Integral Plastic Mounting Feature for Perpendicular Fasteners
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Solution Overview
Problem
Current methods for providing mounting features that use threaded fasteners extending perpendicular to the line of draw in molded plastic components are costly, particularly when using insert molding of threaded bushings.
Innovation Solution
The development of integral mounting features in molded plastic components, which include an embossment with a recess and a bore perpendicular to the recess, allowing for the secure attachment of bolts with perpendicular axes of rotation, and optionally incorporating a compression limiter to prevent plastic compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insert molding of threaded bushing is used to provide mounting features for perpendicular fasteners, then the mounting feature can be provided, but manufacturing cost increases
Solution Approach 1:
The mounting feature is merged with the housing component itself, eliminating the need for separate insert molding of threaded bushings. The embossment with integrated recess and bore becomes part of the housing's molded structure, reducing manufacturing steps and cost while maintaining the perpendicular fastener mounting capability
Solution Approach 2:
The mounting feature is segmented into distinct functional elements (embossment for positioning, recess for nut accommodation, bore for fastener alignment) that are all integrally formed in one molding operation, simplifying the overall manufacturing process compared to separate insert molding
2Adaptability or versatility
If threaded fasteners extend perpendicular to the line of draw, then design constraints are satisfied, but manufacturing complexity increases
Solution Approach 1:
The mounting feature utilizes the vertical dimension with the embossment projecting from the main surface, allowing perpendicular fastener extension while maintaining compatibility with standard molding processes. The recess and bore are positioned in three-dimensional space to accommodate the perpendicular orientation without complicating the molding tooling
Data Source
AI summary
An integral mounting feature for attachment of components to a molded plastic housing component or chassis includes an embossment integrally formed with and projecting away from a main generally planar surface of the housing component or chassis, a recess that extends into the embossment from a top of the embossment, and a bore that extends from a side of the embossment perpendicular to the depth direction of the recess and that is connected with the recess.