Impulse Insert Staking Device for Brass Inserts
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Solution Overview
Problem
Existing insert staking methods, such as hot probe, inductive, and ultrasonic insertion, face challenges including operator safety risks, high costs, and complex machine actuation requirements.
Innovation Solution
A novel impulse insertion device that uses a resistive tip to heat the brass insert, which is then pressed into the plastic using a spring-loaded mechanism, offering controlled and cost-effective insertion with reduced operator risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot probe insert staking is used to heat and press the brass insert into plastic, then the insert can be embedded into the plastic, but the probe is always hot and can burn operators
Solution Approach 1:
The patent applies periodic action by using an impulse heater that delivers heat in short, controlled pulses rather than maintaining continuous heat. The heater is activated only during the brief moment when the insert is being pressed into the plastic, then immediately deactivated. This allows the insert to be heated and embedded reliably while minimizing operator exposure to hot surfaces, thus resolving the contradiction between embedding reliability and operator safety.
2Ease of operation
If inductive insertion is used to heat the brass insert in an induction coil, then control over the process is improved, but the cost increases and significant machine actuation is required
Solution Approach 1:
The patent extracts the heating function from a complex inductive heating system and implements it through a simpler resistive impulse heater. By removing the induction coil and associated control machinery, the invention maintains good process control through the spring-loaded positioning mechanism while significantly reducing device complexity and cost. The heater is a simple resistive element that can be directly controlled without complex electromagnetic systems.
3Reliability
If ultrasonic horn transmits high-frequency sound vibrations to the brass insert, then the insert can be heated and pressed into plastic, but the frequency and intensity make it hazardous for operators
Solution Approach 1:
The patent replaces the ultrasonic mechanical vibration system with a thermal field approach using an impulse heater. Instead of using high-frequency mechanical vibrations to generate heat, the invention uses direct resistive heating followed by thermal conduction to heat the insert and surrounding plastic. This substitution eliminates the hazardous ultrasonic vibrations while maintaining the ability to embed the insert reliably through controlled heating and spring-loaded pressing.
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 impulse insertion method provides efficient and controlled embedding of brass inserts into plastic, reducing costs and minimizing operator safety hazards, while ensuring secure insertion.
Implementation Method 1
The tip essentially creates an electrical short circuit. By passing a low voltage alternating current through the tip, heat is created at the tip. Heat is then conducted to the insert, and in turn, conducted to the plastic.
Implementation Method 2
Heat is then conducted to the insert, and in turn, conducted to the plastic.
Implementation Method 3
A brass insert is held in place by a specially designed collar that is spring-loaded to hold the insert but then to release it once it is in the plastic.
Data Source
AI summary
A novel device and method enabling insert staking of brass inserts into plastic.