Patent Description:
There are many applications for attaching panels to a support structure. Examples include both interior and exterior applications. One specific example includes attaching panels within an aircraft cabin to a structural frame. The panels then form a secondary support structure for interior walls within the cabin.

Current designs include plates that are positioned on opposing sides of the panel. The plates include openings that align with openings in the panel. Fasteners extend through the panel and the plates to connect to a support structure. These designs lack orientation and locking features to properly align the plates on the opposing sides of the panels. This results in a time-consuming build that may also require intricate dimensioning and special tooling to create the components.

Another issue with the current designs is the inability to accommodate for varying panel thicknesses. Fit-up on different constructs can vary with some constructs being loose while others are tight requiring a tool to complete the fastener insertion. These variations can lead to the panels being misaligned when attached to the support structure. These variations can also lead to the panels being inadvertently movable relative to the support structure.

Attachment of the panel to the support structure can also include application of an adhesive. The adhesive is applied to bond the plates to the panel. An issue with the current design is the adhesive tends to migrate into the mounting holes that extend through the panel. This requires cleaning of the holes or otherwise reaming the holes to ensure they are open and able to receive a fastener.

<CIT> discloses "A method enables a link connector (<NUM>) to be coupled to a clevis (<NUM>). The clevis includes a pair of arms (<NUM>, <NUM>) and an opening (<NUM>, <NUM>) that extends therethrough. The link connector includes a first end (<NUM>) that includes an elastomeric portion (<NUM>) that defines an opening. The method includes positioning a support washer (<NUM>) including an opening (<NUM>) extending therethrough adjacent the link connector elastomer portion, and inserting a fastener through the clevis opening, the support washer opening, and the link connector elastomer opening to couple the link connector and the support washer to the clevis such that the link connector is coupled between the clevis arms by the fastener, and such that the support washer thermally insulates at least a portion of the link connector elastomeric portion".

In a first aspect there is provided an assembly as defined in claim <NUM> of the appended claims. In a second aspect there is provided a method as defined in appended claim <NUM>. One example is directed to an assembly to connect a panel to a support member. The assembly comprises a saddle fitting that extends from the support member. The saddle fitting comprises first and second plates that are spaced apart by a gap that receives the panel. An index fitting is configured to engage with an opening in the panel. The index fitting comprises a flange with an inner side configured to contact against a first face of the panel at the opening, and with the flange also including an opposing outer side. The index fitting also comprises a boss that extends outward from the inner side of the flange and is sized to fit within the opening in the panel. The boss comprises a face at an end away from the flange. The assembly also comprises a back fitting with an inner side configured to contact against a second face of the panel at the opening. The back fitting comprises an opening that aligns with the opening in the panel. The assembly comprises one or more fasteners that extend through the boss and connects the saddle fitting to the index fitting. The index fitting is sized for the boss to extend through the opening in the panel and the opening in the back fitting with the inner side of the flange in contact against the first side of the panel. The index fitting is further sized to fit within the gap in the saddle fitting with the outer side of the flange in contact with the first plate and the face of the boss in contact with the second plate.

In another example, the boss comprises a non-circular sectional shape with a larger major axis and a smaller minor axis and with the major axis being perpendicular to the minor axis.

In another example, the face of the boss lies within a first plane and the inner side of the flange lies in a second plane with the first plane parallel to the second plane.

In another example, the flange and the back fitting are both bonded to the panel with an adhesive.

In another example, the flange extends completely around the boss.

In another example, the saddle fitting further comprises a body that forms a channel that receives the support member with the body further comprising one or more openings configured to receive fasteners to attach the saddle fitting to the support member.

In another example, an outer side of the back fitting is spaced away from the second plate of the saddle fitting.

In another example, the flange comprises a cut-out along an outer edge with the cut-out sized to receive a fastener to orient the index fitting relative to the opening in the panel.

One example is directed to an assembly to connect a panel to a support member. The assembly comprises a saddle fitting connected to the support member with the saddle fitting comprising first and second plates that are spaced apart by a gap that receives the panel. A back fitting is positioned between the second plate of the saddle fitting and a second face of the panel with the back fitting shaped to extend around an opening in the panel. An index fitting comprises a flange positioned between the first plate of the saddle fitting and a first face of the panel. The index fitting comprises a boss that extends outward from the flange and through the opening in the panel. The boss comprises a face positioned outward beyond the second face of the panel. The index fitting is wider than the panel and sized to fit within the gap of the saddle fitting with a first end of the index fitting contacting against the first plate of the saddle fitting and a second end of the index fitting contacting against the second plate of the saddle fitting. The assembly also comprises one or more fasteners that connect the saddle fitting to the index fitting.

