Compression molding fastener

• US 9,677,596 B2
• Filed: 05/22/2013
• Issued: 06/13/2017
• Est. Priority Date: 05/22/2012
• Status: Active Grant

• Current Assignee: Continental Structural Plastics Incorporated (Teijin Limited)
• Original Assignee: Continental Structural Plastics Incorporated (Teijin Limited)
• Inventors: Johnston, Christopher
• Primary Examiner(s): Saether, Flemming
• Application Number:
  US14/403,545
• Publication Number:
  US 20150176632A1
• Time in Patent Office: 1,483 Days
• Field of Search: 411429, 411 82, 411180, 411179, D8397
• CPC Class Codes: B29C 2043/3602 with means for positioning, fastening or clamping the material to be formed or preforms inside the mould
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B29C 70/86 Incorporated in coherent impregnated reinforcing layers, e.g. by winding
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/0872 Prepregs
• CPC Class Codes: B29L 2031/727 Fastening elements bolts B29L2001/002; nuts B29L2001/005; screws B29L2001/007; slide fasteners B29L2005/00; buttons for haberdashery B29L2019/00
• CPC Class Codes: F16B 37/122 Threaded inserts, e.g. "rampa bolts"
• CPC Class Codes: F16B 37/14 Cap nuts; Nut caps or bolt caps

Abstract

A method for forming an elevated surface feature for compression molded assemblies includes the placement of an afore-mentioned insert onto an actuated fixture pin with the pin initially in a retracted position. An upper portion of a mold configured with said retracted actuated fixture pin over a preform of pre-preg plies placed on the bottom portion of the mold is then closed. The fixture pin is actuated towards the pre-preg plies when a flowable material fills a molding cavity in the upper portion of the mold. The cavity is configured to form the elevated surface feature with the advancing action of the insert packs out the surface feature under the pressure of the pin to eliminate porosity in the elevated surface feature in the molding cavity.

Claims

1. A molded article comprising:

molded material; and

an insert comprising;

a head with an open end, a lip, and a circular retaining ring defined by parallel walls and surrounding a counter bore;

a cylindrical center space extending from the counter bore within an interior of said insert with a series of threads formed on a cylindrical wall, the cylindrical center space defined by the cylindrical wall to accommodate a fastener;

a multi-faced region with a plurality of flat faces on an exterior of the insert and surrounding the cylindrical center space; and

a tapered region extended from said multi-faced region that terminates in a sharpened leading edge;

wherein said molded material is in contact with said plurality of flat faces and said tapered region of the insert.

2. The molded article of claim 1 wherein said insert further comprising a recessed area on the exterior of the insert and located intermediate between said open end and said multi-faced region.

3. The molded article of claim 1 wherein the sharpened leading edge of said insert forms a point.

4. The molded article of claim 2 wherein said recessed area of said insert below said lip has a circumference that is less than the circumference of said retaining ring.

5. The molded article of claim 1 wherein said insert is formed of a metal, a metal alloy, wood, high temperature plastics, or composite materials.

6. A method for forming an elevated surface feature for compression molded assemblies;

said method comprising;

placing an insert on to an actuated fixture pin with the pin initially in a retracted position;

closing an upper portion of a mold configured with said retracted actuated fixture pin over a preform of pre-preg plies placed on the bottom portion of said mold; and

actuating said fixture pin towards said pre-preg plies when a flowable material fills a molding cavity in the upper portion of the mold, said cavity configured to form said elevated surface feature;

the advancing action of said insert packs out the surface feature under the pressure of the pin to eliminate porosity in the elevated surface feature in the molding cavity; and

wherein said insert comprises;

a head with an open end, a lip, and a retaining ring surrounding a counter bore;

a cylindrical center space extending from the counter bore within an interior of said insert with a series of threads formed on a cylindrical wall, the cylindrical center space defined by the cylindrical wall to accommodate a fastener;

a multi-faced region with a plurality of flat faces on an exterior of the insert and surrounding the cylindrical center space; and

a tapered region extended from said multi-faced region that terminates in a sharpened leading edge;

wherein the sharpened leading edge forms a point;

a rounded recessed area below said lip has a circumference that is less than the circumference of said retaining ring, said insert is formed of a metal, a metal alloy, wood, high temperature plastics, or composite materials.

7. The method of claim 6 further comprising heating said cavity to cure said flowable material.

8. The method of claim 6 further comprising forming a seal between the counter bore and said actuated fixture pin.

9. The method of claim 6 further comprising preventing said flowable material from flowing beyond said retaining ring and said lip.