Connector Element Anchoring Using a Liquefied Thermoplastic Sleeve
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Solution Overview
Problem
Existing methods for anchoring connector elements in objects often compromise between strength of engagement and risk of material damage, as they either weaken the object or cause delamination or fissures.
Innovation Solution
A method involving a thermoplastic sleeve that is inserted into a mounting hole along with a connector element, where mechanical energy is used to liquefy the thermoplastic material, allowing it to enclose and securely anchor the connector element without applying pressure or friction to the object, ensuring a strong and damage-free engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a threaded insert is expanded into engagement with the object, then the strength of engagement is improved, but the risk of causing damage to the material of the object increases
Solution Approach 1:
A thermoplastic sleeve is introduced as an intermediary between the connector element and the object material. The sleeve encloses the connector element and is liquefied to enable anchoring without direct contact between the connector and the object material, thereby preventing delamination or fissures while maintaining strong engagement
Solution Approach 2:
The thermoplastic sleeve undergoes a parameter change from solid to liquid state through energy transfer (heating or ultrasonic vibration). This phase change allows the sleeve to flow and penetrate the object material, creating strong anchoring without mechanical expansion that would damage the object
2Strength
If mechanical pressure or friction is applied to anchor the connector, then the anchoring strength is improved, but the risk of delamination or fissures in the object increases
Solution Approach 1:
The traditional mechanical anchoring system based on pressure and friction is replaced with a thermal/phase-change-based system. The thermoplastic sleeve is liquefied through energy transfer and allowed to flow into the object material, eliminating the need for mechanical pressure or friction that would cause delamination or fissures
3Strength
If the connector element is deeply anchored in the object, then the strength of engagement is improved, but the complexity of the anchoring process increases
Solution Approach 1:
The thermoplastic sleeve is pre-assembled with the connector element before insertion into the object. This preliminary assembly simplifies the anchoring process by eliminating the need for separate steps to position the connector and then apply anchoring force, allowing deep anchoring through a single insertion and liquefaction operation
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 provides a strong and reproducible anchoring process that minimizes the risk of material damage, allowing for accurate positioning and deep anchoring of the connector element, while maintaining the integrity of the object.
Implementation Method 1
transferring energy to liquefy at least a portion of the thermoplastic material of the sleeve
Implementation Method 2
Mechanical vibration may generate friction heat where the sleeve interfaces the connector element and/or the receiving object
Implementation Method 3
The mechanical vibration may be induced by a source of ultrasonic vibration in contact with e.g. the sleeve
Data Source
AI summary
A method of anchoring a connector element (10) in a receiving object (66) comprises inserting a distal end of the connector element (10) into a mounting hole in an insertion direction along an insertion axis; inserting a sleeve (36) comprising a thermoplastic material into the mounting hole, the sleeve (36) enclosing the connector element (10); and transferring energy to liquefy at least a portion of the thermoplastic material of the sleeve (36). A machine (500) configured for carrying out the method and a connector element anchoring kit comprising a connector element (10) and a sleeve (36) comprising thermoplastic material.