Rolled Steel Collar Insert Molding for Variable Mounting Holes

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Solution Overview

Problem

The manufacturing cost of resin molded articles increases due to the need for multiple collar members with different hole diameters to accommodate varying bolt diameters, leading to increased production complexity and costs.

Innovation Solution

A resin molded article design that incorporates a single type of collar member with a rolled collar structure, featuring a tubular body and an entrance path for resin injection during insert molding. This allows for the formation of mounting holes with varying diameters using a single collar type, with one hole serving as a datum and the others absorbing dimensional variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple collar members with different hole diameters are prepared to accommodate varying bolt diameters, then the mounting position can be precisely regulated, but the manufacturing cost increases

Engineering Contradiction:

Improvemounting position precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A single collar member design with a through-hole that allows passage of bolts of different diameters, eliminating the need for multiple collar types. The through-hole serves multiple functions by accommodating various bolt sizes while maintaining precise mounting position regulation through the collar's structural features.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple collar members with different hole diameters are prepared, then each mounting hole can be precisely fitted, but the device complexity increases

Engineering Contradiction:

Improvehole diameter precisionVSAvoidcollar member variety

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The collar member features a through-hole that universally accommodates bolts of different diameters, reducing device complexity by eliminating the need for multiple collar types. The single collar design maintains precision through its structural configuration rather than requiring varied hole diameters.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of varying the collar hole diameter to match different bolt diameters, the invention inverts the approach by keeping the collar hole diameter constant and allowing the bolt to pass through, with the mounting precision achieved through the collar's positioning features rather than hole size matching.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS20250067291A1Resin molded article and collar member

Publication Date: 2025.02.27 YOROZU CORP

AI summary

A resin molded article includes a collar member which is fitted to each of a first fixing part and a second fixing part by insert molding. The collar member is constituted of a rolled collar made of steel and includes a tubular body and an entrance path which guides injection of resin to inside of the tubular body during insert molding. The collar member of a same type is insert-molded to each of the first fixing part and the second fixing part. The first fixing part and the second fixing part respectively include a first mounting hole and a second mounting hole formed by resin injected to the inside of the tubular body via the entrance path.