Terminal Insert Resin Injection Position Design
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Solution Overview
Problem
In injection molding, high-temperature molten resin can inadequately cure near inserted terminals, leading to low-strength parts and cracking due to thermal expansion mismatches in reinforced fiber composites when exposed to cold heat stress.
Innovation Solution
Forming the resin injection position in a projecting shape increases the distance from the gate part to the terminal, reducing heat influence and enhancing resin volume to absorb deformation, while a spherical surface part randomizes fiber orientation to minimize thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal is located near the gate part to simplify assembly, then the manufacturing process is easier, but the resin injection position becomes insufficiently cured due to heat from the terminal
Solution Approach 1:
The patent divides the molded article into distinct regions: a first region containing the gate part and terminal, and a second region containing the resin injection position. This spatial segmentation ensures that the terminal's heat does not affect the curing of the resin injection position, resolving the contradiction between assembly simplicity and curing quality.
Solution Approach 2:
The patent applies different thermal conditions to different regions: the first region near the terminal experiences higher temperature due to heat from the terminal, while the second region at the resin injection position maintains lower temperature for proper curing. This local quality differentiation allows the terminal to be positioned for easy assembly while ensuring proper curing at the resin injection position.
2Volume of moving object
If the terminal is positioned close to the resin injection position for compact design, then the device size is reduced, but cracks develop under cold heat stress due to thermal expansion mismatch
Solution Approach 1:
The patent segments the molded article into a first region with the terminal and a second region with the resin injection position, ensuring spatial separation. This segmentation prevents the thermal expansion mismatch between the terminal and resin from causing cracks, while still maintaining a compact overall design through efficient space utilization.
Solution Approach 2:
The patent introduces a resin layer as an intermediary substance between the terminal and the external environment. This resin layer acts as a buffer that absorbs thermal expansion differences, preventing cracks from developing under cold heat stress while allowing compact terminal positioning.
3Productivity
If high-temperature molten resin is used for molding to improve flow, then the resin fills the mold better, but the terminal stores excessive heat causing insufficient curing
Solution Approach 1:
The patent divides the molded article into a first region containing the terminal and a second region containing the resin injection position. This segmentation allows high-temperature molten resin to flow efficiently through the mold while the terminal's heat does not affect the curing of the resin injection position, maintaining both molding efficiency and proper curing.
Solution Approach 2:
The patent applies different thermal characteristics to different regions: the first region near the terminal tolerates higher temperatures, while the second region at the resin injection position maintains lower temperatures for proper curing. This local quality differentiation enables efficient molding with high-temperature resin while preventing excessive heat storage at the terminal.
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
Prevents low-strength portions and cracking at the resin injection position, improving the quality of molded articles and integrated components like sensor covers and throttle valves by ensuring adequate curing and stress distribution.
Implementation Method 1
the resin, which is formed into the resin injection position, is greater in amount than the conventional art. Thus, the resin of the resin injection part increased in amount disperses and absorbs a deformation caused at the resin injection part when the cold heat stress is received
Implementation Method 2
high-temperature molten resin comes into contact with the inserted terminal so that the terminal stores heat
Implementation Method 3
The linear thermal expansion coefficient of the reinforced fiber with an orientation along one direction, and the linear thermal expansion coefficient of the reinforced fiber with an orientation perpendicular to one direction are different. Thus, the linear thermal expansion coefficient of the resin incorporating the reinforced fiber varies according to the difference in orientation of the reinforced fiber.
Data Source
AI summary
A terminal insert article includes a metal terminal, and a resin molded article in which the terminal is inserted. The molded article is formed by injection molding. When a position of the molded article into which molten resin is injected at time of the injection molding is referred to as a resin injection position, the resin injection position is formed in a projecting shape. The molded article includes a spherical surface part at an opposite position from the resin injection position. The spherical surface part has a spherical surface shape swollen out in a direction away from the resin injection position. A component that constitutes a rotation angle sensor, which detects a rotation angle of a rotatably-supported shaft, is inserted in the molded article.