Composite Housing Frames with Lap Joints and Metal Blanks

Solution Overview

Problem

Existing electronic device housing structures, particularly those made from unreinforced plastic and fiber composites, are vulnerable to damage from impacts and lack aesthetic appeal and proper integration with other device components.

Innovation Solution

The use of fiber-based composite frames formed by winding tape around a mandrel, curing, and machining, with metal blanks bonded to enhance strength and aesthetics, and lap joints to create a robust and aesthetically pleasing housing structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If unreinforced plastic is used for housing structures, then weight is reduced, but impact resistance deteriorates

Engineering Contradiction:

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies composite materials by combining fiber composite materials (such as carbon fiber, glass fiber, or aramid fiber) with plastic matrices to create a housing structure that achieves both lightweight properties and enhanced impact resistance. The fiber-reinforced composite structure allows the housing to maintain low weight while gaining the strength needed to withstand impact events.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If fiber composite materials are used for housing structures, then weight is reduced, but aesthetic appeal and impact resistance deteriorate

Engineering Contradiction:

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses fiber composite materials (carbon fiber, glass fiber, aramid fiber) reinforced with plastic matrices to create housing structures that are lightweight while maintaining aesthetic appeal and impact resistance through proper material selection and composite construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by selectively reinforcing specific areas of the housing structure with fiber composite materials based on impact risk assessment. High-impact areas receive enhanced fiber reinforcement while maintaining overall lightweight design, and surface treatments are applied to specific regions to ensure aesthetic appeal.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If fiber composite housing structures are formed, then weight is reduced, but manufacturing complexity increases

Engineering Contradiction:

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the housing structure into multiple components that can be manufactured separately using optimized processes, then assembled together. This allows complex fiber composite housing structures to be produced through modular manufacturing, reducing overall manufacturing complexity while maintaining lightweight design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes parameter changes by controlling the fiber-to-matrix ratio, fiber orientation, and curing parameters during composite material fabrication to optimize both weight and manufacturability. By adjusting these parameters, the patent achieves lightweight housing structures that can be manufactured efficiently.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a lightweight, impact-resistant, and aesthetically appealing housing structure for electronic devices by distributing stress and maximizing frame strength through fiber orientation and integration with metal components.

Implementation Method 1

The frames may be formed by winding tape around a mandrel and curing the wound tape

Methodology Applied

Scientific EffectCuring:

Implementation Method 2

A metal blank such as an aluminum blank may be bonded to the frame

Methodology Applied

Scientific EffectBonding: Adhesive

Implementation Method 3

Grooves may be machined in the cured tape to form a frame

Methodology Applied

Scientific EffectMachining:

Implementation Method 4

The notched frame members may be attached to one another at right angles using lap joints

Methodology Applied

Scientific EffectLap joint bonding: Adhesive

Implementation Method 5

Fiber tape may be wound around the frame assembly to form a hoop that encircles the frame assembly

Methodology Applied

Scientific EffectWinding:

Implementation Method 6

A curing process may be used to co-cure the wound fiber tape and the frame members of the frame assembly to form a unitary fiber composite structure

Methodology Applied

Scientific EffectCo-curing:

Data Source

PatentUS8888940B2Methods for forming composite housing frames

Publication Date: 2014.11.18

AI summary

Electronic device frames may be formed from fiber composites. Carbon fiber material may be formed into frame members using pultrusion tools. Notches may be machined into the frame members. The machined frame members may be assembled to form a rectangular frame assembly using lap joints. Fiber tape may be wound around the periphery of the frame assembly. Following curing, additional parts such as a metal blank may be bonded to the frame assembly and machined.