Compression Resistant Component With Embedded Limiter
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Solution Overview
Problem
Polymeric plastic components mounted using mechanical fasteners often fail under compressive loads, leading to reduced torque and potential mechanical failure, as existing metal compression limiters are expensive, heavy, and lack manufacturing and application flexibility.
Innovation Solution
A compression resistant component with elongated limiters embedded in the component body, made of a material with a higher compressive modulus than the component body, which can be insert molded or set after molding, allowing for varied geometry and dimensions to distribute compressive forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal compression limiters are used to reinforce the mounting component, then the component can withstand compressive force, but the component becomes heavy and expensive
Solution Approach 1:
The patent uses a composite structure combining polymeric plastic material for the component body with embedded metal compression limiters. This allows the lightweight polymer to serve as the primary structural material while the metal limiters provide localized compressive strength where needed, achieving a balance between overall weight and compressive force resistance.
Solution Approach 2:
Instead of making the entire component from heavy metal, the patent applies metal compression limiters only in specific locations where compressive forces are concentrated (around the fastener bore and at critical stress points). This localized reinforcement provides necessary strength while minimizing additional weight compared to a fully metal construction.
2Strength
If metal bushing is used to limit compressive force, then the component is protected from compression, but the component can rotate about the fastener
Solution Approach 1:
The patent divides the compression limiter function into multiple discrete elements: metal compression limiters embedded in the component body, additional limiters positioned around the fastener bore, and reinforcement ribs. This segmented approach provides both compressive force protection and rotational stability through distributed structural support rather than a single bushing element.
Solution Approach 2:
The patent combines multiple functions into the compression limiter system: compressive force distribution, rotational stability prevention, and structural reinforcement. By integrating these functions into a unified embedded limiter system rather than separate components, the solution simultaneously addresses both compression protection and orientation stability.
3Strength
If screw machined or stamped metal compression limiters are used, then the component can resist compression, but manufacturing flexibility is limited
Solution Approach 1:
The patent incorporates compression limiters into the component body during the molding process itself (insert molding or post-molding embedding). This preliminary integration of reinforcement elements into the manufacturing process eliminates the need for separate machining or stamping operations, thereby improving manufacturing flexibility while maintaining compressive strength.
4Strength
If traditional steel compression limiters are used, then compressive force is resisted, but material weight is high
Solution Approach 1:
The patent employs a composite construction using lightweight polymeric plastic material for the bulk of the component body, with strategic embedding of metal compression limiters only where structurally necessary. This composite approach reduces overall material quantity and weight compared to traditional all-steel compression limiters while maintaining adequate compressive force resistance through targeted reinforcement.
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 solution provides a lightweight, flexible, and effective means to resist compressive forces, reducing material weight by up to 95% compared to traditional steel limiters while maintaining component orientation and functionality.
Implementation Method 1
the elongated compression limiter bears a portion of the compressive force, thereby allowing the component to resist the effects of the compressive force
Data Source
AI summary
A compression resistant component adapted to be mounted to a surface using a mechanical fastener having a component body with a first surface and a second surface and a fastener passage defined by the component body extending from the first surface to the second surface. At least one elongated compression limiter is embedded in the component body displaced from and substantially parallel to a main longitudinal axis of the fastener passage. The elongated compression limiter if formed of a material having a greater compressive modulus that the material of which the component body is formed. When a fastener exerts a compressive force on the mounting component, the elongated compression limiter bears a portion of the compressive force exerted by the fastener on the component body, thereby allowing the component body to resist the effects of the compressive force.