In another example, the saddle fitting is configured to be attached to the support member and comprises one or more openings to receive one or more fasteners.

In another example, the backing fitting is connected to the second face of the panel with an adhesive.

In another example, the flange of the index fitting is connected to the first face of the panel.

In another example, the fasteners comprise quick release pins with a head, an elongated shaft, and a spring loaded member that extends from the shaft.

In another example, one or more openings extend through the boss and the flange of the index fitting with each of the one or more openings configured to receive one of the fasteners to connect the saddle fitting to the index fitting.

In another example, the first end of the index fitting is formed on an outer side of the flange that faces away from the first face of the panel and the second end of the index fitting is formed on the face of the boss.

In another example, the face of the boss is positioned farther outward away from the second face of the panel than an outer side of the back fitting.

In another example, the boss comprises an elongated sectional shape with a major axis that is larger than and perpendicular to a smaller minor axis.

One example is directed to a method of attaching a panel to a support member. The method comprises: inserting an index fitting through an opening in the panel; positioning a first end of the index fitting outward from a first face of the panel and a second end of the index fitting outward from a second face of the panel; contacting the index fitting against a back fitting that is connected to the second face of the panel; inserting the panel, the index fitting, and the back fitting into a gap of a saddle fitting that extends from the support member; and inserting one or more fasteners through the saddle fitting and the index fitting and connecting the panel to the support member.

In another example, the method comprises bonding a flange of the index fitting to the first face of the panel and bonding the back fitting to the second face of the panel.

In another example, the method comprises preventing the index fitting from rotating within the opening in the panel.

In another example, the method comprises positioning a top edge of the panel within the gap of the saddle fitting and positioning a bottom edge of the panel away from the saddle fitting.

In another example, the method comprises contacting the first and second ends of the index fitting against the saddle fitting and spacing the saddle fitting away from the back fitting.

<FIG> illustrates an exploded view of assemblies <NUM> that connect a panel <NUM> to a support member <NUM>. Each assembly <NUM> includes an index fitting <NUM> that engages within an opening <NUM> in the panel <NUM>. The index fitting <NUM> includes a boss <NUM> sized to fit within the opening <NUM> and a flange <NUM> that contacts against a first face <NUM> of the panel <NUM>. A back fitting <NUM> is positioned at a second face <NUM> of the panel <NUM>. A saddle fitting <NUM> is positioned on the support member <NUM>. The saddle fitting <NUM> includes first and second plates <NUM>, <NUM> that are spaced apart by a gap <NUM>. The index fitting <NUM>, back fitting <NUM>, and panel <NUM> are sized to fit within the gap <NUM> with the indexing fitting <NUM> contacting against the first and second plates <NUM>, <NUM>. One or more fasteners <NUM> connect the panel <NUM> to the support member <NUM>.

As illustrated in <FIG>, the indexing fitting <NUM> is configured to be inserted into the opening <NUM> in the panel <NUM> on the first face <NUM>. The index fitting <NUM> includes a boss <NUM> that extends outward from a flange <NUM>. The boss <NUM> includes sidewalls <NUM> and a face <NUM>. In one example, the face <NUM> is flat and lies within a first plane and an inner side <NUM> of the flange <NUM> is flat and lies within a second plane. The first plane and the second plane are parallel. The boss <NUM> has a sectional shape that substantially matches the shape of the opening <NUM> in the panel <NUM>. In the example of <FIG>, the boss <NUM> has an oblong sectional shape with a major axis M and a minor axis N. The axes M, N are perpendicular to each other and the major axis M is larger than the minor axis N. The elongated sectional shape of the boss <NUM> matches the shape of the opening <NUM> and prevents rotation of the indexing fitting <NUM> relative to the panel <NUM>. The boss <NUM> can include a variety of different sectional shapes, including but not limited to oval and polygonal. <FIG> includes a boss <NUM> with a circular sectional shape. To prevent rotation, the flange <NUM> includes a cut-out <NUM> along an outer edge. The cut-out <NUM> is sized to receive a fastener <NUM> that mounts to the panel <NUM>. The cut-out <NUM> and fastener <NUM> function to position the indexing fitting <NUM> at a fixed orientation relative to the panel <NUM>. <FIG> includes a boss <NUM> with a smaller oblong shape than the boss <NUM> of <FIG>.

