Over-molded Compression Limiter with Perforations
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Solution Overview
Problem
Metal compression limiters used in plastic components often fall out before assembly, deform adjacent components, and require multiple sizes to accommodate different attachment holes, leading to incorrect installation risks.
Innovation Solution
A tubular-shaped compression limiter with perforations extending from the outer to the inner surface, integrated into a plastic component through over-molding, allowing secure retention and uniform load transmission without the need for multiple sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal compression limiter is pressed into a bore in the plastic component, then the compression limiter strengthens the plastic and resists applied load, but the pressed-in compression limiter can fall out prior to final installation
Solution Approach 1:
The compression limiter and plastic component are merged into a single integrated part through overmolding. The plastic material is molded over the metal compression limiter, creating a unified component where the metal tube provides structural strength and load resistance while the plastic shell provides retention and prevents fall-out during assembly operations.
2Strength
If a metal compression limiter is pressed into a bore in the plastic component, then the compression limiter resists applied load, but the pressed-in compression limiter can press into and deform the material of the second component
Solution Approach 1:
The metal compression limiter is merged with the plastic component through overmolding, creating a composite structure where the plastic material surrounds and protects the metal tube. This integration allows the metal core to resist loads while the plastic shell prevents direct contact between the metal limiter and the second component, eliminating deformation issues.
3Adaptability or versatility
If three different compression limiters are used for datum hole, slotted hole, and clearance hole, then each hole can be properly accommodated, but there is a risk that compression limiters can be inserted in the wrong holes
Solution Approach 1:
A single universal compression limiter design with standardized dimensions is used for all three hole types (datum, slotted, and clearance holes). The overmolded plastic component provides the necessary variations in hole geometry while the compression limiter itself remains uniform, eliminating confusion and ensuring correct installation while still accommodating different fastening requirements.
4Ease of manufacture
If a metal compression limiter is pressed into a bore, then the compression limiter can be installed, but the process requires separate pressing operation which increases manufacturing complexity
Solution Approach 1:
The compression limiter installation is merged with the plastic component molding process. The metal compression limiters are positioned in the mold cavity before injecting or overmolding the plastic material, allowing both components to be formed in a single manufacturing operation. This eliminates the separate pressing operation and reduces manufacturing complexity.
5Reliability
If a single size compression limiter is used for various fastener hole sizes, then the risk of incorrect installation is reduced, but the compression limiter may not properly fit all hole types
Solution Approach 1:
A standardized compression limiter design serves multiple functions across different hole types. The uniform dimensions of the metal compression limiter ensure consistent installation and eliminate confusion, while the overmolded plastic component provides the necessary adaptations for datum, slotted, and clearance holes through its geometry and fastening features.
Data Source
AI summary
A compression limiter includes a tubular-shaped wall having an outer surface and an inner surface forming a central passage. A plurality of perforations extend through the wall from the outer surface to the inner surface. A plastic component can be formed with the compression limiter by over-molding a plastic body over the compression coupler and extending the plastic body into the plurality of perforations. The compression limiter is thereby firmly secured to the plastic body. Different sized fastener openings can be formed within the compression limiter by extending the plastic body into the central passage of the compression limiter and/or substantially preventing the plastic body from extending into the central passage of the compression limiter.