Composite Component Recess Sealing for Conductor Length
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Solution Overview
Problem
Existing methods for producing composite components with electrically conductive filler materials face challenges such as heat loss and mechanical stress issues, leading to limited conductor track lengths and high fabrication costs, especially when using low-viscosity metal alloys in injection molding.
Innovation Solution
A method involving molding a plastic body with recesses and projections, where the plastic material is displaced into the recesses to create a barrier, reducing heat dissipation and material input, allowing for longer conductor tracks and eliminating the need for additional overmolding, by using flowable filler materials that are solidified within the recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If low-viscosity metal alloy is introduced into recesses in injection molded plastic body, then conductor track structures can be formed, but heat loss across the die causes limited conductor track length to around 500mm
Solution Approach 1:
The plastic material is pressed into the recesses before introducing the filler material, creating a barrier that prevents heat loss. This preliminary action of forming the seal ensures that when the filler material is subsequently introduced, the heat is retained and flowability is maintained over longer distances, enabling conductor tracks exceeding 500mm length.
2Reliability
If large cross section area of conductor tracks is used, then electrical conductivity is improved, but large material input is required
Solution Approach 1:
The plastic material is selectively pressed into the opening-side regions of the recesses, creating localized seals at the entrances while leaving the interior space available for filler material. This local modification allows the recesses to function as sealed containers that retain filler material with smaller cross-sections, reducing the overall material input required while maintaining adequate electrical conductivity through the confined filler material.
3Reliability
If mechanical stress such as shaking is applied to the finished composite component, then loosening of metal from cavity occurs, but additional overmolding can prevent this
Solution Approach 1:
The plastic material displaced into the recesses performs multiple functions automatically: it seals the recesses to prevent heat loss, contains the filler material to prevent loosening under mechanical stress, and eliminates the need for additional overmolding or sealing operations. The system uses its own material (the plastic from projections) to provide the protective functions that would otherwise require separate processes.
4Reliability
If sealing of low-viscosity metal alloy is performed, then filler material retention is improved, but fabrication expense increases
Solution Approach 1:
The sealing function is merged with the existing plastic molded body structure. The projections that are already part of the injection molded plastic body are pressed into the recesses to create seals, combining the sealing function with the structural elements already present in the component. This eliminates the need for separate sealing operations or additional materials, reducing fabrication expenses while ensuring filler material retention.
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 approach enables the production of longer conductor tracks with reduced material usage and lower fabrication costs, while providing mechanical and chemical protection, and eliminating the need for additional sealing and overmolding.
Implementation Method 1
the plastic material displaced into the recess constitutes a barrier between the filler material located in the recess and a die situated on the outside. In this way, the flow of heat from the filler material to the die is lessened
Implementation Method 2
pressing the at least one projection so that plastic material is thereby displaced into an opening-side region of the adjacent recess
Data Source
AI summary
A composite component and methods for producing a composite component are described herein. In some aspects, a method for producing a composite component may include molding a body from a plastic material, such that the molded body has at least one recess arranged adjacent to at least one respective projection. This method may also include pressing the at least one respective projection such that the plastic material of the molded body is thereby displaced into an opening-side region of the at least one recess adjacent thereto. The method may further include introducing flowable filler material into the at least one recess and solidifying the filler material. The filler material may be an electrically conductive filler material.