Sandwich panel inserts and related methods

• US 10,099,767 B2
• Filed: 08/04/2015
• Issued: 10/16/2018
• Est. Priority Date: 08/04/2015
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Lewis, Michael Steven, Reeves, Brad Jeremy, Bradley, James S., Mills, Christopher John, Balachander, Supriya, Wilkie, Brian M.
• Primary Examiner(s): Yoo, Jun
• Application Number:
  US14/818,004
• Publication Number:
  US 20170036750A1
• Time in Patent Office: 1,169 Days
• CPC Class Codes: B64C 1/12 Construction or attachment of skin panels
• CPC Class Codes: F16B 5/01 by means of fastening elements specially adapted for honeycomb panels
• CPC Class Codes: F16L 5/00 Devices for use where pipes, cables or protective tubing pass through walls or partitions passing insulated pipes through walls F16L59/121; arrangements for leading electric cables or lines through walls, floors or ceilings H02G3/22
• CPC Class Codes: H02G 3/22 Installations of cables or lines through walls, floors or ceilings, e.g. into buildings

Abstract

The present disclosure relates to inserts for use with sandwich panels, such as composite panels, and related methods. Presently disclosed inserts may include a retention feature and/or an anti-rotation feature that may be configured to retain the insert in place within a bore formed in the sandwich panel. In this manner, presently disclosed inserts may be secured without the use of adhesive compounds, which may increase efficiency and/or reduce costs in manufacturing apparatus that include one or more sandwich panels having one or more inserts placed therein. Presently disclosed methods of installing an insert into a sandwich panel may include rotating the insert with respect to the sandwich panel as the insert is installed, such that a portion of the insert may be positioned under the skin of the sandwich panel (e.g., a portion of the insert may be positioned between the skin and the core of the sandwich panel).

Claims

1. A method of installing an insert into a bore formed in a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, the method comprising:

providing at least one insert, each of the at least one inserts comprising;

a panel-engaging structure configured to engage one of the first skin and the second skin of the sandwich panel when the insert is installed in the sandwich panel;

an opposing end opposite the panel-engaging structure;

a body configured to engage the core of the sandwich panel when the insert is installed in the sandwich panel, the body having a hole formed therein, the hole extending from the panel-engaging structure into the body and to the opposing end;

a retention feature configured to retain the insert in the sandwich panel without the use of adhesives, wherein the retention feature engages the sandwich panel when the insert is installed in the sandwich panel; and

an anti-rotation feature configured to prevent rotation of the insert with respect to the sandwich panel, wherein the anti-rotation feature is configured to resist rotation of the insert with respect to the sandwich panel about a longitudinal axis of the hole, and wherein the insert is configured to receive a secondary object within the hole, the secondary object being configured to transfer a localized load to the sandwich panel via the insert;

forming at least one bore in the sandwich panel, the first skin of the sandwich panel having a first inner surface and an opposite first outer surface, the second skin of the sandwich panel having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and the core being sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the at least one bore comprises forming at least one bore such that it extends through at least one of the first skin and the second skin, and into the core; and

installing the at least one insert into a respective bore of the at least one bores, such that the panel-engaging structure of the insert engages the sandwich panel, and such that the body of the insert is positioned within the respective bore in the core of the sandwich panel, wherein the installing of the at least one insert comprises rotating the at least one insert about a longitudinal axis of the bore, and wherein the installing the at least one insert comprises breaking a bond between the first skin and the core and/or breaking a bond between the second skin and the core, adjacent the respective bore.

2. The method according to claim 1, wherein the installing the at least one insert comprises rotating the at least one insert at least 5°

, at least 10°

, at least 20°

, at least 30°

, at least 40°

, at least 50°

, at least 60°

, at least 70°

, at least 80°

, at least 90°

, at least 120°

, at least 150°

, and/or at least 180°

, and wherein the rotating the at least one insert effectuates at least one of engaging the retention feature with the sandwich panel and engaging the anti-rotation feature with the sandwich panel.

3. The method according to claim 2, wherein the rotating the at least one insert about the longitudinal axis of the bore comprises rotating the at least one insert such that at least a portion of the panel-engaging structure is rotated to a position between the core and one of the first skin and the second skin.

4. The method according to claim 1, further comprising inserting at least one secondary object within the hole of a respective insert of the at least one inserts, the at least one secondary object being configured to transfer a localized load to the sandwich panel via the insert.

5. The method according to claim 1, wherein the installing the at least one insert is performed without the use of a potting compound, a quick-cure adhesive, or a UV-cure adhesive.

