# US 10,118,351 B2 · Method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,118,351 B2 - Document ID: US10118351B2 - Status: Granted - Kind: B2 - Application number: 14/875,187 - Filed: 2015-10-05 - Published: 2016-01-28 - Granted: 2018-11-06 - Earliest claimed: 2011-07-22 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Edward McMurray Fisher, Jr.; Brian Allen Carter - Web page: https://patentgrep.com/patent/US10118351B2 ## CPC - B29C 70/682: {Preformed parts characterised by their structure, e.g. form} - B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)} - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B29C 45/14311: {using means for bonding the coating to the articles (B29C45/14795 takes precedence)} - B29C 45/14631: {Coating reinforcements (fibre reinforcements B29C45/0005)} - B29C 70/683: {Pretreatment of the preformed part, e.g. insert} - F16B 37/122: {Threaded inserts, e.g. "rampa bolts"} - B29C 2043/181: {encapsulated} - B29K 2101/12: Thermoplastic materials - B29K 2105/06: containing reinforcements, fillers or inserts - B29K 2105/20: Inserts - Y10T 403/47: Molded joint - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism is provided. The method includes fixing a molded-in insert in a mold cavity. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, and has a substantially concave configuration, and the groove has a groove radius of 0.025 inch or greater, and greater than or equal to a groove depth. The method includes introducing a fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert, enclosing the mold cavity, heating and compressing the material in the mold cavity to consolidate the material around the molded-in insert and to form a consolidated fiber reinforced thermoplastic composite structure with the molded-in insert, cooling the structure, and removing the structure with the molded-in insert from the mold cavity. ## Claims ### Claim 1 A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism, the method comprising: fixing the molded-in insert in a mold cavity, the molded-in insert comprising: a cylindrical body, comprising a first circumferential substantially flat surface and a second circumferential substantially flat surface, having identical widths and diameters; and a circumferential groove, formed in the cylindrical body and extending between the first circumferential substantially flat surface and the second circumferential substantially flat surface, and wherein: the 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 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 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. ### Claim 2 (depends on 1) The method of claim 1, further comprising prior to fixing the molded-in insert in the mold cavity, treating a surface of the circumferential groove of the molded-in insert to promote bonding of the fiber reinforced thermoplastic composite material to the surface of the circumferential groove. ### Claim 3 (depends on 2) The method of claim 2, wherein treating the surface of the circumferential groove comprises at least one of solvent wiping, abrading, grit blasting, sanding, sandblasting, chemical cleaning, chemical etching, sol gel treatment, primer treatment, or adhesive treatment. ### Claim 4 (depends on 1) The method of claim 1, wherein the molded-in insert is consolidated with the fiber reinforced thermoplastic composite material via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting. ### Claim 5 (depends on 1) The method of claim 1, wherein the method minimizes or eliminates formation of void areas of no reinforcement and minimizes or eliminates cutting of fibers in the fiber reinforced thermoplastic composite material. ### Claim 6 (depends on 1) The method of claim 1, wherein the circumferential groove is formed in an exterior surface of the cylindrical body. ### Claim 7 (depends on 1) The method of claim 1, wherein the circumferential groove is formed in an interior surface of the cylindrical body. ### Claim 8 (depends on 1) The method of claim 1, wherein the cylindrical body further comprises a third circumferential substantially flat surface, having a width and a diameter identical to those of the first circumferential substantially flat surface. ### Claim 9 (depends on 1) The method of claim 1, wherein the fiber reinforced thermoplastic composite material comprises reinforcing fibers in a resin matrix, wherein the reinforcing fibers are made of a material comprising one of graphite, glass, carbon, boron, ceramics, aramids, polyolefins polyethylenes, or polymers. ### Claim 10 (depends on 6) The method of claim 6, wherein the cylindrical body further comprises at least one second circumferential groove formed in the exterior surface of the cylindrical body. ### Claim 11 (depends on 7) The method of claim 7, wherein the cylindrical body further comprises at least one second circumferential groove formed in the interior surface of the cylindrical body. ### Claim 12 (depends on 1) The method of claim 1, wherein the circumferential groove is formed in an exterior surface of the cylindrical body, and the cylindrical body further comprises a second circumferential groove, formed in an interior surface of the cylindrical body. ### Claim 13 (depends on 1) The method of claim 1, wherein the molded-in insert is made of a machinable material selected from a group comprising a metal material, a ceramic material, and a composite material. ### Claim 14 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. ### Claim 15 (depends on 14) The method of claim 14, wherein treating the surface of the at least one circumferential groove comprises at least one of solvent wiping, abrading, grit blasting, sanding, sandblasting, chemical cleaning, chemical etching, sol gel treatment, primer treatment, or adhesive treatment. ### Claim 16 (depends on 14) The method of claim 14, wherein the molded-in insert is consolidated with the fiber reinforced thermoplastic composite material via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting. ### Claim 17 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. ### Claim 18 (depends on 17) The method of claim 17, wherein treating the surface of the at least one circumferential groove comprises at least one of solvent wiping, abrading, grit blasting, sanding, sandblasting, chemical cleaning, chemical etching, sol gel treatment, primer treatment, or adhesive treatment. ### Claim 19 (depends on 17) The method of claim 17, wherein the molded-in insert is consolidated with the fiber reinforced thermoplastic composite material via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting. ### Claim 20 (depends on 17) The method of claim 17, further comprising after forming the composite part, using the composite part in a transport vehicle selected from a group comprising an aircraft, an aerospace vehicle, a space launch vehicle, a rocket, a satellite, a rotorcraft, a watercraft, a boat, a train, an automobile, a truck, and a bus.