Hybrid Metal-Polymer Structural Component for Electronic Assembly Weight Reduction
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Solution Overview
Problem
Conventional electronic assembly systems rely on metal components for structural elements, which are heavy, limiting weight reduction and increasing vehicle efficiency, especially in aircraft applications, while non-metal materials lack the necessary mechanical and electrical properties.
Innovation Solution
A method of constructing electronic assemblies using a combination of metal and polymer elements, where the metal element is optimized for minimum thickness and area to achieve electromagnetic shielding and electrical bonding properties, and the polymer element is maximized for structural and thermal properties, using finite element analysis to determine the optimal proportions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used for structural elements in electronic assemblies, then mechanical strength, electrical properties, and electromagnetic shielding are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining metal and polymer elements in a hybrid structural component. The metal element provides mechanical strength, electrical bonding, and electromagnetic shielding, while the polymer element reduces weight and provides thermal management. This composite approach resolves the contradiction by achieving required mechanical properties with reduced overall weight compared to pure metal construction.
Solution Approach 2:
The structural component is segmented into distinct metal and polymer elements, each optimized for specific functions. The metal element is designed with minimum material thickness and area to achieve required electromagnetic shielding and electrical bonding, while the polymer element is maximized for structural support and thermal properties. This segmentation allows weight reduction while maintaining necessary metal properties.
2Weight of moving object
If non-metal materials are used to reduce weight, then weight is reduced, but mechanical and electrical properties are insufficient
Solution Approach 1:
The patent uses composite materials combining polymer and metal elements to overcome the limitations of pure polymer materials. The polymer element provides weight reduction and structural support, while the integrated metal element supplies the necessary mechanical strength, electrical bonding, and electromagnetic shielding properties that pure polymers cannot provide.
Solution Approach 2:
The structural component applies local quality by concentrating metal material only in specific regions where mechanical strength, electrical bonding, and electromagnetic shielding are required, while using polymer material in regions where weight reduction and thermal management are prioritized. This localized material distribution achieves necessary properties without excessive weight.
3Object-affected harmful factors
If metal material thickness is increased to improve electromagnetic shielding, then electromagnetic shielding property is improved, but weight and material usage increase
Solution Approach 1:
The patent applies partial action by providing electromagnetic shielding only to the extent necessary to meet performance requirements, rather than using excessive metal thickness throughout. The metal element is designed with minimum material thickness calculated to achieve the required shielding effectiveness, avoiding unnecessary weight while maintaining adequate protection against electromagnetic interference.
Solution Approach 2:
The patent uses parameter changes by optimizing the metal element thickness to the minimum value that achieves the required electromagnetic shielding property. Through calculation and analysis, the metal thickness parameter is precisely determined to provide adequate shielding while minimizing weight, rather than using conservative over-design.
4Reliability
If metal area is increased to improve electrical bonding, then electrical bonding property is improved, but weight and material usage increase
Solution Approach 1:
The patent applies partial action by providing electrical bonding area only where necessary to achieve required bonding properties. The metal element area is optimized to the minimum extent needed for adequate electrical bonding, rather than using excessive metal area throughout the component, thus reducing weight while maintaining reliability.
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
This approach results in a structural component that meets mechanical and electrical requirements while minimizing weight, achieving the necessary shielding, bonding, and thermal properties, thereby enhancing vehicle efficiency and reducing weight.
Implementation Method 1
A minimum material thickness required of the metal element for achieving a required electromagnetic shielding property is determined
Implementation Method 2
A minimum area required of the metal element for achieving a required electrical bonding property is determined
Implementation Method 3
The metal and polymer elements together are configured to exhibit mechanical properties required of the structural component, including a required structural property and a required thermal property
Data Source
AI summary
A system and method of constructing an electronic assembly. A structural component is identified as a candidate for forming as a combined construction of a metal element and a polymer element. A minimum material thickness required of the metal element for achieving a required electromagnetic shielding property is determined. A minimum area required of the metal element for achieving a required electrical bonding property is determined. A maximum polymer element proportion of the structural component that meets a required structural property and a required thermal property is determined. The structural component is designed with the metal element having the minimum material thickness and the minimum area and with the polymer element having the maximum polymer element proportion. The structural component is manufactured from the polymer element and the metal element to meet the mechanical and electrical properties, and the structural component in the electronic assembly.