Threaded Insert Positioning in Composite Molds
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Solution Overview
Problem
Existing methods for incorporating threaded inserts into composite materials are imprecise, costly, and difficult to implement, especially when fibers are layered on a mold, leading to issues with axial and radial alignment and insert extraction.
Innovation Solution
A process using partially threaded pins inserted into a mold with digital control, allowing precise orientation and removal, along with inserts featuring perimetric ridges and cylindrical cavities for secure coupling, and a kit including an extractor for easy pin removal and bushing replacement to prolong insert life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If threaded inserts are inserted in the unprocessed state between fiber layers and worked after resin cure with digital control machines, then the exact position of threaded holes can be ensured in the final product, but the working process becomes extremely expensive, long and difficult to carry out
Solution Approach 1:
The threaded inserts are pre-threaded before being placed in the mold, eliminating the need for post-cure threading operations. The inserts are positioned on pins during mold assembly, and the fiber layers are arranged around them before curing. This preliminary preparation of threads resolves the contradiction by achieving precise positioning without requiring expensive and time-consuming digital control machine operations after resin cure.
2Ease of manufacture
If inserts are slipped onto smooth pins firmly fixed to the mould as disclosed in WO 2006/063185, then the threaded inserts can be incorporated before curing, but the exact arrangement in the final product is not ensured and only inserts with holes arranged on axes perfectly parallel to the extraction axis can be incorporated
Solution Approach 1:
The pin is divided into two functional segments: a smooth portion for inserting the threaded insert and a threaded portion for securing the insert in the correct position. This segmentation allows the insert to be easily slipped onto the smooth part while the threaded part ensures precise axial and radial arrangement by screwing the insert onto the pin, resolving the contradiction between ease of manufacture and manufacturing precision.
3Strength
If a perimetric outer ridge is provided on the insert as disclosed in WO 2006/063185, then the insert can be prevented from penetrating into the final product, but only contact between outer surfaces prevents the insert from coming off in the opposite direction under excessive pressure
Solution Approach 1:
The threaded connection between the insert and the pin acts as an intermediary mechanical linkage that provides reliable retention. Instead of relying solely on surface contact and friction, the threaded engagement creates a positive mechanical interlock that prevents the insert from coming off under excessive pressure, resolving the contradiction between strength and reliability.
4Manufacturing precision
If pins are firmly fixed to the mould as disclosed in prior art, then the inserts can be positioned during curing, but the pins cannot be easily removed or reused for manufacturing new products
Solution Approach 1:
The pin is designed with a dynamic configuration that allows it to be easily removed from the mold after curing and reinserted for subsequent production cycles. The separation of the smooth insertion portion and the threaded fixation portion enables the pin to be detached by unscrewing, making the system adaptable and reusable, thus resolving the contradiction between manufacturing precision and ease of manufacture.
Data Source
AI summary
A process for manufacturing products made of composite materials is disclosed which includes the steps:screwing at least one insert provided with a threaded hole on the outer thread of at least one pin partially inserted in a removable manner in a mold;arranging on the mold one or more fiber layers provided with at least one opening in which the insert is arranged;curing resin with the layers arranged on the mold, so as to obtain a product made of a composite material which incorporates the insert and the layers;rotating the pin in the insert for removing it from the mold.The present invention also relates to a mold, devices and a kit which can be employed for carrying out the process, as well as to products manufactured with this process and/or these means.