Composite Molded Vent Structure for Protected Membrane Venting
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Solution Overview
Problem
The existing casing member structures with integrated gas permeable membranes have limited design freedom due to restricted space for membrane arrangement and ventilation channel configuration, leading to difficulties in demolding and requiring additional bonding processes.
Innovation Solution
A composite molded body with a ventilation channel comprising a first and second ventilation path, where the gas permeable membrane is positioned at a midway portion, allowing for non-linear configurations and integration during injection molding, with an inserted member supporting the membrane to enhance design freedom and prevent exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gas permeable membrane is arranged parallel to a wall surface of the casing member along the wall surface, then the membrane is protected from exposure, but the space for membrane arrangement is limited and design freedom is reduced
Solution Approach 1:
The invention transitions from arranging the gas permeable membrane in a planar configuration parallel to the wall surface to a three-dimensional arrangement where the membrane is positioned within a recessed portion that extends into the casing member. This dimensional change allows the membrane to be protected while providing sufficient arrangement space and design freedom for non-linear ventilation channel configurations.
Solution Approach 2:
The gas permeable membrane is nested within a recessed portion of the casing member, similar to a doll within a doll structure. This nesting approach protects the membrane from external damage while integrating it into the casing member structure, allowing for flexible ventilation channel design without exposing the membrane to the outside environment.
2Adaptability or versatility
If a separate internal member is provided within the casing member, then functional requirements are met, but demolding becomes difficult or impossible
Solution Approach 1:
The invention merges the gas permeable membrane with the casing member by integrating the membrane into a recessed portion of the casing member. This combining approach allows the membrane to function as a separate component while being structurally integrated, enabling easy demolding without requiring separate internal members that would complicate the manufacturing process.
3Ease of manufacture
If the ventilation path extends linearly along one direction corresponding to the mold opening direction, then the injection molding process is simplified, but the configuration freedom of ventilation channels is limited
Solution Approach 1:
The invention enables non-linear ventilation channel configurations by utilizing the three-dimensional space within the recessed portion of the casing member. The ventilation path can extend in multiple directions and follow complex routes while still being formed through injection molding, as the recessed structure provides the necessary spatial freedom without complicating the molding process.
4Productivity
If the gas permeable membrane is exposed to the outside, then ventilation efficiency is improved, but the membrane is easily damaged
Solution Approach 1:
The recessed portion of the casing member acts as an intermediary structure that protects the gas permeable membrane from external damage while still allowing ventilation to occur. The membrane remains enclosed within the recessed portion, shielded from physical damage, while the ventilation channels provide efficient gas exchange between the interior and exterior environments.
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 a higher degree of freedom in designing the gas permeable membrane arrangement and ventilation channel configuration, allowing for integral molding and improved water-proofness and dust-proofness without exposing the membrane to external damage.
Implementation Method 1
a gas permeable membrane disposed in a midway portion of the ventilation channel
Implementation Method 2
a gas permeable membrane that blocks water droplets, oil droplets, and dusts but permits ventilation
Implementation Method 3
a main portion formed of an injection-moldable resin material
Implementation Method 4
a resin filling step of filling the cavity with a resin material to mold the main portion
Data Source
AI summary
A composite molded body includes a main portion formed of resin, a ventilation channel configured within the main portion, a gas permeable membrane, and two inserted members embedded in the main portion. The ventilation channel has a first ventilation path P1 extending in a direction intersecting the gas permeable membrane and has an opening end leading to the external air, and a second ventilation path extending in a direction different from the direction in which the first ventilation path extends and having an opening end leading to the internal space of the casing. The inserted member forms a portion of the second ventilation path and has a membrane supporting portion formed with a through hole. The through hole constitutes a portion of the first ventilation path, and communicates with the internal space of the casing via the second ventilation path.