6. The method according to claim 1, wherein one or more of the forming the at least one bore in the sandwich panel and the installing the at least one insert into the respective one of the at least one bores is automated.

7. The method according to claim 1, wherein the panel-engaging structure is substantially triangular.

8. The method according to claim 7, wherein the installing the at least one insert into the respective bore comprises installing the at least one insert such that at least a portion of the panel-engaging structure is positioned between the first inner surface of the first skin and the core.

9. A method of installing an insert into a bore formed in a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, the method comprising:

providing at least one insert, each of the at least one inserts comprising;

a panel-engaging structure configured to engage one of the first skin and the second skin of the sandwich panel when the insert is installed in the sandwich panel;

an opposing end opposite the panel-engaging structure;

a body configured to engage the core of the sandwich panel when the insert is installed in the sandwich panel, the body having a hole formed therein, the hole extending from the panel-engaging structure into the body and to the opposing end;

a retention feature configured to retain the insert in the sandwich panel without the use of adhesives; and

an anti-rotation feature configured to prevent rotation of the insert with respect to the sandwich panel, wherein the anti-rotation feature is configured to resist rotation of the insert with respect to the sandwich panel about a longitudinal axis of the hole, wherein the insert is configured to receive a secondary object within the hole, the secondary object being configured to transfer a localized load to the sandwich panel via the insert, and wherein the anti-rotation feature comprises a retainer;

forming at least one bore in the sandwich panel, the first skin of the sandwich panel having a first inner surface and an opposite first outer surface, the second skin of the sandwich panel having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and the core being sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the at least one bore comprises forming at least one bore such that it extends through at least one of the first skin and the second skin, and into the core;

installing the at least one insert into a respective bore of the at least one bores, such that the panel-engaging structure of the insert engages the sandwich panel, and the body of the insert is positioned within the respective bore in the core of the sandwich panel; and

installing the retainer on at least one of the at least one inserts, the retainer being configured to resist movement of the at least one of the at least one inserts with respect to the sandwich panel.

10. The method according to claim 9, wherein the retainer comprises a plurality of tabs, at least a portion of each of the plurality of tabs being configured to be positioned between the first inner surface of the first skin and the core or between the second inner surface of the second skin and the core.

11. The method according to claim 9, wherein the retainer comprises a through-hole, and wherein the installing the retainer on at least one of the at least one inserts comprises installing the retainer such that the through-hole is substantially concentric with the hole of the body of the insert.

12. The method according to claim 9, wherein the installing the retainer on at least one of the at least one inserts comprises installing the retainer such that it covers an exposed area of the core of the sandwich panel.

13. The method according to claim 9, wherein the retainer comprises a substantially flat surface and at least one projecting tab extending from the substantially flat surface, and wherein the installing the retainer on at least one of the at least one inserts comprises installing the retainer such that the substantially flat surface of the retainer engages the panel-engaging structure of the insert and such that the at least one projecting tab of the retainer engages one or more of the core, the first skin, and the second skin of the sandwich panel.

14. The method according to claim 9, wherein the panel-engaging structure is substantially triangular.

15. A method of installing an insert into a bore formed in a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, the method comprising:

providing at least one insert, each of the at least one inserts comprising;

a panel-engaging structure configured to engage one of the first skin and the second skin of the sandwich panel when the insert is installed in the sandwich panel;

an opposing end opposite the panel-engaging structure;

a body configured to engage the core of the sandwich panel when the insert is installed in the sandwich panel, the body having a hole formed therein, the hole extending from the panel-engaging structure into the body and to the opposing end;

a retention feature configured to retain the insert in the sandwich panel without the use of adhesives, wherein the retention feature engages the sandwich panel when the insert is installed in the sandwich panel; and

an anti-rotation feature configured to prevent rotation of the insert with respect to the sandwich panel, wherein the anti-rotation feature is configured to resist rotation of the insert with respect to the sandwich panel about a longitudinal axis of the hole, and wherein the insert is configured to receive a secondary object within the hole, the secondary object being configured to transfer a localized load to the sandwich panel via the insert;

forming at least one bore in the sandwich panel, the first skin of the sandwich panel having a first inner surface and an opposite first outer surface, the second skin of the sandwich panel having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and the core being sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the at least one bore comprises forming at least one bore such that it extends through at least one of the first skin and the second skin, and into the core; and

installing the at least one insert into a respective bore of the at least one bores, such that the panel-engaging structure of the insert engages the sandwich panel, and such that the body of the insert is positioned within the respective bore in the core of the sandwich panel, wherein the installing of the at least one insert comprises rotating the at least one insert about a longitudinal axis of the bore, and wherein the installing the at least one insert into the respective bore comprises installing the at least one insert such that at least a portion of the panel-engaging structure is positioned between the first inner surface of the first skin and the core.

