of both parallel and tapered designs. A three stepped insert design evolved with the mid-point of each parallel diameter following a taper. The mating hole in the plastic also followed the same stepped profile but at smaller diameters, designed to create the necessary interference during heat insertion. By carefully selecting the difference in diameter between the steps, says PSM, the small leading insert diameter had a large clearance with the large top hole diameter, providing excellent location. With this design the two leading insert diameters were also a free fit with the top two moulded hole diameters, providing excellent alignment and location. As a result, during heat insertion the insert travel is less than one third of the total insert length. The PSM design team had developed a Sonic-Lok
replacement, with the location and alignment properties of a tapered insert but with all of the benefits of parallel hole technology. The new aluminium Tri-Step insert had met all of its design objectives and gave the following key benefits:
• Equivalent pull-out and direct torque resistance to brass designs.
• 66% weight reduction. • Excellent location and alignment. • Typically a 20% cost saving compared with equivalent brass inserts.
• Typically a two second insertion time saving compared with tapered brass inserts.
• Lead free. PSM states that the new Tri-Step has been well received
by both OEMs and tier 1 & 2 moulders and is currently being specified on a number of new automotive projects. Feedback from the market was that in addition to the oversize aluminium range of Tri-Step, a thin walled reduced diameter range was required for less demanding applications and for areas where space was limited. PSM therefore introduced a thin-walled range, available in thread sizes M2 - M8, in two standard lengths and available in a variety of materials. Both Tri-Step designs are protected by a granted UK patent
and a PCT international patent application that is currently progressing through the foreign country stages.
www.psminternational.com
Sheet Metal Fasteners Hall: 21 Stand: D53 Inserts for plastics
Flangeform®
Tri-step®
PSM International Ferry Lane, Pembroke, South Wales, SA71 4RE, United Kingdom Tel: +44 (0) 1646 683 501 • Fax: +44 (0) 1646 687 251 email:
europe@psminternational.com • web:
www.psminternational.com
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