Composite Housing Frame Molding with C-Shaped Edge Stiffening
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Solution Overview
Problem
Existing methods for forming a housing using a carbon-fiber-reinforced resin base plate struggle to create complex mechanical sections, such as ribs, and high standing walls, due to design limitations that prevent secure inlet placement for molten resin injection, which hinders the achievement of optimal stiffness and structural integrity.
Innovation Solution
A housing is formed by temporarily fixing an inlet/mold positioning pin in a base plate positioning hole, allowing molten resin to be injected and forming a C-shaped frame section protruding outside the base plate, using a mold with sliders to create a frame with a C-shaped cross-section around the base plate, ensuring maximum resin usage and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the carbon-fiber-reinforced resin base plate is extended to the frame of the housing, then the area of use of the base plate is increased, but edges of the sliders may correspond to the outer edge of the base plate, making it difficult to secure an inlet for injecting molten resin
Solution Approach 1:
The patent extends the base plate not only in the planar direction but also in the thickness direction to form a standing wall portion. This dimensional extension creates a stepped structure where the inlet can be positioned on the standing wall portion, away from the edge of the flat plate portion, thus avoiding the slider edge alignment issue while maximizing the usable area of the base plate.
2Strength
If sliders are moved along the carbon-fiber-reinforced resin base plate inside and outside the housing to form a C-shaped frame, then the stiffness of the housing is improved, but the complexity of the molding process increases
Solution Approach 1:
The patent combines the base plate and the frame into a single integrated molded part using carbon-fiber-reinforced resin. The base plate, standing wall portion, and frame are formed as one piece through a single molding process, eliminating the need for separate components and assembly steps while maintaining the C-shaped cross-section for enhanced stiffness.
3Weight of moving object
If a housing is formed by outsert molding of a frame around a carbon-fiber-reinforced resin base plate, then weight and thickness are reduced, but it is difficult to provide complex mechanical sections such as ribs on the base plate
Solution Approach 1:
The patent utilizes the moldability of carbon-fiber-reinforced resin to directly form complex mechanical sections such as ribs, standing walls, and C-shaped frames during the injection molding process. By changing the manufacturing approach from post-processing or assembly to in-mold forming, complex structures are achieved while maintaining the weight and thickness benefits of the carbon-fiber material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the creation of a housing with enhanced stiffness and structural integrity by forming a C-shaped frame around the base plate, allowing for improved mechanical strength and flexibility while maintaining slimness and lightness, and allows for accurate positioning and removal of the base plate during molding.
Implementation Method 1
injecting molten resin into the mold through the inlet
Data Source
AI summary
According to one embodiment, a housing includes a base plate and a frame formed on an outer edge of the base plate. The base plate includes a positioning hole for positioning in a mold. At least, the frame has a cross-section protruding outside the base plate. A positioning pin fit into the positioning hole is provided in the mold. An inlet through which molten resin is injected into a cavity of the mold is opened in the positioning pin. In the housing, the frame is formed on the outer edge of the base plate by injecting synthetic resin into the mold through the inlet.