Insert-Molded Plastic Joint With Metal Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing joints, particularly those with metal components, suffer from actuation noise and require lubrication, while plastic alternatives are less stressable and require larger dimensions, leading to increased size and installation space issues.
Innovation Solution
A joint design featuring a metal core surrounded by a plastics material casing, where the core is insert-molded with the plastics material to create a bi-component part, allowing for high stressability and reduced noise and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used in joints, then stressability and strength are improved, but actuation noise increases and lubrication is required
Solution Approach 1:
The patent applies composite materials by combining a metal core with a plastics material casing body. The metal core provides high stressability and strength, while the plastics material casing reduces actuation noise. This composite structure allows the joint to achieve both high stressability and low noise operation simultaneously, resolving the contradiction between strength and noise generation.
Solution Approach 2:
The patent implements the nesting principle by placing the metal core inside the plastics material casing body. The core is at least partially received within the casing body, creating a nested configuration where the inner metal component is surrounded by the outer plastics material. This nested structure allows the metal core to provide structural strength while being acoustically isolated by the plastics casing, thereby reducing actuation noise.
2Object-generated harmful factors
If plastics material is used to replace metal, then actuation noise is reduced, but stressability decreases and component dimensions must increase
Solution Approach 1:
The patent uses composite materials to overcome the limitation of plastics material. By combining plastics material (which reduces noise) with a metal core (which provides high stressability), the joint achieves both low actuation noise and high strength without requiring increased component dimensions. The composite structure allows each material to contribute its advantageous properties.
Solution Approach 2:
The patent applies local quality by using different materials in different regions of the joint component. The metal core is positioned in regions requiring high stressability and strength, while the plastics material casing is used in regions where noise reduction is prioritized. This localized material assignment allows the component to achieve both low noise and high stressability without uniform dimension increases.
3Strength
If plastics material component dimensions are increased, then stressability is compensated, but installation space requirements increase
Solution Approach 1:
The patent employs composite materials to maintain high stressability without increasing component dimensions. The metal core provides high strength-to-weight ratio and high stressability in a compact form, eliminating the need to increase the overall component size that would be required if only plastics material were used. This allows the joint to achieve high stressability while maintaining compact installation space requirements.
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 enables a joint that is highly stressed yet compact, with minimal actuation noise, by using a metal core insert-molded within a plastics casing, effectively addressing noise and size concerns in joint design.
Implementation Method 1
an injection device for injecting a plastics material in free-flowing form into the cavity
Implementation Method 2
the free-flowing plastics material which in particular may be a thermoplastics material, in the context of an injection-molding process for producing the injection-molded component is brought into direct contact with the core and is cured there
Implementation Method 3
the core of the highly stressable material to be (at least partially) insert molded with the plastics material for the casing body
Data Source
AI summary
An injection-molded component having a casing body of plastics material and a core which is made of a core material, in particular of a metal, which is at least partially received within the casing body and is at least partially insert-molded. The injection-molded component may in particular serve as a joint part of a joint. As a result of the preferably metallic core, the injection-molded component, despite comparatively small dimensioning, is capable of being comparatively highly stressed. By virtue of the casing body of plastics material, a minor actuation noise may be implemented for the joint, even without complex lubrication.