Vehicle Rack Housing Material Dimensional Stability
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Solution Overview
Problem
Thermoplastic resin-based materials used in vehicle torque sensors suffer from poor dimensional stability due to thermal expansion and contraction, leading to airtightness issues and potential leaks in high-temperature environments.
Innovation Solution
A composition for a rack housing member comprising polybutylene terephthalate, acrylonitrile-styrene-acrylate copolymer, and polyethylene terephthalate, combined with glass fibers and plate-shaped mineral fillers, which provides enhanced dimensional stability, rigidity, and chemical resistance through optimized weight ratios and intrinsic viscosities, improving injection moldability and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic resin (polyester-based resin) is used for rack housing member, then mechanical and electrical properties are improved, but dimensional stability deteriorates due to thermal expansion and contraction
Solution Approach 1:
The patent uses a composite material system consisting of polyester-based resin combined with specific inorganic fillers (glass fiber: 20-40 parts, plate-shaped mineral filler: 10-30 parts, spherical filler: 5-20 parts) to achieve both mechanical strength and dimensional stability. The multi-component filler system works synergistically to reduce thermal expansion while maintaining structural properties.
Solution Approach 2:
The patent specifies precise parameter ranges for the resin components (polyester-based resin with specific intrinsic viscosity: 0.6-1.2 dl/g, polybutylene terephthalate content: 40-70 parts, polyethylene terephthalate content: 10-30 parts) to control thermal expansion coefficients and achieve dimensional stability while maintaining mechanical properties.
2Stability of the object's composition
If inorganic filler is added to improve dimensional stability, then warpage during injection molding is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs different types of fillers with specific functions: glass fiber for structural reinforcement, plate-shaped mineral filler for reducing warpage through anisotropic expansion control, and spherical filler for improving flow characteristics. Each filler type addresses specific local requirements within the composite material.
Solution Approach 2:
The synergistic combination of multiple filler types creates a balanced composite system where the total filler content (35-90 parts per 100 parts resin) achieves dimensional stability without excessive complexity, as the fillers complement each other's functions.
3Manufacturing precision
If glass fiber and plate-shaped mineral filler are used to reduce warpage, then injection moldability is improved, but processing difficulty increases
Solution Approach 1:
The patent specifies optimal parameter ranges for glass fiber (20-40 parts, specific aspect ratio) and plate-shaped mineral filler (10-30 parts, specific particle size distribution) to ensure proper flow during injection molding while achieving warpage reduction. The spherical filler (5-20 parts) further improves processability by reducing viscosity.
Data Source
AI summary
The present disclosure relates to a composition for a rack housing member of a vehicle having excellent dimensional stability, and a rack housing member of a vehicle formed therefrom. In an embodiment, the composition for a rack housing member of a vehicle comprises 100 parts by weight of a base resin containing polybutylene terephthalate, an acrylonitrile-styrene-acrylate copolymer, and polyethylene terephthalate, and 40 to 75 parts by weight of an inorganic filler, wherein the inorganic filler includes a glass fiber and a plate-shaped mineral filler.