Multi-Material Boss Insert for Repeated Die-Cast Fastening
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Solution Overview
Problem
Thin-walled metal enclosures with bosses suffer from fastening failure due to wear-and-tear from repeated assembly and disassembly, leading to chipping or cracking, and replacing bosses with durable materials increases costs.
Innovation Solution
A multi-material boss comprising a boss cylinder and an augmenting cylinder with a filler metal layer, where the augmenting cylinder has a higher liquidus temperature and hardness than the boss cylinder, providing enhanced mechanical properties without the need for pre-threaded parts or additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bosses are made from die cast metal, then manufacturing cost and ease of production are improved, but fastening durability and strength deteriorate due to wear-and-tear from repeated assembly and disassembly
Solution Approach 1:
The boss is constructed as a composite structure combining a die cast metal boss cylinder with a harder augmenting cylinder insert. The augmenting cylinder is made of material with higher hardness and melting temperature than the boss cylinder, providing enhanced wear resistance and fastening durability while maintaining the cost-effectiveness of die casting for the main enclosure body.
2Reliability
If threaded inserts or bushings are used to replace bosses, then fastening durability is improved, but manufacturing cost increases due to pre-threaded parts and additional adhesives
Solution Approach 1:
The invention merges the boss structure with the threaded insert function into a single integrated component. The augmenting cylinder is press-fit directly into the die cast boss cylinder, eliminating the need for separate threaded inserts, pre-threaded parts, and adhesive bonding processes. This integration maintains fastening durability while reducing manufacturing complexity and cost.
3Strength
If augmenting cylinder with higher hardness is inserted into boss cylinder, then fastening strength is improved, but device complexity increases due to multi-material construction
Solution Approach 1:
The augmenting cylinder is nested within the boss cylinder, with the harder augmenting insert placed inside the softer die cast boss body. This nested configuration provides enhanced fastening strength at the stress concentration point while keeping the overall structure simple and maintaining the advantages of die casting for the enclosure body.
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
The multi-material boss enhances fastening durability and stability, reducing the risk of failure and associated costs by integrating a stronger material within the existing die cast structure, ensuring reliable assembly and disassembly without the need for additional components or adhesives.
Implementation Method 1
The filler metal layer is made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, at least partially compressed between the base rim of the augmenting cylinder and first base of the interior of the boss cylinder
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
A multi-material boss, configured for fastening of a fastener thereto, being a feature of a die cast part, comprising a boss cylinder, an augmenting cylinder, and a filler metal layer is provided. The boss cylinder is made of the same material as the die cast part having a first hardness, and has a first interior. The augmenting cylinder is made of an augmenting material having a second hardness, is fixedly secured in the first interior of the boss cylinder, and has a second interior defined by a second cylindrical shaped wall, a base rim, and a second opening. The second hardness is greater than the first hardness. The fastener is fastened to the multi-material boss via the second opening of the augmenting cylinder having the higher liquidus temperature and greater hardness.