Substrate Insert Plate Structure for Stronger Resin Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inserts for molded supports lack sufficient mechanical strength, particularly when made from materials different from the resin, and are not suitable for both injection molding and heating and compression processes.
Innovation Solution
An insert with a body extending along a longitudinal axis and a base featuring at least one plate with through holes oriented perpendicular to the base plane, and protrusions on one surface forming depressions on the opposite surface, enhancing mechanical strength and shear resistance, suitable for thermoplastic and thermosetting substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rivets with circular holes are used for molded supports, then the insert can be embedded in resin, but the mechanical strength is insufficient
Solution Approach 1:
The patent replaces traditional circular holes with oval-shaped holes in the base plate. This curvature change allows resin and reinforcing fibers to penetrate more effectively and distribute stress more uniformly, significantly improving the mechanical strength of the insert-resin connection while maintaining manufacturing feasibility through standard drilling and molding processes.
Solution Approach 2:
The patent introduces localized protrusions on one surface of the base plate that create corresponding depressions on the opposite surface. These localized structural modifications enhance mechanical interlocking with the resin at critical stress points, improving overall strength without requiring complex changes to the entire insert structure.
2Strength
If inserts are made from materials different from resin (e.g., steel), then mechanical connection is achieved, but sufficient mechanical strength in the injection-molded part is difficult to achieve
Solution Approach 1:
The patent creates a composite structure where the metal insert base plate is embedded in resin with reinforcing fibers. The oval-shaped holes allow fiber penetration that creates a hybrid metal-resin-fiber composite connection, combining the strengths of different materials to achieve superior mechanical strength that neither material could provide alone.
Solution Approach 2:
The patent transitions from traditional through-hole fastening to a multi-dimensional connection system. The oval holes provide radial fiber reinforcement, while the protrusions-depressions feature adds vertical interlocking dimension, creating a three-dimensional mechanical bond that enhances material compatibility and overall connection strength.
3Ease of manufacture
If through holes are oriented at an angle to improve fiber penetration, then injection molding is improved, but the insert is not suitable for heating and compression processes
Solution Approach 1:
The patent designs the base plate with oval-shaped holes and protrusions that serve multiple functions across different manufacturing processes. The oval geometry facilitates fiber penetration during injection molding, while the protrusions provide mechanical interlocking during heating and compression processes, making the insert universally suitable for various manufacturing methods.
Solution Approach 2:
Instead of angling the holes to optimize for one process (injection molding), the patent inverts the approach by using perpendicular oval holes with surface protrusions. This configuration optimizes for the most critical mechanical strength requirement while still accommodating injection molding, thereby achieving broader process versatility.
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 insert provides improved mechanical strength and shear resistance, ensuring a secure mechanical connection with molded supports, suitable for both thermoplastic and thermosetting materials, and applicable in various industries such as automotive, naval, and aeronautical sectors.
Implementation Method 1
At least one protrusion is formed on a first surface of said at least one plate and forms a hollow on a second surface of said at least one plate
Implementation Method 2
at least one through orifice oriented along an axis of orientation perpendicular to the base plane being formed in said at least one plate
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
Insert intended to be mounted on a support (11), comprising a body (12) extending along a longitudinal axis (B) and a base (13) having at least one plate (15a, 15b) extending along a base plane (C), at least one through orifice (16) oriented along an orientation axis (A) perpendicular to the base plane (C) being formed in said at least one plate (15a, 15b), at least one protrusion being formed on a first surface of said at least one plate (15a, 15b) and forming a hollow on a second surface of said at least one plate (15a, 15b).