Composite Shell Decorative Piece Welding

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Solution Overview

Problem

Conventional protective shells made of fiber composite material lack variety in appearance, failing to adequately differentiate individual tastes and provide unique visual effects.

Innovation Solution

A composite material shell with a base plate of thermoplastic resin and reinforcing fibers, featuring multiple decorative pieces made of the same material, arranged non-directionally and overlapped on the base plate, providing unique reflection and depth variations through hot compression welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional manufacturing methods are used to produce protective shells with regular patterns, then the manufacturing process is simple and consistent, but the appearance variety is limited and fails to differentiate individual tastes

Engineering Contradiction:

Improveappearance varietyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The protective shell is divided into a base plate and multiple separate decorative pieces. Each decorative piece can be independently manufactured and then assembled onto the base plate, allowing for various combinations and arrangements to create different appearance patterns without complicating the overall manufacturing process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple decorative pieces are overlapped and arranged on the base plate in a nested-like configuration. The decorative pieces can be stacked and positioned at different levels, creating depth variations and complex visual effects while maintaining a systematic assembly approach

Inventive Principle:

Principle #7Nested doll (Nesting)

2Illumination intensity

If multiple decorative pieces are overlapped and non-directionally arranged on the base plate, then unique visual effects with reflection and depth variations are achieved, but the manufacturing and assembly process becomes more complex

Engineering Contradiction:

Improvevisual effect qualityVSAvoidassembly ease

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

Different decorative pieces are positioned at specific locations on the base plate to create localized visual effects. Each decorative piece can have different orientations, shapes, and positions, allowing for customized appearance designs while maintaining a systematic assembly methodology

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The decorative pieces are arranged in non-directional and asymmetric patterns on the base plate, breaking the monotony of conventional symmetric designs. This asymmetric arrangement creates unique visual effects and depth variations, making each protective shell appearance distinct and personalized

Inventive Principle:

Principle #4Asymmetry

3Ease of manufacture

If regular patterns such as parallel strips or interlacing strips are used on protective shells, then the manufacturing process is straightforward, but the designs fail to highlight individual differences

Engineering Contradiction:

Improvemanufacturing easeVSAvoiddesign variety

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The protective shell design transitions from static regular patterns to a dynamic assembly system where multiple decorative pieces can be arranged in various configurations. The decorative pieces can be positioned and oriented differently to create changing visual effects, allowing the same base structure to produce multiple unique designs

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

By changing the arrangement parameters of the decorative pieces (position, orientation, overlap degree, spacing), a wide variety of appearance designs can be achieved from the same set of components. This parameter-based design approach maintains manufacturing simplicity while dramatically increasing design versatility

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 offers a range of unique visual effects and appearances, allowing for various patterns and reflections, enhancing the aesthetic appeal and differentiating the composite material shells from conventional ones.

Implementation Method 1

multiple decorative pieces are overlapped, and are welded on the base plate

Methodology Applied

Scientific EffectHot compression welding: Welding

Data Source

PatentUS11807032B2Composite material shell and manufacturing method for the same

Publication Date: 2023.11.07 COREX MATERIALS CORP

AI summary

A composite material shell having a base plate made of thermoplastic resin and reinforcing fibers and multiple decorative pieces. Each of the multiple decorative pieces is made of a composite material containing thermoplastic resin and reinforcing fibers. An area of each of the multiple decorative pieces is smaller than an area of the base plate, wherein the multiple decorative pieces are non-directionally arranged, are overlapped, and are welded on the base plate whereby the composite material shell provides unique reflection and depth variations of visual effect.