Resin-Metal Hydraulic Switch Body Warping Prevention
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Solution Overview
Problem
The integration of resin and metal in molded articles often results in warping due to differing shrinkage ratios, which is exacerbated in elongated objects, and existing solutions that attempt to prevent warping by forming grooves over the entire width of the article restrict design freedom by limiting the placement of other parts.
Innovation Solution
The article features a resin main portion molded with recesses for electronic parts and grooves connecting these recesses to the outer peripheral edge, allowing for the release of tensile stress caused by thermal expansion differences, while minimizing the groove's length to avoid hindering the arrangement of other parts, and includes conical holes and anchors to secure the metal plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If grooves are formed over the entire width of the molded article to prevent warping, then warping is reduced, but the degree of freedom of design is impaired due to restricted placement of other parts
Solution Approach 1:
The groove is segmented into two parts: a first groove extending from the resin outer peripheral edge to a first position, and a second groove extending from the resin outer peripheral edge to a second position, where the grooves do not overlap when projected onto the plate surface. This segmentation allows the grooves to be distributed strategically to release tensile stress without spanning the entire width, thereby preventing warping while preserving design freedom for placing electronic parts and other structures.
Solution Approach 2:
The grooves are positioned at specific locations rather than extending uniformly across the entire width. The first and second grooves are arranged to target specific stress concentration areas, allowing stress release at critical locations while leaving other areas intact for component placement. This localized approach maintains design flexibility while effectively preventing warping.
2Strength
If the resin and metal plate are molded integrally, then structural strength is improved, but warping occurs due to different shrinkage ratios during cooling
Solution Approach 1:
The groove structure is divided into multiple segments (first groove and second groove) that are strategically positioned on the resin outer peripheral surface. These segmented grooves allow controlled release of tensile stress generated by differential shrinkage between resin and metal, preventing warping while maintaining the integral structure's overall strength.
Solution Approach 2:
The grooves act as intermediary stress-release features that mediate between the resin and metal plate. By providing controlled discontinuities in the resin structure, the grooves allow the resin to accommodate its shrinkage without transmitting excessive tensile stress to the metal plate, thereby preventing warping while preserving the integral bonding between materials.
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 solution effectively reduces warping of the plate/resin molded article by releasing tensile stress through strategically designed grooves and recesses, maintaining design freedom by not requiring grooves to span the entire article width, and ensures secure anchoring of the metal plate.
Implementation Method 1
The groove enables a release of tensile stress caused by the different thermal expansion and shrinkage characteristics of the plate and resin
Implementation Method 2
The resin and the metal both shrink when the resin cools and solidifies. However, the shrinkage ratios of the metal and the resin differ.
Data Source
AI summary
A hydraulic switch body (1) has a metal plate (10) and a resin main portion (20) molded on a first surface (13) of the metal plate (10). A hydraulic switch (2) and busbar circuits (30) are mounted in recesses (21) of the main portion (20). Grooves (22) connect the recesses (21) and the outer peripheral edge of the main portion (20) to release a tensile stress created at the outer surface (14) of the main portion (20) due to a difference between shrinkage ratios of resin and metal during the resin molding to prevent the hydraulic switch body (1) from warping. The lengths of the grooves (22) are shortened by using the recess portions (21). Therefore, the grooves (22) are less likely to hinder the arrangement of other structural parts.