16. A method of installing an insert into a bore formed in a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, the method comprising:

providing at least one insert, each of the at least one inserts comprising;

a panel-engaging structure configured to engage one of the first skin and the second skin of the sandwich panel when the insert is installed in the sandwich panel;

an opposing end opposite the panel-engaging structure;

a body configured to engage the core of the sandwich panel when the insert is installed in the sandwich panel, the body having a hole formed therein, the hole extending from the panel-engaging structure into the body and to the opposing end;

a retention feature configured to retain the insert in the sandwich panel without the use of adhesives, wherein the retention feature engages the sandwich panel when the insert is installed in the sandwich panel; and

an anti-rotation feature configured to prevent rotation of the insert with respect to the sandwich panel, wherein the anti-rotation feature is configured to resist rotation of the insert with respect to the sandwich panel about a longitudinal axis of the hole, and wherein the insert is configured to receive a secondary object within the hole, the secondary object being configured to transfer a localized load to the sandwich panel via the insert;

forming at least one bore in the sandwich panel, the first skin of the sandwich panel having a first inner surface and an opposite first outer surface, the second skin of the sandwich panel having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and the core being sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the at least one bore comprises forming at least one bore such that it extends through at least one of the first skin and the second skin, and into the core; and

installing the at least one insert into a respective bore of the at least one bores, such that the panel-engaging structure of the insert engages the sandwich panel, and such that the body of the insert is positioned within the respective bore in the core of the sandwich panel, wherein the installing of the at least one insert comprises rotating the at least one insert about a longitudinal axis of the bore, and wherein the anti-rotation feature of the panel-engaging structure comprises at least one extension extending from a primary perimeter of the panel-engaging structure, wherein the at least one extension is configured to be positioned adjacent one of the first skin and the second skin when the insert is installed in the sandwich panel.

17. The method according to claim 16, wherein the extension is wedge-shaped, having a variable thickness along its length.

18. A method of installing an insert into a bore formed in a sandwich panel, the sandwich panel comprising a first skin, a second skin opposite the first skin, and a core therebetween, the method comprising:

providing at least one insert, each of the at least one inserts comprising;

a panel-engaging structure configured to engage one of the first skin and the second skin of the sandwich panel when the insert is installed in the sandwich panel;

an opposing end opposite the panel-engaging structure;

a body configured to engage the core of the sandwich panel when the insert is installed in the sandwich panel, the body having a hole formed therein, the hole extending from the panel-engaging structure into the body and to the opposing end;

a retention feature configured to retain the insert in the sandwich panel without the use of adhesives, wherein the retention feature engages the sandwich panel when the insert is installed in the sandwich panel; and

an anti-rotation feature configured to prevent rotation of the insert with respect to the sandwich panel, wherein the anti-rotation feature is configured to resist rotation of the insert with respect to the sandwich panel about a longitudinal axis of the hole, and wherein the insert is configured to receive a secondary object within the hole, the secondary object being configured to transfer a localized load to the sandwich panel via the insert;

forming at least one bore in the sandwich panel, the first skin of the sandwich panel having a first inner surface and an opposite first outer surface, the second skin of the sandwich panel having a second inner surface and an opposite second outer surface, the first outer surface and the second outer surface facing away from one another, and the core being sandwiched between the first inner surface of the first skin and the second inner surface of the second skin, wherein the forming the at least one bore comprises forming at least one bore such that it extends through at least one of the first skin and the second skin, and into the core;

installing the at least one insert into a respective bore of the at least one bores, such that the panel-engaging structure of the insert engages the sandwich panel, and such that the body of the insert is positioned within the respective bore in the core of the sandwich panel, wherein the installing of the at least one insert comprises rotating the at least one insert about a longitudinal axis of the bore;

forming a cut-out in the first skin to expose a portion of the core, wherein the cut-out has a first surface area that is larger than a second surface area of the bore; and

seating at least a portion of the panel-engaging structure of the insert into the cut-out;

wherein the installing the at least one insert comprises rotating the insert about a longitudinal axis of the bore such that the insert engages the sandwich panel and the cut-out.

19. The method according to claim 18, further comprising forming a plurality of slits in the first skin, wherein each slit of the plurality of slits extends radially outward from the cut-out, and wherein the installing the at least one insert comprises engaging one or more of the panel-engaging structure, the retention feature, and the anti-rotation feature with the plurality of slits.