Annular Screw Part With Insertion Sleeve for Torque Resistance
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Solution Overview
Problem
Existing screw parts with annular cross-sections face issues such as high material loss, out-of-round deformation, and weak torque resistance due to symmetrical fiber alignment and high manufacturing tolerances.
Innovation Solution
The introduction of an insertion sleeve overmolded within the base element, which is coaxially aligned with the inner channel, prevents symmetrical fiber alignment and enhances torque resistance by distributing the polymeric mass more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sprues are used for injection molding, then the polymeric mass distribution is improved, but material loss increases significantly
Solution Approach 1:
The base element is divided into multiple injection zones with dedicated injection points distributed around the inner channel, allowing independent control of polymeric mass flow to different regions without requiring multiple sprues
Solution Approach 2:
A core part is introduced as an intermediary tool during injection molding that defines the inner channel geometry and facilitates uniform polymeric mass distribution throughout the base element, eliminating the need for multiple sprues
2Ease of manufacture
If the sprue is positioned facing the inner channel, then manufacturing is simplified, but deformation and stress unevenness increase
Solution Approach 1:
Different regions of the base element are assigned different injection points positioned at optimal locations relative to the inner channel, allowing localized control of filling patterns to minimize deformation while maintaining manufacturing simplicity
Solution Approach 2:
The injection points are distributed in a radial pattern around the inner channel rather than using a single axial sprue, transforming the injection approach from one-dimensional to two-dimensional to achieve better stress distribution
3Reliability
If grooves of reduced diameter are created for sealing elements, then sealing function is improved, but torque resistance decreases due to weakening points
Solution Approach 1:
The base element uses a fiber-reinforced polymeric mass that combines the plastic matrix with reinforcing fibers, creating a composite material that maintains high torque resistance even in regions with reduced diameter grooves for sealing elements
Solution Approach 2:
The polymeric mass parameters are optimized by controlling fiber orientation and distribution through the injection molding process, enhancing the mechanical strength of the base element in critical torque transmission zones while allowing groove formation for sealing
4Ease of manufacture
If fiber alignment is symmetrical, then manufacturing is easier, but torque resistance and preload force maintenance deteriorate
Solution Approach 1:
The injection points are positioned asymmetrically around the inner channel in specific patterns that induce controlled fiber orientation during injection, creating an asymmetric fiber alignment that optimizes torque resistance and preload force maintenance in the base element
Solution Approach 2:
The fiber reinforcement is pre-distributed in the polymeric mass before injection, and the injection process itself is designed to align fibers in predetermined patterns that enhance mechanical performance before the base element is even assembled
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 results in a screw part with improved torque resistance, reduced manufacturing tolerance, and lower material loss, while also preventing creep behavior and maintaining preload force.
Implementation Method 1
a locally different shrinkage behavior during solidification of the polymeric mass leads to deformations
Implementation Method 2
an insertion sleeve is arranged in the base element coaxially with the inner channel, which insertion sleeve is at least partially encapsulated by the polymeric mass
Data Source
AI summary
A screw part with an annular cross-section and having a base element that is hollow, cylindrical and at least partially injection-molded from a plasticized polymeric mass containing fibers. The base element includes at least one internal and/or external thread and an inner channel for arranging and/or passing through a conduit system element. The inner channel has at least one sealing section for sealing with the conduit system element and/or at least one support section for supporting and/or guiding the conduit system element and/or at least one retaining section for directly or indirectly locking the conduit system element. An insertion sleeve is arranged in the base element coaxially with the inner channel. The insertion sleeve is at least partially encapsulated by the polymeric mass with the polymeric mass facing radially towards the inner channel and radially away from the inner channel. A process for manufacturing such a screw part.