Interference-Fit Insert Anchoring for Uniform Thermoplastic Joining
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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 material liquefies and penetrates the opening walls to form anchorage, but the insert must be moved significantly within the opening which increases process time and energy consumption
Solution Approach 1:
The insert is pre-positioned in the opening before applying ultrasonic vibration, establishing the correct location in advance. This preliminary positioning eliminates the need to move the insert during the vibration phase, reducing process time while ensuring proper anchorage location.
Solution Approach 2:
The anchoring process is divided into distinct phases: first positioning the insert in the opening, then applying ultrasonic vibration to liquefy the thermoplastic material at the interface, and finally allowing the material to penetrate and solidify. This segmentation allows each phase to be optimized independently.
2Strength
If ultrasonic vibration is applied to anchor thermoplastic inserts in penetrable materials, then the insert material liquefies and penetrates the opening walls to form anchorage, but significant energy is consumed during the process
Solution Approach 1:
By positioning the insert before applying vibration energy, the system ensures that all subsequent energy input is efficiently used for material liquefaction and penetration rather than being wasted on moving the insert. This preliminary positioning optimizes energy utilization.
3Strength
If the insert is moved significantly during ultrasonic vibration anchoring, then the thermoplastic material can penetrate the opening walls, but the anchorage uniformity decreases especially in large anchoring areas
Solution Approach 1:
The insert is positioned in the opening before vibration is applied, establishing uniform contact between the insert surface and the penetrable material throughout the entire anchoring area. This preliminary positioning ensures that ultrasonic energy is distributed uniformly, resulting in consistent material liquefaction and penetration across the whole interface, thereby achieving uniform anchorage even in large areas.
4Strength
If existing ultrasonic vibration methods are used to anchor inserts, then the thermoplastic material penetrates the penetrable material, but undesired material deformation or damage may occur
Solution Approach 1:
By positioning the insert before applying vibration, the system establishes proper alignment and contact conditions in advance, allowing controlled and localized material deformation only at the interface where penetration is desired, while protecting the bulk materials from unwanted deformation or damage.
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 material deformation or damage, while 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
Implementation Method 3
the material having thermoplastic properties is liquefied due to friction heat
Implementation Method 4
when the material having thermoplastic properties is liquefied
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.