Method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material

A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism, the molded-in insert comprising a cylindrical body with at least one circumferential groove formed in the cylindrical body, the method comprising:

• treating a surface of the at least one circumferential groove of the molded-in insert to promote bonding of the fiber reinforced thermoplastic composite material to the surface of the at least one circumferential groove;
• fixing the molded-in insert in a mold cavity, wherein:
• the cylindrical body comprises a first circumferential substantially flat surface and a second circumferential substantially flat surface, having identical widths and diameters;
• the at least one circumferential groove extends between the first circumferential substantially flat surface and the second circumferential substantially flat surface;
• the at least one circumferential groove has a substantially concave configuration, a groove depth, a groove width, and a groove radius of 0.025 inch or greater;
• the groove radius is constant and is greater than or equal to the groove depth;
• the groove width is greater than the groove depth;
• and
• the at least one circumferential groove is configured to be filled with the fiber reinforced thermoplastic composite material and is configured to mold in place within or to a consolidated fiber reinforced thermoplastic composite structure;
• introducing the fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert;
• enclosing the mold cavity;
• heating and compressing the fiber reinforced thermoplastic composite material in the mold cavity to consolidate the fiber reinforced thermoplastic composite material around the molded-in insert, such that reinforcing fibers from the fiber reinforced thermoplastic composite material flow into and fully fill the at least one circumferential groove in order to form the high strength mechanical locking mechanism that retains the molded-in insert in place in the fiber reinforced thermoplastic composite material and forms the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert;
• cooling the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert;
• and
• removing the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert from the mold cavity.

method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism, the molded-in insert comprising a cylindrical body with at least one circumferential groove formed in the cylindrical body, the method comprising:

• treating a surface of the at least one circumferential groove of the molded-in insert to promote bonding of the fiber reinforced thermoplastic composite material to the surface of the at least one circumferential groove;
• fixing the molded-in insert in a mold cavity, wherein:
• the cylindrical body comprises a first circumferential substantially flat surface and a second circumferential substantially flat surface, having identical widths and diameters;
• the at least one circumferential groove extends between the first circumferential substantially flat surface and the second circumferential substantially flat surface;
• the at least one circumferential groove has a substantially concave configuration, a groove depth, a groove width, and a groove radius of 0.025 inch or greater;
• the groove radius is constant and is greater than or equal to the groove depth;
• the groove width is greater than the groove depth;
• and
• the at least one circumferential groove is configured to be filled with the fiber reinforced thermoplastic composite material and is configured to mold in place within or to a consolidated fiber reinforced thermoplastic composite structure;
• introducing the fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert;
• enclosing the mold cavity;
• heating and compressing the fiber reinforced thermoplastic composite material in the mold cavity to consolidate the fiber reinforced thermoplastic composite material around the molded-in insert such that reinforcing fibers from the fiber reinforced thermoplastic composite material flow into and fully fill the at least one circumferential groove to form the high strength mechanical locking mechanism that retains the molded-in insert in place in the fiber reinforced thermoplastic composite material and forms the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert;
• cooling the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert;
• removing the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert from the mold cavity;
• and
• using the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert to form a composite part with the molded-in insert.