The flange <NUM> of the indexing fitting <NUM> is larger than the opening <NUM> in the panel <NUM>. This sizing maintains the boss <NUM> within the opening <NUM> and prevents the indexing fitting <NUM> from being pushed through the opening <NUM>. The flange <NUM> includes an inner side <NUM> and an outer side <NUM>. The inner side <NUM> is flat to contact against the first face <NUM> of the panel <NUM> when the boss <NUM> is positioned in the opening <NUM>. In one example, the flange <NUM> extends completely around the boss <NUM> to contact against the panel <NUM> at points around the opening <NUM>. In another example, the flange <NUM> is discontinuous and does not extend completely around the boss <NUM>.

One or more openings <NUM> extend through the boss <NUM> and flange <NUM>. Each of the openings <NUM> is sized to receive a fastener <NUM>. <FIG> includes an example with a pair of openings <NUM>. <FIG> include examples with a single opening <NUM>.

The back fitting <NUM> is positioned on the second face <NUM> of the panel <NUM>. The back fitting <NUM> is positioned at the opening <NUM> to contact and support the boss <NUM>. The back fitting <NUM> can extend completely around the opening <NUM>, or can extend partially around the opening <NUM>. In one example as illustrated in <FIG>, the back fitting <NUM> has an annular shape with a central opening <NUM>. The opening <NUM> is sized and shaped to match the opening <NUM> in the panel <NUM>. The back fitting <NUM> has a substantially a thin, flat shape with an inner side <NUM> that contacts against the panel <NUM> and an outer side <NUM> faces away from the panel <NUM>. The inner side <NUM> is flat to facilitate contact with the second face <NUM> of the panel <NUM>.

The saddle fitting <NUM> extends from the support member <NUM> to engage with the index fitting <NUM>. In one example, the saddle fitting <NUM> is a separate piece that is connected to the support member <NUM> with one or more fasteners. In another example, the saddle fitting <NUM> is integral with the support member <NUM> and having a one-piece unitary construction.

An adhesive <NUM> can secure one or more of the index fitting <NUM> and back fitting <NUM> to the panel <NUM>. In one example as illustrated in <FIG>, the adhesive <NUM> can extend completely around the opening <NUM> on one or both of the first and second faces <NUM>, <NUM> of the panel <NUM>. Other examples can include the adhesive <NUM> positioned along one or more limited sections of the opening <NUM>. In use, the adhesive <NUM> bonds the inner side <NUM> of the flange <NUM> of the index fitting <NUM> to the first face <NUM> of the panel <NUM> and the inner side <NUM> of the back fitting <NUM> to the second face <NUM> of the panel <NUM>. This bonding provides for carrying a shear load through the faces <NUM>, <NUM> of the panel <NUM>. In other examples, the index fitting <NUM> and back fitting <NUM> are not bonded to the panel <NUM>.

As illustrated in <FIG>, the saddle fitting <NUM> includes first and second plates <NUM>, <NUM> that are separate by a gap <NUM>. One or more openings <NUM> extend through the first and second plates <NUM>, <NUM> to receive the fasteners <NUM>. A body <NUM> extends between and connects to the first and second plates <NUM>, <NUM>. The body <NUM> is configured to engage with the support member <NUM>. In one example as illustrated in <FIG>, the body <NUM> includes a C-shape cavity that receives the support member <NUM>. One or more fasteners <NUM> extend through and connect the body <NUM> to the support member <NUM>.

Fasteners <NUM> connect the panels <NUM> to the support members <NUM>. The fasteners <NUM> include an elongated length to extend through the saddle fitting <NUM>, assembly <NUM>, and panel <NUM>. In one example, fasteners <NUM> are quick release pins as illustrated in <FIG>. The fasteners <NUM> include a head <NUM> and an elongated shaft <NUM>. A spring loaded pin extends outward from the shaft <NUM>. In another example, the fasteners <NUM> include an elongated nut with a threaded end configured to receive a nut.

