Composite Plate Structure with Exposed Core Layer for Enhanced Bonding
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Solution Overview
Problem
Portable electronic devices require increased structural strength to withstand shakes and pressures while maintaining a slim and lightweight design, which existing composite materials fail to achieve effectively.
Innovation Solution
A composite plate structure comprising a first fiber layer, a second fiber layer, and a core layer, where the core layer is exposed at a specific region to allow resin to flow and bond with both fiber layers, enhancing structural strength without additional adhesives, and featuring recessed portions and protruding resin components for enhanced binding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional composite materials are used to reduce weight and thickness, then portability is improved, but structural strength against shakes and pressures deteriorates
Solution Approach 1:
The composite plate is segmented into multiple functional layers: a first fiber layer, a second fiber layer with a first region having a smaller area, and a core layer disposed between them. The second fiber layer is divided into a first region (exposed area) and a second region (covered area), creating distinct functional zones that segment the load-bearing and bonding functions.
Solution Approach 2:
The invention transitions from traditional planar composite structures to a three-dimensional multi-layer structure with vertical stacking of fiber layers and core layer, plus horizontal differentiation through the first region exposure. This dimensional complexity enables simultaneous weight reduction and strength enhancement.
2Strength
If thicker composite materials are used to increase structural strength, then strength is improved, but device thickness increases contrary to slim design trends
Solution Approach 1:
The invention employs a composite structure combining fiber layers (first and second) with a core layer, where each layer contributes different mechanical properties. The fiber layers provide tensile strength while the core layer provides compressive strength and structural support, achieving high strength-to-thickness ratio.
3Strength
If resin components are added to enhance bonding between layers, then structural strength is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The core layer is designed to be exposed at the first region of the second fiber layer, enabling the resin component to directly bond to the core layer without requiring additional adhesive layers or complex assembly steps. The structure itself facilitates the bonding process.
Solution Approach 2:
The core layer is pre-positioned between the first and second fiber layers during composite plate manufacturing, with the first region intentionally exposed. This preliminary arrangement ensures that when the resin component is later applied, it can immediately bond to the exposed core layer surface without requiring additional preparation or alignment steps.
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 method significantly increases the structural strength of the composite plate by forming a strong bond between the core and fiber layers, reducing thickness to align with slim design trends while maintaining durability.
Implementation Method 1
the resin component is combined with the core layer at the first region
Data Source
AI summary
A composite plate structure includes a composite plate and a resin component. The composite plate includes a first fiber layer, a second fiber layer and a core layer. The second fiber layer has a first region, wherein an area of the second fiber layer is smaller than an area of the first fiber layer. The core layer is disposed between the first fiber layer and the second fiber layer, wherein the core layer is exposed at the first region. The resin component is connected to the composite plate, wherein the resin component is combined with the core layer at the first region. In addition, a manufacturing method of the composite plate is also provided.