Dissimilar Material Joint Protrusion for Resin-Metal Housing
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Solution Overview
Problem
Dissimilar material joints between thermoplastic resin and thin metal bases in electronic component housings face issues such as deformation and peeling due to thermal expansion differences and molding shrinkage, leading to warpage and reduced durability.
Innovation Solution
A dissimilar material joint design featuring a metal base with protrusions or grooves that increase contact area with the resin rib, including inverted V-shaped or S-shaped grooves, to enhance bonding and prevent deformation, using thermoplastic resin composition with fillers and injection molding for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the thickness of the metal plate is reduced to less than 0.5 mm for weight reduction and compactness, then the weight and size of the housing are reduced, but significant warpage deformation occurs in the housing due to the total area of the joint to the inner and outer surfaces being significantly different
Solution Approach 1:
The invention applies local quality by creating protrusions at specific locations on the metal base where resin ribs are joined. These localized protrusions increase the bonding area precisely where needed to prevent warpage, while the rest of the thin metal base maintains its lightweight advantage. The protrusions are strategically positioned at joint areas where deformation is most likely to occur.
Solution Approach 2:
The invention introduces a third dimension by forming protrusions that extend from the metal base surface into the resin rib. This vertical dimension adds bonding area without increasing the horizontal footprint of the metal plate, allowing enhanced connection strength while maintaining the thin-profile design for weight reduction.
2Weight of moving object
If the thickness of the metal plate is reduced to less than 0.5 mm, then the weight is reduced, but the housing hardness and deformation resistance decrease
Solution Approach 1:
The invention creates a composite structure combining thin metal base with resin ribs that have protrusions. This composite approach allows the metal base to provide structural framework and weight efficiency, while the resin ribs with protrusions provide localized reinforcement and deformation resistance, achieving both weight reduction and maintained strength.
Solution Approach 2:
The protrusions provide localized reinforcement at critical stress points where resin ribs connect to the metal base. This localized quality enhancement prevents deformation without requiring the entire metal base to be thicker, maintaining overall lightweight design while improving specific areas of strength and hardness.
3Strength
If a resin rib is joined to a thin metal base for reinforcement, then the bonding area is increased, but deformation and peeling occur due to difference in coefficient of thermal expansion and molding shrinkage
Solution Approach 1:
The protrusions create localized zones of enhanced bonding between the resin rib and metal base. These localized quality improvements concentrate the bonding interface where thermal expansion and shrinkage stresses are most problematic, providing targeted reinforcement that prevents peeling and deformation without requiring extensive bonding area throughout the entire joint.
Solution Approach 2:
The protrusions are formed on the metal base before the resin rib is joined to it. This preliminary action creates pre-formed bonding interfaces that guide the resin flow and establish strong mechanical interlocking from the start, preventing subsequent peeling and deformation caused by thermal expansion differences and molding shrinkage.
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
The joint effectively reduces deformation and peeling, maintaining strength and preventing warpage even after long-term use, by increasing the bonding area between the resin and metal, thus improving the mechanical and thermal properties of the housing.
Implementation Method 1
a resin intrudes into fine ruggedness shape of a metal surface formed at least in the joined portion
Implementation Method 2
dissimilar material joining in which a resin intrudes into fine ruggedness shape of a metal surface
Implementation Method 3
the metal base forms a protrusion protruding inside of the resin rib on at least a part of the joined portion
Implementation Method 4
the protrusion has a groove structure formed so as to extend continuously in a longitudinal direction of the resin rib
Data Source
AI summary
A dissimilar material joint including a joined portion between a resin rib and a metal base, in which the metal base forms a protrusion protruding inside of the resin rib on at least a part of the joined portion.