Insert for load application and/or anchorage of various components into respectively onto a composite sandwich panel and method of producing a lightweight support structure comprising the same

1. Insert ( 50 ) for load application and/or anchorage of various components into respectively onto a composite sandwich panel ( 5 ), the insert ( 50 ) comprising:

a. a rotationally symmetric inner insert ring ( 51 );

b. a rotationally symmetric outer insert ring ( 52 ) arranged concentrically with respect to said inner insert ring ( 51 );

c. an insert connecting portion ( 53 ) connecting said inner insert ring ( 51 ) with said outer insert ring ( 52 ); and

d. an insert trench ( 54 ) provided between the outer insert ring ( 52 ) and the inner insert ring ( 51 ), wherein

e. the outer insert ring ( 52 ) comprises at least one channel ( 57 ) that extends from the insert trench ( 54 ) through the outer insert ring ( 52 ).

2. Insert ( 50 ) according to claim 1 , characterised in that:

the insert ( 50 ) is configured to be fitable into an essentially rotationally symmetric cut-out ( 30 ) of the composite sandwich panel ( 5 ) extending through a first face sheet ( 10 ) and into a lightweight core ( 15 ) of the composite sandwich panel ( 5 );

the inner insert ring ( 51 ) and outer insert ring ( 52 ) are configured to be receivable within an essentially rotationally symmetric and essentially concentric inner cut-out ( 31 ) respectively outer cut-out ( 32 ) of the composite sandwich panel ( 5 )

the insert trench ( 54 ) is configured for receiving a support ( 40 ) of the composite sandwich panel ( 5 ) provided between its inner cut-out ( 31 ) and outer cut-out ( 32 );

the insert connecting portion ( 53 ) is configured to be restable on a support face sheet disc ( 42 ) of the support ( 40 ) of the of the composite sandwich panel ( 5 ).

3. Insert ( 50 ) according to claim 1 , characterised in that the insert ( 50 ) is a self-cutting insert ( 50 ), its inner insert ring ( 51 ) being at least partially provided with an abrasive coating and/or a saw-tooth geometry ( 51 . 3 ) and its outer insert ring ( 52 ) being at least partially provided with an abrasive coating and/or a sawtooth geometry ( 52 . 3 ) configured for cutting, by rotation of the insert ( 50 ) around its rotational axis (R), an inner cut-out ( 31 ) and an outer cutout ( 32 ) of an insert cut-out ( 30 ) into said composite sandwich panel ( 5 ) by cutting through a first face sheet ( 10 ) and into a lightweight core ( 15 ) of the composite sandwich panel ( 5 ).

4. Insert ( 50 ) according to claim 1 , characterised in that the insert ( 50 ) further comprises a self-contained adhesive ( 56 ) arranged and configured for adhering the insert ( 50 ) into a cut-out ( 30 ) upon introduction therein.

5. Insert ( 50 ) according to claim 4 , characterised in that:

said self-contained adhesive ( 56 ) is provided in said insert trench ( 54 ) between the inner insert ring ( 51 ) and the outer insert ring ( 52 );

the at least one channel ( 57 ) is configured such that upon fitting of the insert ( 50 ) into the cut-out ( 30 ) of the composite sandwich panel ( 5 ), the support face sheet disc ( 42 ), formed within the first face sheet ( 10 ) between the inner cut-out ( 31 ) and the outer cutout ( 32 ) of the composite sandwich panel ( 5 ) forces said adhesive ( 56 ) through said at least one channel ( 57 ).

6. Insert according to claim 5 ,

characterised in that said at least one channel ( 57 ) is/are provided at an angle with respect to a rotational axis (R) of the insert ( 50 ), thereby ensuring that upon insertion of the insert ( 50 ) into the cut-out ( 30 ) of the composite sandwich panel ( 5 ), the adhesive ( 56 ) is at least partially spread over a circumference of the outer insert ring ( 52 ).

7. Insert according to claim 1 , characterised in that the inner insert ring ( 51 ) comprises a tapered conical section ( 51 . 5 ) and/or the outer insert ring ( 52 ) comprises a tapered conical section ( 52 . 5 ) for self-aligning the insert ( 50 ) upon insertion into a cut-out ( 30 ) of the composite sandwich panel ( 5 ).

8. Insert according to claim 1 , characterised in that the insert ( 50 ) is made of a material with essentially same thermal expansion coefficient as a first face sheet ( 10 ) of the composite sandwich panel ( 5 ) it is configured to be fitted into.

9. Insert according to claim 1 , characterised in that the insert ( 50 ) comprises an insert receiving area ( 55 ) for receiving a fixture ( 100 ) for attaching and/or anchoring of various components into respectively onto the composite sandwich panel ( 5 ), the insert receiving area ( 55 ) being preferably provided with at least partially distorted thread to prevent the fixture ( 100 ) thread-locked therein from loosening due to vibrations.