Listed below are the most common installation methods used to install compression limiters.
Press In: This method assumes that no melting of the plastic takes place. The insert (compression limiter) is pressed in place with a pre-determined amount of interference to the hole.
Mold In: This method assumes the part will be placed onto a core pin in the mold and the plastic will be molded around the part.
Thermal Insertion: During this process the insert (compression limiter) is placed into a molded or drilled hole that is slightly smaller than the main diameter of the insert. A heated probe then contacts the insert, causing the plastic to melt in a localized area around the insert. The insert is driven to the required depth or slightly below to allow for a slight withdrawal that may occur. The probe is then removed and the plastic re-solidifies around the insert. This process provides similar results when compared to ultrasonic insertion but utilizes “heat” rather than ultrasonic energy to melt the plastic.
Ultrasonic Insertion: During this process an insert is placed into a molded or drilled hole that is slightly smaller than the main diameter of the insert. Ultrasonic energy is applied to the insert with the use of an ultrasonic welder and a hardened steel or titanium horn. The ultrasonic energy develops frictional heat at the interface of the insert and plastic. This causes localized melting of the plastic while the insert is driven to the required depth. The plastic then re-solidifies, and the insert is secured in place.