Tapped Insert Fusible Area for Insert Molding

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Solution Overview

Problem

Conventional tapped inserts in insert molding face issues with accidental material engagement and irreversible damage to the tapping during molding, due to variable axial lengths and mold heights, leading to mediocre quality and damage.

Innovation Solution

Incorporating a fusible area with greater axial deformability between the threaded section and the heads, which deforms under compressive force without affecting the threaded section, allowing for adjustable axial length and preventing damage during mold closure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the axial length of the insert is variable according to manufacturing tolerances, then the ease of manufacture is improved, but the manufacturing precision of the mold closure is worsened leading to material engagement or tapping damage

Engineering Contradiction:

Improveease of manufactureVSAvoidmold closure precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The insert includes a fusible area with different material properties (greater axial deformability) compared to the rest of the shank. This parameter change allows the insert to accommodate variations in axial length while protecting the critical threaded section from damage during mold closure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The shank is segmented into distinct functional areas: a threaded axial section for forming the tapping, a fusible area with greater deformability, and heads at the axial ends. This segmentation allows each section to perform its specific function independently, with the fusible area absorbing dimensional variations.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the height between mold parts is constant but insert axial length varies, then the productivity is improved, but the reliability of the tapping quality is worsened due to accidental material engagement or damage

Engineering Contradiction:

ImproveproductivityVSAvoidtapping quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fusible area acts as a pre-designed cushioning zone that absorbs excessive compressive forces before they can reach the threaded section. This beforehand cushioning protects the tapping from damage while allowing the mold to close with constant height regardless of insert length variations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a fusible area with greater axial deformability is added to the shank, then the reliability of the tapping protection is improved, but the device complexity increases

Engineering Contradiction:

Improvetapping protectionVSAvoidinsert structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of making the entire shank complex, only a specific local area (the fusible area) is given different material properties with greater axial deformability. This localized modification provides the necessary protection while keeping the overall structure relatively simple and easy to manufacture.

Inventive Principle:

Principle #3Local quality

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 ensures proper mold closure without damaging the tapping, enhancing the quality of the insert molding by allowing axial shortening of the insert under compressive force, thus preventing material engagement and maintaining the integrity of the threaded section.

Implementation Method 1

the shank comprises at least one fusible area of greater axial deformability located between said threaded axial section and one of the heads, configured to deform under a predefined compressive force applied to the heads without causing deformation of said threaded axial section

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS8556560B2Tapped insert to be insert moulded and insert moulding method

Publication Date: 2013.10.15 BOLLHOFF OTALU SA

AI summary

A tapped insert to be insert molded comprises a shank provided at its axial ends with flanges delineating two axially opposite heads of the insert. The shank is provided with an internally threaded axial section to form a tapping. Means for blocking the insert in rotation after insert molding and means for blocking the insert axially in translation after insert molding are arranged on the outside of the shank. The shank comprises at least one fusible area of greater axial deformability located between the threaded axial section and one of the heads. The fusible area is configured to deform under a predefined axial compressive force applied to the heads without causing deformation of the threaded axial section.The invention also relates to a method for insert molding such an insert.