Composite Insert Stiffener Design for Extrusion Coating Deflection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The '2K direct extrusion coating' technique in the automobile sector often causes deflections in plug-in contacts due to high forces exerted by thermoplastic material, leading to deviations from the target position and manufacturing defects in sensors with composite inserts.
Innovation Solution
A composite insert with a premolded part featuring a first three-dimensional sealing surface and stiffeners extending beyond the transition region to the injection mold, providing increased rigidity and improved sealing, which compensates for manufacturing tolerances and reduces deflections during extrusion-coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion-coating with thermoplastic material is performed, then the sensor is enclosed and coated, but high forces are exerted on the composite insert causing deflections of the plug-in contacts and deviations from the target position
Solution Approach 1:
The composite insert is divided into functionally distinct regions: a rigid metallic contact element region for electrical connections and a flexible premolded part region for sealing and cushioning. This segmentation allows the rigid portion to maintain contact position accuracy while the flexible portion absorbs extrusion forces
Solution Approach 2:
The premolded part is pre-formed with cushioning properties and positioned around the metallic contact element before the extrusion-coating process. This beforehand cushioning protects the sensitive contact elements from the high forces exerted during thermoplastic material injection, preventing deflections and position deviations
2Stability of the object's composition
If the plug area is designed to reduce deflection, then contact stability improves, but the plug area remains a weak point in the sensor structure
Solution Approach 1:
The composite insert combines metallic contact elements with a premolded part made of flexible material. This composite structure leverages the high strength and rigidity of metal for contact stability while utilizing the flexibility and damping properties of the premolded part to eliminate structural weaknesses, creating a balanced design that maintains both contact stability and overall reliability
3Manufacturing precision
If a three-dimensional sealing surface is formed tapering away from the transition region, then sealing accuracy improves and manufacturing tolerances are compensated, but the design complexity increases
Solution Approach 1:
The sealing surface is designed with a tapered conical geometry rather than a flat or complex curved surface. This simple conical shape effectively compensates for manufacturing tolerances in both the composite insert and injection mold while maintaining ease of manufacturing and assembly, avoiding excessive design complexity
Data Source
AI summary
A composite insert has at least one metallic contact element which is extrusion-coated with the aid of a premolded part which has a first three-dimensional sealing surface to an injection mold, a stiffener of the contact element being formed beyond a transition region of the premolded part to the injection mold.