Insert Injection-Molded Case With Holding Portions

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Solution Overview

Problem

Conventional insert injection-molded products using glass fiber resin suffer from deformation, protruding glass components affecting slimness and appearance, high defect rates, and increased manufacturing costs due to the need for expensive materials and shifting metal plates during the molding process.

Innovation Solution

An insert injection-molded case using polycarbonate resin with holding portions and fixing members in the mold to prevent deflection, allowing accurate metal plate positioning and reducing manufacturing costs, while maintaining a metallic appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If glass fiber resin is used to prevent deformation, then deformation resistance is improved, but glass components protrude from the appearance affecting slimness and surface quality

Engineering Contradiction:

Improvedeformation resistanceVSAvoidsurface smoothness and slimness

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The patent changes the material parameter from glass fiber reinforced resin to polycarbonate resin, which provides adequate deformation resistance without the protrusion problem. The holding portions are strategically positioned to provide structural support where needed, allowing the use of non-reinforced polycarbonate resin that maintains surface smoothness and enables slim design while preventing deformation during cooling.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent segments the structural support function from the bulk material by introducing discrete holding portions that couple to fixing members in the mold. This allows the main body to use smooth polycarbonate resin while localized support structures prevent deformation, separating the reinforcement function from the material composition.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If glass fiber resin is used to prevent deformation, then deformation resistance is improved, but manufacturing cost increases due to expensive material

Engineering Contradiction:

Improvedeformation resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive glass fiber resin with cheaper polycarbonate resin. The temporary structural support during molding is provided by the holding portions and fixing members, which are part of the mold system rather than the final product. This approach uses a lower-cost material that achieves the same deformation prevention function through structural design rather than material reinforcement.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If metal plate positioning is not secured during insert injection-molding, then manufacturing simplicity is maintained, but metal plate shifts causing high defect rate

Engineering Contradiction:

Improveprocess simplicityVSAvoidmetal plate positioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent implements preliminary positioning of the metal plate using fixing portions that couple to fixing members in the mold before the injection molding process begins. This pre-positioning ensures accurate metal plate placement while maintaining process simplicity, as the fixing structure is integrated into the mold design and automatically positions the metal plate during setup.

Inventive Principle:

Principle #10Preliminary action

4Stability of the object's composition

If outer surface is irregular due to glass components, then deformation resistance is improved, but metallic coating deposition becomes difficult

Engineering Contradiction:

Improvestructural stabilityVSAvoidcoating deposition quality

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from glass fiber reinforced resin to smooth polycarbonate resin, creating an irregularity-free surface that is suitable for metallic coating deposition. The structural stability previously provided by glass fibers is replaced by holding portions that couple to fixing members, allowing the surface to remain smooth while maintaining deformation resistance through structural design.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9259868B2Insert injection-molded case

Publication Date: 2016.02.16 SAMSUNG ELECTRONICS CO LTD

AI summary

An insert injection-molded case that provides a better appearance and a reduced defective rate of manufacture can be utilized for a number of products, including but not limited to a cover for portable communication devices. The case preferably includes: a metal plate having one or more fixing portions coupled to fixing members formed in a mold respectively; an injection-molded case body injection molded with the metal plate; and one or more holding portions formed in the injection-molded case body during the injection molding and coupled to the fixing members respectively to prevent deflection of the injection-molded case body caused during a cooling operation after the injection molding.