Insert-Molded Functional Member With Gradient Thickness
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Solution Overview
Problem
Insert-molding of functional members in substrate storage containers often results in deformation due to shrinkage during molding, leading to accuracy and position deterioration, and existing solutions lack specific designs for adhesion reinforcing ribs.
Innovation Solution
A substrate storage container design featuring a functional member with a thick section and a thin section that decreases in thickness towards the outer edge, formed integrally with the container body or lid, where the thin section is either acute, inclined, or convex, and is flush with the container body's inner surface, reducing stress and deformation during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a functional member is insert-molded into the container body, then the functional member can be integrally formed with the container body, but shrinkage occurs during molding causing deformation and dimensional inaccuracy
Solution Approach 1:
The attachment part is designed with non-uniform thickness, featuring a thick section at the base and a thin section at the outer edge. This local variation in geometry allows the thick section to provide structural strength and adhesion during molding, while the thin section reduces stress concentration and prevents deformation, thereby resolving the contradiction between integral formation strength and dimensional accuracy
Solution Approach 2:
The thickness parameter of the attachment part is strategically varied from the thick section to the thin section. This parameter change optimizes the balance between adhesion strength (requiring sufficient thickness) and stress relaxation (benefiting from reduced thickness), preventing sink marks and deformation while maintaining integral formation
2Manufacturing precision
If the attachment part is made thin to reduce deformation, then stress is reduced, but adhesion strength with the container body decreases
Solution Approach 1:
The attachment part employs local quality variation with a thick section at the base providing adhesion strength and a thin section at the outer edge reducing stress. This localized thickness optimization ensures sufficient bonding to the container body while minimizing deformation during molding
Solution Approach 2:
Instead of uniformly reducing thickness throughout the attachment part, the invention introduces a dimensional gradient from the thick section to the thin section. This gradual transition in the thickness dimension allows stress to be distributed more effectively, maintaining adhesion while reducing deformation
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 design effectively suppresses deformation of the functional member during molding, ensuring accurate positioning and improved manufacturing processes by relaxing stress and enhancing adhesion with the container body, while allowing for different materials with varying friction coefficients for improved slidability and wear resistance.
Implementation Method 1
a groove portion into which a molding resin flows is formed on a functional member to relax stress in shrinking
Implementation Method 2
a vertical or horizontal adhesion reinforcing rib is formed on a functional member to increase a degree of adhesion with a container body
Data Source
AI summary
There is provided a substrate storage container 1 capable of suppressing deformation of a functional member insert-molded and a method of manufacturing the container 1, and an device positioning member 4 as the functional member including: an attachment part 41 having a thick section 413 formed in thickness equal to a wall member of a container body 10 or a lid 20 and a thin section 410 decreasing in thickness as it approaches toward an outer edge from the thick section 413; and a body part 42 coupled to the attachment part 41, the device positioning member 4 being disposed on the container body 10 or the lid 20 so that a first surface 420 of the thick section 413 is flush with an inner surface of the wall member.