Expandable Threaded Insert for Calibrated Manifold Holes
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Solution Overview
Problem
Existing plug and sealing systems for manifolds are complex and expensive to manufacture, lack depth control during installation, and do not allow for connection to other parts or the creation of calibrated holes in pressurized fluid systems.
Innovation Solution
A system comprising a cylindrical sleeve and core with a tapered outer wall, where the core is press-fit into the sleeve to expand against the hole, creating a threaded connection that allows for secure attachment of parts and the installation of a calibrated metering orifice in pressurized fluid manifolds, with a method involving a threaded rod for easy installation and adjustable depth control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a stem is included in the insert to enable connection to other parts, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent merges the connection function directly into the core by forming threads on the outer surface of the core itself, eliminating the need for a separate stem component. This integration maintains adaptability while reducing device complexity.
Solution Approach 2:
The core serves multiple functions: it provides structural support, creates the sealed bore when expanded, and simultaneously provides threaded connection capability through its outer surface. This multi-functionality eliminates the need for additional components like stems.
2Ease of operation
If a rivet system with breaking stem is used for installation, then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent removes the complex breaking stem mechanism entirely from the insert design. Instead, installation is achieved by expanding the core within the sleeve using a simple expansion tool, eliminating the need for manufactured breaking stems.
Solution Approach 2:
The insert performs its own installation through the expansion mechanism where the core is pulled into the sleeve, causing the sleeve to expand and seal against the bore automatically, without requiring complex pre-manufactured breaking stems.
3Reliability
If the insert is designed to seal the hole completely, then reliability is improved, but adaptability worsens as connection to other parts is not allowed
Solution Approach 1:
The insert is segmented into two functional zones: the sleeve provides sealing against the bore, while the core with its threaded outer surface provides connection capability. This segmentation allows both sealing and connection functions to coexist without interference.
Solution Approach 2:
Different parts of the insert have different properties: the sleeve is designed for sealing contact with the bore, while the core is designed with threaded surfaces for connection. This local differentiation enables both sealing reliability and connection adaptability.
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
Enables easy, repeatable installation of inserts in manifolds and other parts, allowing for secure attachment and calibrated pressure management in fluid systems, while withstanding high pressures and facilitating connection to other parts without the need for a stem.
Implementation Method 1
The core includes a through-hole and a tapered outer wall, and the through-hole has a threaded portion. The cylindrical core has an outer diameter that fits into the hole of the first part such that when the core is pulled into the cylindrical sleeve, the cylindrical sleeve expands against the hole of the first part to secure the insert to the first part.
Implementation Method 2
The threaded member has threads sized to engage with the threaded portion of the through-hole of the core such that the threaded member and insert secure the first and second parts together.
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 2C~2D
AI summary
An insert (1) for connecting first and second parts (101; 100) each having holes, the insert having a cylindrical sleeve (5) and a core (3). The cylindrical sleeve having a central void and an outer diameter sized to fit into the hole in the first part. The central void having a uniform diameter across a length of the cylindrical sleeve. The core having a through-hole (14) and a tapered outer wall (2) such that when the core is pulled into the cylindrical sleeve, the cylindrical sleeve expands against the hole of the first part to secure the insert to the first part. The through-hole of the core having a threaded portion at a first end of the core to engage with a threaded fastener to secure the second part to the first part. The first end of the core is press-fit into the cylindrical sleeve.