Ceramic Fiber Thermoplastic Composite Frame for RF Isolation
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Solution Overview
Problem
Designing multi-purpose frame components for consumer electronic devices that are both strength-compatible and aesthetically pleasing while providing RF isolation is challenging, as existing materials struggle to balance conductivity, strength, and compactness.
Innovation Solution
A composite material mixture of ceramic fibers and thermoplastics is used, which can be injection molded to form load-bearing structures, offering RF isolation, strength compatibility with metal components, and aesthetic appeal by varying the volume percentage of ceramic fibers to achieve desired properties such as tensile modulus and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials are used for frame components, then structural strength is achieved, but RF isolation performance deteriorates
Solution Approach 1:
The patent applies composite materials by combining ceramic fibers (providing RF isolation) with thermoplastic polymers (providing structural strength). This composite approach allows the frame component to simultaneously achieve both RF isolation performance and structural strength, resolving the contradiction between these two requirements.
2Volume of moving object
If multi-purpose components are designed to reduce device size, then compactness is improved, but material compatibility and aesthetic integration worsen
Solution Approach 1:
The patent implements multi-functionality by designing frame components that simultaneously serve structural support, RF isolation, and aesthetic purposes. The ceramic fiber-reinforced thermoplastic composite enables a single component to fulfill multiple functions, achieving compactness while maintaining material compatibility and aesthetic integration.
Solution Approach 2:
The patent applies parameter changes by adjusting the volume percentage of ceramic fibers (5-50%) in the composite material to optimize the balance between RF isolation performance and structural strength. This parameter adjustment allows tailoring the material properties to meet specific design requirements for different application scenarios.
3Reliability
If ceramic fiber content is increased to improve RF isolation, then RF isolation performance is improved, but processing difficulty and material homogeneity worsen
Solution Approach 1:
The patent applies parameter changes by optimizing the ceramic fiber volume percentage range (5-50%) to balance RF isolation performance with processability. This parameter optimization ensures that sufficient ceramic fibers are present for effective RF isolation while maintaining enough thermoplastic matrix for proper material homogeneity and ease of manufacturing through injection molding.
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
The ceramic fiber and thermoplastic composite material provides a strong, lightweight, and aesthetically compatible solution for forming frame components in electronic devices, enabling smaller, more compact designs with reduced RF losses and improved packaging efficiency.
Implementation Method 1
The ceramic fibers can be selected to be relatively non-conductive. For instance, the dielectric constant of the ceramic fibers can be between about 4-35.
Implementation Method 2
The injection moldable material can be used to form a device component alone or in combination with other materials. For instance, using an injection molding process, the material can be used to join a number of metal components together
Implementation Method 3
The ceramic fiber can be coated to allow it bond to the thermoplastic.
Data Source
AI summary
Materials, apparatus and methods of forming structural components for consumer electronics devices are described. In one embodiment, ceramic fibers, such as alumina, are mixed with a thermoplastic, such as nylon, to form a composite material usable in an injection molding process. The volume percent of ceramic fibers used with the thermoplastic can be selected to improve the strength properties of the composite material. Pigments can be added to the composite material to affect its aesthetic appeal. In one embodiment, the composite material including the ceramic fibers can be used to form frame components usable in a consumer electronic device. The frame components can be load bearing structures that are externally visible or used within the interior of the device.