with a second insert piece attached via a mechanical interlock, such as a screw fit or snap-fit, to create a threaded hole for fasteners, eliminating the need for potting compounds and enhancing attachment strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cavity is formed through the panel skin to install the threaded insert, then the insert can be housed in the core, but the panel skin coverage on the external face of the insert is lost, reducing pull-out strength
Solution Approach 1:
The threaded insert is divided into two separate pieces: a first insert piece that remains embedded in the core with panel skin coverage, and a second insert piece that is attached to the first piece. This segmentation allows the first piece to maintain structural integration while the second piece provides the threaded interface, resolving the contradiction between ease of installation and pull-out strength.
Solution Approach 2:
The second insert piece is positioned within a bore of the first insert piece, creating a nested configuration. The second piece extends through the panel skin to provide external threading while the first piece remains nested within the core structure. This nesting allows both functions to coexist: the first piece maintains pull-out strength through core embedding, while the second piece provides accessible threading.
2Strength
If potting compound is used to secure the insert, then the insert can be bonded to the composite panel, but additional processing steps and materials are required, reducing manufacturing efficiency
Solution Approach 1:
The invention extracts and eliminates the need for potting compound from the manufacturing process. Instead of using additional bonding materials and curing steps, the insert pieces are mechanically integrated into the structure during panel fabrication. The first insert piece is embedded in the core and the second piece is attached to it, creating a self-contained mechanical solution that removes the separate potting compound application and curing steps, thereby improving manufacturing efficiency while maintaining bond strength.
3Ease of operation
If the cavity is formed through the first panel skin, then the insert can be accessed from the external face, but the first face of the insert has limited or no attachment to the first panel skin, reducing force transfer
Solution Approach 1:
The solution moves the threaded interface to a different dimensional plane by using a second insert piece that extends through the panel skin in the thickness direction. The first insert piece maintains full attachment to the first panel skin within the core plane, while the second insert piece provides the threaded interface that extends beyond the panel skin surface. This dimensional arrangement allows both full panel skin coverage for force transfer and external accessibility for fastener installation.
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 design improves the pull-out strength and force transfer of threaded inserts by ensuring full panel skin coverage and eliminates the need for additional processing steps, enhancing the efficiency and reliability of the manufacturing process.
Implementation Method 1
a first bonding material bonds the first panel skin to the core; wherein the first bonding material bonds the first panel skin to the first face of the first insert piece
Data Source
AI summary
A composite panel comprising a first panel skin, a second panel skin and a core arranged between the first panel skin and the second panel skin. The composite panel having a threaded insert for receiving a fastener, the threaded insert arranged within a cavity of the core of the composite panel.