Metal-Plastic Composite Plate for Combined Electrical and Structural Joining
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Solution Overview
Problem
Existing electrical devices, such as food coolers, fans, lamps, and music systems, face complexity and high assembly time due to separate electrical and mechanical connections, leading to increased manufacturing costs.
Innovation Solution
The integration of a metal-plastic composite panel that serves both as a mechanical support and electrical conductor, eliminating the need for separate connections by combining mechanical and electrical functions in a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate electrical connections and mechanical support structures are used, then reliable electrical connection and mechanical support are achieved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines separate electrical connection components and mechanical support structures into a single integrated metal-plastic composite panel. The panel includes conductive metal layers for electrical connection and non-conductive plastic layers for mechanical support, eliminating the need for separate components and reducing assembly complexity while maintaining both electrical reliability and mechanical strength
Solution Approach 2:
The metal-plastic composite panel serves multiple functions simultaneously: it provides electrical connection through conductive metal layers, mechanical support through non-conductive plastic layers, and structural integration. This multi-functional design reduces the number of components needed and simplifies the overall device architecture
2Ease of manufacture
If multiple separate components are used for mechanical support and electrical connection, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate components (electrical connectors, mechanical supports, insulators) into a single metal-plastic composite panel manufactured through compression molding. This integration reduces the number of parts that need to be manufactured, stored, and assembled, thereby lowering overall manufacturing costs despite the complexity of the composite material process
Solution Approach 2:
The patent employs composite materials consisting of conductive metal layers (e.g., aluminum, copper) and non-conductive plastic layers (e.g., polyethylene, polypropylene) combined in a single panel. This composite structure allows both electrical and mechanical functions to be achieved within one component, reducing the total material cost and assembly cost compared to using multiple separate components
3Productivity
If a single integrated panel is used, then assembly is simplified and manufacturing cost is reduced, but electrical insulation and conductivity requirements must be precisely met
Solution Approach 1:
The patent uses composite materials with distinct conductive metal layers and non-conductive plastic layers that are inherently suited for their respective functions. The metal layers provide reliable electrical conductivity while the plastic layers provide inherent electrical insulation and mechanical support, reducing the need for additional precision measures compared to using homogeneous materials
Solution Approach 2:
The metal-plastic composite panel features local quality variations where different layers serve different functions: conductive metal layers in specific positions for electrical connection and non-conductive plastic layers in other positions for insulation and mechanical support. This localized functional differentiation allows the single panel to meet both electrical and mechanical requirements without compromising assembly simplicity
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 simplifies assembly, reduces manufacturing costs, and enhances electrical safety and durability by ensuring reliable electrical connections while maintaining structural integrity.
Implementation Method 1
The metal-plastic composite panel electrically connects the two electrical components of the two housing bodies
Implementation Method 2
a dielectric and/or electrically non-conductive plastic layer arranged between these two metal layers
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an electrical appliance (1), in particular a food cooler, fan, lamp and/or music system, comprising a first housing body (3) comprising a first electrical component (5), a second housing body (4) comprising a second electrical component (6), and a connecting body (7) that mechanically connects the two housing bodies (3, 4). According to the invention, the connecting body (7) is formed from a metal-plastic composite plate (8) and the metal-plastic composite plate (8) is electrically connected to the two electrical components (5, 6) of the two housing bodies (3, 4).