State-Changing Interlayer Connections for Tolerance and Isolation
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Solution Overview
Problem
Existing methods for connecting electronic device components often require high manufacturing tolerances for individual elements, which can be costly and complex, and may not allow for electrical isolation or alignment adjustments.
Innovation Solution
Using an intermediate element that changes states to connect two or more elements, allowing components with low manufacturing tolerances to be assembled with high precision and electrical isolation, using materials like insulating or dielectric substances to ensure structural and mechanical bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional connection methods (snaps, mechanical fasteners, adhesives) are used to connect housing components, then the components can be connected, but high manufacturing tolerances are required for individual elements which increases cost and complexity
Solution Approach 1:
A compression element is introduced as an intermediary component between the first and second housing components. This compression element absorbs dimensional variations and misalignments through elastic deformation, allowing the housing components to be connected without requiring high manufacturing tolerances. The compression element acts as a buffer that mediates the connection between elements with lower precision.
Solution Approach 2:
The compression element changes its physical parameters (length, cross-sectional area) in response to applied compressive forces. This parameter change allows the element to accommodate dimensional variations in the housing components while maintaining a secure connection. The elastic deformation of the compression element compensates for manufacturing tolerances in the connected components.
2Reliability
If traditional connection methods are used, then components can be connected, but electrical isolation between conductive elements cannot be ensured
Solution Approach 1:
The compression element is constructed from composite materials that combine electrical insulation properties with mechanical compliance. This allows the single component to simultaneously provide both mechanical connection and electrical isolation between conductive housing elements, eliminating the need for separate isolation components.
Solution Approach 2:
The compression element serves multiple functions simultaneously: it provides mechanical connection between housing components, absorbs dimensional variations, and ensures electrical isolation between conductive elements. This multi-functionality reduces the overall complexity of the connection system while achieving both mechanical and electrical requirements.
3Manufacturing precision
If high manufacturing tolerances are required for individual elements, then assembly precision can be achieved, but production cost and complexity increase
Solution Approach 1:
The compression element is designed beforehand to compensate for expected dimensional variations in the housing components. By incorporating this cushioning element into the design, the system can accommodate manufacturing tolerances without requiring expensive high-precision manufacturing processes for the individual housing components.
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
Enables the assembly of components with high tolerances while accommodating manufacturing imperfections, ensuring electrical isolation and alignment, reducing complexity and cost, and allowing for flexible design.
Implementation Method 1
an intermediate element that changes states to connect two or more elements
Implementation Method 2
the material of the intermediate element can include an insulating or a dielectric material
Data Source
AI summary
This is directed to connecting two or more elements using an intermediate element constructed from a material that changes between states. An electronic device can include one or more components constructed by connecting several elements. To provide a connection having a reduced or small size or cross-section and construct a component having high tolerances, a material can be provided in a first state in which it flows between the elements before changing to a second state in which it adheres to the elements and provides a structurally sound connection. For example, a plastic can be molded between the elements. As another example, a composite material can be brazed between the elements. In some cases, internal surfaces of the elements can include one or more features for enhancing a bond between the elements and the material providing the interface between the elements.