Molded Support Insert Structure for Higher Shear Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inserts designed for moulded supports, such as rivets and screws, fail to provide sufficient mechanical strength, especially when made from different materials than the resin, leading to inadequate tensile and shear stresses in thermoplastic or thermosetting composite materials.
Innovation Solution
The design includes a metal insert with a body and base featuring protuberances on one surface forming hollows on the opposite surface, and through holes with inclined truncated contours, enhancing mechanical strength by increasing contact surface area and reinforcing fiber penetration, suitable for thermoplastic and thermosetting supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rivets with flat bases are used in injection-moulded parts, then the manufacturing process is simple, but the mechanical strength is insufficient
Solution Approach 1:
The base of the insert is provided with protuberances that create curved, non-planar surfaces. This curvature increases the contact area between the insert base and the molded part, thereby improving mechanical strength and resistance to extraction forces while maintaining a relatively simple overall structure
Solution Approach 2:
The base includes through holes that allow resin fibers to penetrate and reinforce the insert structure. This creates a composite structure where the molded part material reinforces the insert, significantly improving mechanical strength without requiring complex internal structures
2Strength
If steel rivets are used with thermoplastic or thermosetting resin, then material selection is flexible, but mechanical strength of composite materials is difficult to obtain
Solution Approach 1:
Through holes are formed in the base to allow resin and reinforcing fibers to penetrate into the insert structure. This creates a mechanical interlock and chemical bonding between the steel insert and the thermoplastic/thermosetting composite material, achieving strong adhesion despite material incompatibility
Solution Approach 2:
The insert structure combines metal (steel) with polymer composite materials (resin and glass fibers) to create a hybrid composite structure. The through holes allow the resin and fibers to penetrate and bond with the metal base, creating a strong interface between dissimilar materials
3Strength
If through holes with perpendicular contours are used, then manufacturing is simple, but fiber penetration and mechanical strength are insufficient
Solution Approach 1:
The through holes are given inclined truncated contours rather than simple perpendicular shapes. This asymmetric, angled geometry improves the mechanical interlock between the insert and molded part, enhancing shear strength and fiber penetration while remaining manufacturable with standard drilling and tapering processes
Data Source
AI summary
Insert designed to be fitted on a support, including a body extending along a longitudinal axis and a base including at least one plate extending along a base plane, at least one through hole oriented along an orientation axis perpendicular to the base plane being formed in said at least one plate, at least one protuberance being formed on a first surface of said at least one plate and forming a hollow on a second surface of said at least one plate.