Part positioning and assembly process for creep sensitive material

A method of positioning and assembling two parts wherein at least one part is of a creep sensitive material, said method comprising:

• providing a mold equipped for molding a first part, said mold equipped with at least one spindle configured to define at least one centering hole in said first part during molding;
• providing at least one annular insert sized to be received over a corresponding one of said at least one spindle, said at least one annular insert comprising material unaffected by creep, said at least one annular insert having a circumferential wall including an outer circumferential surface and an inner bore with geometry different from geometry of a corresponding one of at least one spindle, said at least one annular insert including:
• two wall passages extending through said wall from the outer circumferential surface to the inner bore, wherein said two wall passages arranged on diametrically opposing sides of a circumferential wall of said annular insert, said two wall passages are any of:
• at least one through orifice,
• at least one recess formed in an end face of said insert,
• or a slot;
• fitting said at least one annular insert onto said corresponding one of at least one spindle of said mold, wherein said difference in geometry defines an intermediate volume void between said at least one annular insert and said corresponding one of at least one spindle, wherein said two wall passages open into said bore at said intermediate volume;
• molding said creep sensitive material into said mold forming said first part, said molding step including flowing a portion of said creep sensitive material through said two wall passages to fill said intermediate volume between said at least one annular insert and said corresponding one of at least one spindle forming diametrically opposing first and second crescent shaped segments within said bore, said diametrically opposing first and second crescent shaped segments both secured to the inner wall of said at least one annular insert and extending axially within said inner bore between opposing axial ends of said at least one annular insert, wherein the first crescent segment is connected to and formed by molded plastic creep sensitive material extending through a first one of said two wall passages and the second crescent shaped segment is connected to and formed by molded plastic creep sensitive material extending through a second one of said two wall passages;
• wherein diametrically opposing first and second crescent shaped segments form opposing sides of said at least one centering hole axially extending between said opposing axial ends of said annular insert, said at least one centering hole having a radially oblong cross section;
• unmolding said first part from said mold and said at least one spindle, wherein said at least one annular insert remains secured to said first part, wherein said at least one annular insert extends through a corresponding one of at least one opening in said first part and having an axial length selected that said at least one annular insert is operable as a compression limiter and opens at opposing sides of said first part, and said at least one spindle leaves at least one centering hole extending axially through said annular insert;
• providing a second part having at least one mounting hole positioned against and aligned with a corresponding one of said at least one centering hole of said first part;
• wherein said at least one centering hole comprises a first centering hole of a first one of at least one annular insert having a first radially oblong cross section, aligned with its oblong length along a first axis providing free play along said first axis, and a second centering hole, of a second one of at least one annular insert having a second radially oblong cross section, aligned with its oblong length along a second axis providing free play along said second axis, wherein said first axis is perpendicular to said second axis and said first and second axes are offset such that said first axis does not cross said second centering hole and said second axis does not cross said first centering hole;
• providing at least one centering screw or a pin, said at least one centering screw or pin sized for insertion into a corresponding one of said at least one centering hole, wherein said at least one centering hole has geometry permitting free play between said centering screw or pin and corresponding said centering hole in a first direction taken normal to an axis of said centering hole;
• arranging said first and second parts with said at least one mounting hole and at least one centering hole positioned for rough alignment, said rough alignment in which one of said at least one centering screw or pin is insertable through one of said at least one centering hole into said corresponding one of said at least one mounting hole;
• positioning said first part relative to said second part by inserting said at least one centering screw or pin though said corresponding one of said at least one centering hole into said mount hole, one of said at least one centering screw or pin operative as a centering post for alignment of said parts, said free play maintaining rough alignment while said free play permitting fine alignment between said first and second parts;
• and
• securing said first and second parts together by attachment screws.