Interference-Fit Insert Joining for Uniform Thermoplastic Anchorage
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Solution Overview
Problem
Existing methods for joining objects with thermoplastic inserts in penetrable materials, such as ultrasonic vibration techniques, often require moving the insert significantly within the opening and result in non-uniform anchorage, especially when large anchoring areas are involved.
Innovation Solution
Establishing an interference fit between the insert and the opening walls, followed by applying mechanical vibration to liquefy the thermoplastic material, allowing it to penetrate the penetrable material, thereby achieving strong and uniform lateral anchorage without the need for extensive insert movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic vibration is applied to anchor thermoplastic inserts in penetrable materials, then the insert can be joined to the opening, but the insert must be moved significantly within the opening resulting in non-uniform anchorage
Solution Approach 1:
The insert is positioned in the opening before applying ultrasonic vibration, establishing preliminary contact between the thermoplastic material and the penetrable material. This preliminary positioning ensures that when vibration is applied, the thermoplastic material immediately liquefies and penetrates the penetrable material at multiple locations simultaneously, creating uniform anchorage without requiring significant insert movement during the vibration phase.
2Ease of manufacture
If the insert is moved significantly during vibration application to achieve anchorage, then joining can be accomplished, but the anchorage uniformity deteriorates
Solution Approach 1:
Ultrasonic vibration is applied to the insert after positioning, causing the thermoplastic material to liquefy through friction heat at the interface with the penetrable material. The vibration energy enables the liquefied material to penetrate the penetrable material structure, creating strong anchorage connections without requiring mechanical movement of the insert bulk, thereby maintaining both process simplicity and anchorage uniformity.
3Strength
If thermoplastic material is liquefied by friction heat during vibration, then penetration into penetrable material occurs, but extensive insert movement is required
Solution Approach 1:
The thermoplastic material is liquefied locally at the interface between the insert and the penetrable material through friction heat generated by ultrasonic vibration. This localized liquefaction allows the material to penetrate the penetrable material structure without requiring the entire insert to move significantly, as the penetration occurs at the molecular level through the liquefied material flowing into the penetrable material's structure.
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
This method reduces the time and energy required for anchorage, ensures high uniformity of the anchorage strength, and prevents undesired movement of the objects during the process, maintaining the integrity of the penetrable material.
Implementation Method 1
the material having thermoplastic properties is liquefied due to friction heat at least where in contact with the fibrous or porous material
Implementation Method 2
mechanical vibration, in particular ultrasonic vibration
Data Source
AI summary
A method for joining two objects by anchoring an insert portion provided on one of the objects in an opening provided on the other one of the objects. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. Before such liquefaction and interpenetration, an interference fit is established in which such opposite surfaces are pressed against each other, and, for the anchoring, mechanical vibration energy and possibly a shearing force are applied, wherein the shearing force puts a shear stress on the interference fit.