Molded Liner on Substrate with Protrusions for Electronic Housings
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Solution Overview
Problem
Existing electronic component housings are often inadequate in protecting against impacts and fluids, with injection molded housings lacking strength and machined housings being heavy.
Innovation Solution
A structure comprising a substrate with protrusions or depressions that a molded liner attaches to, formed through additive printing or other methods, providing a lightweight and watertight seal while electrically isolating components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molded housings are used, then manufacturing efficiency is improved, but structural strength deteriorates
Solution Approach 1:
The patent applies composite materials by combining a metal substrate (aluminum or aluminum alloy) with a molded liner material (thermoplastic elastomer, thermoplastic polyurethane, or thermoplastic polyamide). The metal substrate provides structural strength while the molded liner provides sealing and protection, resolving the contradiction between manufacturing efficiency and structural strength.
2Strength
If machined housings are used, then structural strength is improved, but weight increases
Solution Approach 1:
The housing is segmented into two distinct components: a metal substrate that provides structural strength and a molded liner that provides sealing and protection. This segmentation allows each component to be optimized for its specific function, with the metal substrate being thin-walled (reducing weight) yet maintaining strength through its structural role.
3Strength
If a molded liner is attached to a substrate with protrusions and depressions, then attachment strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the attachment features (protrusions and depressions) directly into the substrate manufacturing process through additive printing or other formation methods, rather than adding separate attachment components. This integration reduces the number of separate parts and assembly steps, maintaining manufacturing simplicity while achieving strong attachment.
Data Source
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AI summary
Structures include a substrate having a base surface. The base surface includes a plurality of protrusions extending from the base surface and/or a plurality of depressions extending into the base surface. The structures include a molded liner. The molded liner encapsulates the plurality of protrusions and/or the molded liner extends into at least a portion of the plurality of depressions.