Laminated Ceramic-Polymer Body for Wear and Impact Resistance
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Solution Overview
Problem
Synthetic resin outer coverings for electronic devices exhibit low wear resistance and scratch resistance, while ceramic materials offer high resistance but are prone to fracture under impact.
Innovation Solution
A laminated body composed of a dense ceramic tabular member and a polymer tabular member, with the ceramic member providing high mechanical strength and the polymer member offering flexibility, bonded together to enhance impact resistance, wear resistance, and scratch resistance while reducing weight and dielectric constant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a ceramic material is used as an outer covering, then wear resistance and scratch resistance are improved, but impact resistance deteriorates due to fracture tendency
Solution Approach 1:
The patent applies composite materials by combining a ceramic layer and a polymer layer into a single laminated structure. The ceramic layer provides wear resistance and scratch resistance, while the polymer layer provides impact resistance and flexibility. This composite approach resolves the contradiction by integrating the advantages of both materials while mitigating their individual weaknesses.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers of the laminated body. The ceramic layer is positioned to provide surface hardness and wear resistance where needed, while the polymer layer is positioned to provide impact absorption and flexibility where needed. This spatial differentiation of material properties resolves the contradiction between wear resistance and impact resistance.
2Strength
If a ceramic material is used as an outer covering, then scratch resistance is improved, but weight increases
Solution Approach 1:
The patent uses composite materials to achieve scratch resistance with reduced weight. The thin ceramic layer provides the necessary scratch resistance, while the polymer layer provides structural support and impact resistance, allowing for overall weight reduction compared to a solid ceramic component of equivalent thickness.
Solution Approach 2:
The patent employs a thin film approach by using a thin ceramic layer bonded to a polymer substrate. This thin-film ceramic layer provides scratch resistance without requiring the full thickness needed for a solid ceramic component, thereby reducing overall weight while maintaining the desired scratch resistance property.
3Strength
If a single-layer ceramic body is used, then wear resistance is improved, but dielectric constant increases
Solution Approach 1:
The patent applies composite materials to reduce the dielectric constant while maintaining wear resistance. The polymer layer has a lower dielectric constant than ceramic materials, so by creating a laminated structure with both materials, the overall dielectric constant of the outer covering is reduced compared to a solid ceramic body, while the ceramic layer continues to provide wear resistance.
Data Source
AI summary
A laminated body is provided that exhibits impact resistance, wear resistance and scratch resistance, and which enables a reduction in weight together with a reduction in the dielectric constant. The laminated body 100 includes a first tabular member 10 configured from a ceramic material and having a first thickness t1, and a second tabular member 20 configured from a polymer material and having a second thickness t2. The laminated body 100 withstands a falling-ball impact breaking test from a height that is higher than that exhibited by a single layer body that is configured from the ceramic material and of a thickness t3 that is the sum of the first thickness t1 and the second thickness t2.