Fiber-Reinforced Camera Bracket Structure to Prevent Molding Warp
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Solution Overview
Problem
The challenge is to prevent deformation during the molding of a camera bracket made of resin containing reinforcing fibers, as uneven surfaces lead to irregular fiber orientation and shrinkage differences, causing the bracket to warp.
Innovation Solution
The camera bracket features a lens hood portion with first protruding portions on the inner face and second protruding portions on the outer face, which helps maintain similar fiber orientations on both surfaces, reducing deformation and improving heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the lens hood portion is formed with an uneven surface by injection molding of fiber-reinforced resin, then the heat resistance of the bracket is improved, but the bracket undergoes deformation and warping
Solution Approach 1:
The patent applies local quality by providing protruding portions only at specific locations on the lens hood portion rather than making the entire surface uneven. This localized approach allows the resin to flow more uniformly in the main molding direction while still providing heat resistance at critical areas, thus preventing overall deformation of the lens hood portion
Solution Approach 2:
The protruding portions are designed with asymmetric characteristics where they extend more prominently in the direction opposite to the lens hole rather than being uniformly distributed. This asymmetric design creates a controlled flow pattern for the fiber-reinforced resin that maintains consistent fiber orientation and reduces differential shrinkage, thereby preventing warping while preserving heat resistance
2Temperature
If the surface of the molded product is made uneven, then heat resistance is improved, but the reinforcing fibers become irregularly oriented causing deformation
Solution Approach 1:
The uneven surface is created locally through protruding portions rather than across the entire lens hood portion. This localized unevenness allows heat resistance to be improved at specific areas while the overall surface maintains sufficient smoothness to ensure uniform fiber orientation and consistent resin flow, preventing deformation
Solution Approach 2:
The patent applies partial action by providing protruding portions only where heat resistance is most needed, rather than making the entire surface uneven. This partial application of surface unevenness achieves the necessary heat resistance while minimizing the impact on fiber orientation uniformity and overall structural stability
Data Source
AI summary
A camera bracket made of a resin containing reinforcing fibers includes: a plate-shaped base portion disposed along a vehicle inner side face of a window panel; a lens hood portion recessed from the base portion in a direction opposite to the window panel, forming a view space between the lens hood portion and the window panel; and a lens hole formed in the base portion to communicate with the view space. A plurality of first protruding portions are provided on an inner face, which is oriented to the view space, of the lens hood portion. A plurality of second protruding portions are provided on an outer face, which is opposite to the inner face, of the lens hood portion. The lens hood portion may expand, toward a first direction to which the lens hole is oriented, in a second direction orthogonal to the first direction.