<FIG> illustrates a system <NUM> with a number of different assemblies <NUM> that connect panels <NUM> to support members <NUM>. The panels <NUM> can be used to construct a variety of different structures. One example includes the panels <NUM> being positioned within the interior of an aircraft. Another example includes the panels <NUM> forming walls within an interior of a building. In one example as illustrated in <FIG>, each panel <NUM> includes two or more assemblies <NUM>. A first assembly <NUM> includes a boss <NUM> with an oblong sectional shape that is inserted into an oblong opening <NUM>. A second assembly <NUM> includes a boss <NUM> with a circular section shape that is inserted into a circular opening <NUM>. The first assembly <NUM> with the oblong boss <NUM> is referred to as a locating connector as it locates the position panel <NUM> relative to the support member <NUM>. The second assembly <NUM> with the circular boss <NUM> is a floating connector and further supports the connection of the panel <NUM> to the support members <NUM>. The assemblies <NUM> are spaced apart along the panel <NUM>. The assemblies <NUM> can be connected to the same or different support members <NUM>.

<FIG> illustrates an assembly <NUM> that connects a panel <NUM> to a support member <NUM>. The indexing fitting <NUM> is positioned with the boss <NUM> extending through the opening <NUM> in the panel <NUM>. The boss <NUM> includes a length L1 measured between the inner side <NUM> of the flange <NUM> and the face <NUM>. The length L1 is greater than a width W of the panel <NUM>. This sizing provides for the inner side <NUM> to contact against the first face <NUM> of the panel <NUM> and the face <NUM> to be positioned outward beyond the second face <NUM> of the panel <NUM>. The back fitting <NUM> is positioned at the second face <NUM> of the panel <NUM>. The face <NUM> of the boss <NUM> extends outward farther than the outer side <NUM> of the back fitting <NUM>. In one example, a gap is formed between the second plate <NUM> and the outer side <NUM> of the back fitting <NUM>.

When the index fitting <NUM> is inserted into the opening <NUM>, the inner side <NUM> of the flange <NUM> contacts against the first face <NUM> of the panel. The boss <NUM> is sized to extend outward beyond the second face <NUM> of the panel <NUM>. The boss <NUM> extends outward beyond the second face <NUM> and amount that is greater than a thickness of the back fitting <NUM> that is measured between the inner and outer sides <NUM>, <NUM>. This sizing results in the face <NUM> of the boss <NUM> contacting against the second plate <NUM> of the saddle fitting <NUM>. The back fitting <NUM> does not interfere with this contact.

The size of the index fitting <NUM> provides for each of the ends to extend outward beyond the faces <NUM>, <NUM> of the panel <NUM>. This also reduces or prevents the adhesive <NUM> from migrating into the one or more openings <NUM>.

The panel <NUM>, index fitting <NUM>, and back fitting <NUM> are sized to fit within the gap <NUM> of the saddle fitting <NUM>. The outer side <NUM> of the flange <NUM> contacts against the first plate <NUM> and the face <NUM> contacts against the second plate <NUM>. That is, the index fitting <NUM> includes a length L2 measured between the outer side <NUM> of the flange <NUM> and the face <NUM>. This length L2 is less than or equal to a width of the gap <NUM>. The saddle fitting <NUM> engages just the index fitting <NUM>. This engagement eliminates variations in the connections due to panel thickness variations and stack-up tolerances.

The boss <NUM> protrudes through and extends outward beyond the back fitting <NUM>. This positioning provides for the boss <NUM> to contact against and be supported by the back fitting <NUM>. In one example, the flange <NUM> of the index fitting <NUM> and the back fitting <NUM> are bonded to the panel <NUM> with an adhesive <NUM>. With the boss <NUM> contacting with the saddle fitting <NUM>, shear loads on the panel <NUM> are carried through the first and second faces <NUM>, <NUM>. In another example, the flange <NUM> and/or the back fitting <NUM> are positioned against the panel <NUM> but are not bonded to the panel <NUM>.

The assemblies <NUM> can support a variety of different panels <NUM>. One example is a honeycomb core composite sandwich panel <NUM> that includes a low density interior honeycomb core with high-rigidity outer sheets that form the first and second faces <NUM>, <NUM>. Other examples include panels <NUM> constructed from various materials including but are not limited to wood, plastic, metal, and combinations thereof. The various panels <NUM> can include various shapes and sizes. In one example, the panels <NUM> are CNC-machined to accommodate various configurations. The various configurations can provide unique ceiling attachment points, load paths, and system interfaces.

One application for the assemblies <NUM> is to support structural members within an interior of an aircraft. <FIG> illustrates an aircraft <NUM> with a fuselage <NUM> that forms a cabin area for transporting passengers and a crown area for housing systems and supports. As illustrated in <FIG>, the cabin area <NUM> includes rows of seats <NUM> to accommodate the passengers. The crown area <NUM> contains the panels <NUM> which are attached to support members <NUM>. Interior linings <NUM> are attached to the panels <NUM> to form a boundary between the cabin area <NUM> and crown area <NUM>. The interior linings <NUM> can further be configured to form various other features within the cabin area <NUM>.

