Composite Sheet with Protruding Resin Layer for Over-Molding
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Solution Overview
Problem
Existing composite sheets used in electronic apparatuses are heavy, costly, and fail to bond well with injection molding materials during the over-molding process, affecting the thickness, weight, and protective strength of the housing.
Innovation Solution
A composite sheet comprising a first sheet layer, a second sheet layer, and a solid layer, where the solid layer is made of thermoplastic resin, is used. The solid layer is positioned between the first and second sheet layers, capable of protruding from the interlayer space to bond with injection molding materials, reducing weight and cost while maintaining rigidity and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite sheet is formed by stacking same reinforced fiber layers, then protective strength is increased, but weight increases and cost increases
Solution Approach 1:
The composite sheet is segmented into three distinct layers: a first reinforced fiber layer, a second reinforced fiber layer, and a plastic resin layer positioned between them. This segmentation allows each layer to serve its specific function - the fiber layers provide structural strength while the plastic resin layer reduces weight and enables bonding, thereby achieving protective strength without excessive weight from uniform thick fiber stacking.
Solution Approach 2:
Different regions of the composite sheet have different material compositions optimized for their specific functions. The outer fiber layers are optimized for strength and protection, while the inner plastic resin layer is optimized for weight reduction and bonding capability. This local quality differentiation allows the structure to achieve overall strength without requiring excessive fiber thickness throughout the entire sheet.
2Strength
If composite sheet is formed by stacking same reinforced fiber layers, then protective strength is increased, but cost increases
Solution Approach 1:
The composite sheet is segmented into three distinct layers: a first reinforced fiber layer, a second reinforced fiber layer, and a plastic resin layer positioned between them. This segmentation allows each layer to serve its specific function - the fiber layers provide structural strength while the plastic resin layer reduces weight and enables bonding, thereby achieving protective strength without excessive weight from uniform thick fiber stacking.
Solution Approach 2:
Different regions of the composite sheet have different material compositions optimized for their specific functions. The outer fiber layers are optimized for strength and protection, while the inner plastic resin layer is optimized for weight reduction and bonding capability. This local quality differentiation allows the structure to achieve overall strength without requiring excessive fiber thickness throughout the entire sheet.
3Ease of manufacture
If composite sheet uses traditional structure, then manufacturing is simple, but bonding with injection molding material is poor
Solution Approach 1:
The plastic resin layer is strategically positioned at the bonding interface between the composite sheet and the injection molded part. This local concentration of resin at the interface area provides excellent bonding capability without requiring resin throughout the entire composite sheet structure, thus maintaining manufacturing simplicity while significantly improving bonding reliability.
Solution Approach 2:
The plastic resin layer acts as an intermediary material between the reinforced fiber layers and the injection molding material. It facilitates bonding by providing a chemically and physically compatible interface that enhances adhesion between the composite sheet and the molded part, thereby improving bonding capability while maintaining the simplicity of the manufacturing process.
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 results in a lighter, cost-effective composite sheet that maintains the structural integrity and shape of the electronic apparatus housing, enhancing its protective properties and manufacturing quality by reducing the need for multiple reinforced layers and preventing permeation of injection molding materials.
Implementation Method 1
compressing a rough composite sheet from a first thickness to a second thickness in a preset mold under a preset temperature, so that a solid layer is heated to be softened to protrude from an interlayer space
Implementation Method 2
the protruded portion of the solid layer is bonded with the injection molding material
Data Source
AI summary
The embodiment of the present disclosure provides a composite sheet, an electronic apparatus and a method for producing a component from the composite sheet, the composite sheet comprises a first sheet layer, a second sheet layer and a solid layer, wherein, the first sheet layer comprises at least one layer of first reinforced material; the second sheet layer comprises at least one layer of second reinforced material; the solid layer is located between the first sheet and the second sheet layer, wherein the solid layer is capable of being protruded from an interlayer space between the first sheet and the second sheet layer. Because the solid layer may be thermoplastic resin material which has a light weight, the entire weight of the composite sheet may be reduced. And during the over-molding process, the solid layer can effectively prevent the injection molding plastics from permeating into the composite sheet and thus prevent the deformation problem of the sheet layers on the surfaces of the composite sheet caused by the permeation, so that the composite sheet can maintain a better shape and the product quality is increased.