In-situ Polymerized Cast Element for Vehicle Electrical Components
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Solution Overview
Problem
Conventional methods for producing vehicle electrical system components using thermoplastic melts often require high pressures, high temperatures, and can cause mechanical and thermal stress on electrical components, limiting design flexibility and increasing the risk of damage to sensitive inserts.
Innovation Solution
The use of an in-situ polymerization process to create a cast element from a low-viscosity polymerization compound, such as polyamide, which allows for lower pressure injection, reduced temperature requirements, and improved wetting behavior, enabling the encapsulation of electrical components with lower stress and greater design freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic melts are used to mold cast elements, then the encapsulation of electrical components can be achieved, but high pressures and high temperatures are required causing mechanical and thermal stress on electrical components
Solution Approach 1:
The patent changes the physical and chemical parameters of the casting process by using low-viscosity casting compounds instead of thermoplastic melts. This allows the process to proceed at lower temperatures and pressures, specifically reducing thermal stress on electrical components while maintaining effective encapsulation and protection
Solution Approach 2:
The patent utilizes the phase transition properties of casting compounds that remain in liquid state at lower temperatures compared to thermoplastic melts. The low viscosity liquid casting compound can penetrate and encapsulate electrical components without requiring high-temperature phase changes, thereby reducing thermal stress while achieving complete coverage
2Manufacturing precision
If thermoplastic melts are used for casting, then encapsulation can be achieved, but the high viscosity requires high injection pressures
Solution Approach 1:
The patent fundamentally changes the viscosity parameter of the casting material by using specially formulated low-viscosity casting compounds. This parameter change enables the injection process to proceed at significantly lower pressures while still achieving complete mold filling and high-quality encapsulation of electrical components
3Ease of manufacture
If conventional casting processes are used, then production can proceed, but design flexibility is limited and complex shapes are difficult to produce
Solution Approach 1:
The patent changes the viscosity and flow characteristics parameters of the casting compound to enable the material to flow into complex mold geometries and produce intricate shapes. The low-viscosity casting compound can fill detailed mold cavities and create complex encapsulated structures that would be difficult to achieve with conventional high-viscosity thermoplastic melts
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 reduces mechanical and thermal stress on electrical components, allows for easier production of complex shapes, and enhances the sealing and protective properties of the cast elements, while enabling the use of sensitive inserts and facilitating easier assembly by allowing the polymerization to occur directly at the point of use.
Implementation Method 1
The plastic is produced virtually on site in a negative mold, workpiece mold or mold used in casting or injection molding by polymerisation of an introduced monomer
Data Source
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Figure 5~6
AI summary
The onboard power supply element (2) for a motor vehicle comprises an electrical component which is overmoulded at least in regions by a cast element (6), in particular made of a thermoplastic synthetic material. The cast material (6) is thereby produced by an in situ polymerization method. By this means, the load of the electrical component is reduced during overmoulding in comparison to conventional methods. Due to a low viscosity of the initially monomer casting compound, a complete overmoulding and penetration into intermediate spaces is additionally achieved so that, in particular, a reliable seal is guaranteed.