<FIG> illustrated a method of attaching a panel <NUM> to a support member <NUM>. The method includes inserting an indexing fitting <NUM> through an opening <NUM> in the panel <NUM> (block <NUM>). This includes positioning the boss <NUM> through the opening <NUM>. The boss <NUM> includes a sectional shape and size that matches the opening <NUM>. A first end of the indexing fitting <NUM> is positioned outward from a first face <NUM> of the panel <NUM> and a second end is positioned outward from a second side <NUM> of the panel <NUM> (block <NUM>). The first end of the index fitting <NUM> includes the outer side <NUM> of the flange <NUM> and the second end of the index fitting <NUM> includes the face <NUM> of the boss <NUM>. The index fitting <NUM> contacts against a back fitting <NUM> that is connected to the second face <NUM> of the panel <NUM> (block <NUM>). This includes the sidewall <NUM> of the boss <NUM> contacting against the edge of the back fitting <NUM> formed at the opening <NUM>. The panel <NUM>, the indexing fitting <NUM>, and the back fitting <NUM> are inserted into a gap <NUM> of the saddle fitting <NUM> that extends from the support member <NUM> (block <NUM>). Once positioned in the gap <NUM>, one or more fasteners <NUM> are inserted through the saddle fitting <NUM>, the indexing fitting <NUM>, and the back fitting <NUM> to connect the panel <NUM> to the support member <NUM> (block <NUM>).

One or more additional assemblies <NUM> can support and position the panel <NUM>. These additional assemblies <NUM> can attached to the support members <NUM> in a similar manner.

The index fitting <NUM>, back fitting <NUM>, and saddle fitting <NUM> can be constructed from a variety of materials, including but not limited to plastics and metals. These elements can be constructed from the same or different materials.

By the term "substantially" with reference to amounts or measurement values, it is meant that the recited characteristic, parameter, or value need not be achieved exactly. Rather, deviations or variations, including, for example, tolerances, measurement error, measurement accuracy limitations, and other factors known to those skilled in the art, may occur in amounts that do not preclude the effect that the characteristic was intended to provide.

Claim 1:
An assembly (<NUM>) to connect a panel (<NUM>) to a support member (<NUM>), the assembly (<NUM>) comprising:
a saddle fitting (<NUM>) that extends from the support member (<NUM>), the saddle fitting (<NUM>) comprising first and second plates (<NUM>, <NUM>) that are spaced apart by a gap (<NUM>) that receives the panel (<NUM>);
an index fitting (<NUM>) configured to engage with an opening (<NUM>) in the panel (<NUM>), the index fitting (<NUM>) comprising:
a flange (<NUM>) with an inner side (<NUM>) and an opposing outer side (<NUM>), the inner side (<NUM>) configured to contact against a first face (<NUM>) of the panel (<NUM>) at the opening (<NUM>);
a boss (<NUM>) that extends outward from the inner side (<NUM>) of the flange (<NUM>) and is sized to fit within the opening (<NUM>) in the panel (<NUM>), the boss (<NUM>) comprising a face (<NUM>) at an end away from the flange (<NUM>);
a back fitting (<NUM>) with an inner side (<NUM>) configured to contact against a second face (<NUM>) of the panel (<NUM>) at the opening (<NUM>), the back fitting (<NUM>) further comprising an opening (<NUM>) that aligns with the opening (<NUM>) in the panel (<NUM>);
one or more fasteners (<NUM>) that extend through the boss (<NUM>) and connect the saddle fitting (<NUM>) to the index fitting (<NUM>); and
the index fitting (<NUM>) sized for the boss (<NUM>) to extend through the opening (<NUM>) in the panel (<NUM>) and the opening (<NUM>) in the back fitting (<NUM>) with the inner side (<NUM>) of the flange (<NUM>) in contact against the first face (<NUM>) of the panel (<NUM>), the index fitting (<NUM>) further sized to fit within the gap (<NUM>) in the saddle fitting (<NUM>) with the outer side (<NUM>) of the flange (<NUM>) in contact with the first plate (<NUM>) and the face (<NUM>) of the boss (<NUM>) in contact with the second plate (<NUM>).