Chassis Structure with Sealed Foam Layer and Peripheral Resin Joining
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Solution Overview
Problem
The existing chassis structures for electronic devices, which use a foam layer sandwiched between fiber-reinforced resin plates, face challenges in controlling the amount of thermoplastic resin entering the foam layer, complicating the manufacturing process and increasing costs.
Innovation Solution
A chassis structure with a foam layer sealed between fiber-reinforced resin plates, where the frame body is joined to the peripheral portion of the plate-like body without entering the foam layer, simplifying the manufacturing process and ensuring high joining strength by maximizing the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic resin is injection-molded on the end face of the plate-like body to enter the foam layer, then high joining strength is obtained, but the amount of resin entering the foam layer cannot be controlled, complicating the manufacturing process
Solution Approach 1:
The plate-like body is divided into a central portion (with foam layer) and peripheral portions (without foam layer). This segmentation allows the resin to be injected only into the peripheral portions where it can properly join the frame body without uncontrollably entering the foam layer, thus maintaining joining strength while simplifying manufacturing control
Solution Approach 2:
The foam layer is selectively positioned only in the central portion of the plate-like body, leaving the peripheral portions free of foam. This local quality differentiation enables the resin to flow and join effectively at the periphery while the central foam layer remains sealed, resolving the contradiction between achieving strong joints and controlling resin flow
2Ease of manufacture
If the foam layer is sealed between fiber-reinforced resin plates without thermoplastic resin entry, then manufacturing process is simplified and costs are reduced, but joining strength may be compromised
Solution Approach 1:
By segmenting the plate-like body into central and peripheral portions with different foam layer configurations, the invention enables simplified manufacturing (resin doesn't need to control entry into foam) while maintaining joining strength (resin joins the frame body to the foam-free peripheral portions which are structurally integrated with the central portion)
Solution Approach 2:
The solution moves the joining function from a vertical dimension (resin entering through thickness into foam layer) to a horizontal dimension (resin joining at the peripheral surface where foam is absent), thereby simplifying the process while maintaining joint strength
Data Source
AI summary
A chassis structure is disclosed. A chassis includes a plate-like body in which a foam layer is located between a pair of fiber-reinforced resin plates, and a frame body formed of a thermoplastic resin and joined to a peripheral portion of the plate-like body. The plate-like body is configured such that its peripheral portion is formed by an ear-like joint portion where the pair of fiber-reinforced resin plates are joined together without the foam layer located therebetween, thereby sealing the foam layer inside the pair of fiber-reinforced resin plates. The frame body is joined to the plate-like body in a state where the frame body is in contact with the joint portion.