Sealing Plug for Threaded Inserts in Insert Moulding
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Solution Overview
Problem
Existing methods for creating component inserts in flowable, curable materials or fiber materials often result in damage to internal threads or openings due to penetration of the material, leading to structural weaknesses and increased manufacturing costs.
Innovation Solution
A component insert with a sealing plug, featuring a cylinder-like sealing body and removable assembly aid, is used to prevent the flowable material from entering the internal structure, ensuring the interior remains free from the material during molding by adapting to the component's inner shape and expanding to create a seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If component inserts with through holes or perforated side walls are used, then ease of manufacture and assembly are improved, but material penetration into the interior causes damage to internal threads and structural weaknesses
Solution Approach 1:
A sealing plug is introduced as an intermediary element between the component insert and the flowable curable material. The sealing plug has a sealing body that adapts to the inner shape of the component insert and expands to seal the through holes and perforations, preventing material penetration while allowing the component insert to maintain its open design for ease of manufacture
Solution Approach 2:
The sealing plug is inserted into the component insert before the component insert is molded into the flowable curable material. This preliminary sealing action prevents material from entering the interior during the molding process, eliminating the need for post-manufacturing repairs or replacements
2Reliability
If sealing layers are applied to component inserts, then material penetration is prevented, but manufacturing complexity and costs increase
Solution Approach 1:
The sealing plug utilizes parameter changes in its material properties - it is provided in a compressed state for insertion, then expands to its normal larger diameter within the component insert. This expansion creates the sealing effect without requiring complex sealing layers or additional manufacturing steps
Solution Approach 2:
The sealing plug transitions from a compressed, space-efficient state during insertion to an expanded, sealing state within the component insert. This dynamic transformation simplifies the insertion process while achieving effective sealing, avoiding the need for complex static sealing structures
3Reliability
If axial compression is applied to wire helixes, then sealing is improved, but leakage still occurs and reject rates increase
Solution Approach 1:
The sealing function is separated from the structural function of the component insert. The sealing plug is a distinct, separate element that provides sealing independently of the component insert's structural integrity, allowing each element to be optimized for its specific function without compromising the other
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 solution effectively prevents material penetration into the component insert, maintaining structural integrity and reducing manufacturing costs by ensuring a clean, sealed interior, allowing for the use of component inserts with through holes and perforated side walls without damage.
Implementation Method 1
a cylinder-like sealing body (10) with a radial outer surface that is adaptable to an inner surface of the component insert (50; 60)
Implementation Method 2
molding the component insert (50; 60) with sealing plug (1) into at least one flowable, curable material
Data Source
Figure 1~2
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AI summary
The present invention discloses a component insert 50 with a sealing plug 1 such that the component insert can be insert moulded into flowable, hardenable materials or into materials that are saturated with flowable, hardenable liquids. Here, the sealing plug 1 seals off the component insert 50 (in this case a wire-type threaded insert) against the ingress of the flowable, hardenable material.