Metal Foam Reinforced Back Plate for Portable Systems
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Solution Overview
Problem
Current portable information handling systems face challenges in achieving sufficient structural integrity while maintaining low weight and compact dimensions, particularly in ruggedized applications, due to limitations in materials and structural components.
Innovation Solution
The development of metal foam manufacturing methods involving specific alloy melts with additives like iridium oxide, ceramic particulate, and calcium carbonate, which are heated to evolve gas and then cooled to form metal foam castings with tailored densities and pore sizes for use in structural components, such as reinforced back plates, to enhance strength and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials and structures are used for chassis and packaging, then weight and thickness can be reduced through packaging design advancements, but sufficient structural integrity for ruggedized applications becomes difficult to achieve
Solution Approach 1:
The patent applies metal foam, a porous material, as a structural element within the housing. The metal foam provides structural integrity and strength while maintaining low weight due to its porous structure. The housing includes a shell and a structural element comprising metal foam, which achieves both strength and weight reduction simultaneously.
Solution Approach 2:
The patent uses composite materials by combining metal foam with the housing shell structure. The structural element comprising metal foam is integrated into the housing to create a composite structure that leverages the advantages of both the shell material and the metal foam material, achieving optimal strength-to-weight ratio.
2Weight of moving object
If metal foam with large pore sizes and low density is used, then weight is reduced, but structural strength becomes insufficient for small computer system parts
Solution Approach 1:
The patent applies parameter changes by controlling the density and pore size of the metal foam to achieve the desired balance between weight and strength. The metal foam is configured with specific density parameters that are optimized for the particular application, allowing the structural element to provide sufficient strength while maintaining low weight.
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 resulting metal foam components provide high strength and low weight, enabling compact and reliable designs for portable information handling systems, addressing the need for improved structural integrity without increasing weight or size.
Implementation Method 1
heating the second melt to evolve gas, wherein a metal foam is generated in the second melt
Implementation Method 2
cooling the second melt to solidify a metal foam casting
Data Source
AI summary
Methods for manufacturing a metal foam and a metal foam reinforced back plate may be used to provide high-strength and low weight structural elements in portable information handling systems. A method for manufacturing a metal foam may include selectively adding iridium oxide and ceramic particulate to a light-metal allow to create desired mechanical properties of the metal foam.