Metallic Spatter Cover for Plastic Electronics Modules

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Solution Overview

Problem

Plastic electronics modules in industrial settings are prone to damage from hot spatter materials during welding and other processes, as the plastic housings deform, degrade, or become contaminated, while metallic modules are not always readily available.

Innovation Solution

A protective cover device comprising a one-piece metallic structure or multiple metal cover sections adhesively applied to a plastic electronics module, providing a thermally insulative air gap and aligning with connector and indicator openings to maintain functionality and protect the module from hot spatter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If plastic housings are used in electronics modules, then manufacturing cost and availability are improved, but resistance to hot spatter materials deteriorates

Engineering Contradiction:

Improvemanufacturing availabilityVSAvoidhot spatter damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

A metallic cover is introduced as an intermediary protective layer between the hot spatter environment and the plastic housing. The cover shields the plastic housing from direct contact with hot spatter materials, allowing the module to be manufactured with plastic housing while maintaining resistance to hot spatter damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The module housing system becomes a composite structure combining metal (protective cover) and plastic (housing) materials. Each material leverages its strengths: the metal cover provides hot spatter resistance while the plastic housing provides manufacturing advantages, creating a hybrid solution that overcomes the limitations of either material alone.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If metallic housings are used to protect from hot spatter, then resistance to hot spatter materials is improved, but manufacturing availability and cost deteriorate

Engineering Contradiction:

Improvehot spatter resistanceVSAvoidmanufacturing availability

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The protective function is segmented from the housing structure. Instead of requiring the entire housing to be metallic, only a separate metallic cover component is used to provide protection. This allows the majority of the module to remain plastic (easy to manufacture) while a specific protective segment is made of metal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metallic cover serves as a mediator that provides hot spatter protection without requiring the entire housing to be metallic. This intermediate protective layer enables the use of plastic housing while achieving the desired protection level.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If a protective cover is added to the plastic module, then protection from hot spatter is improved, but device complexity increases

Engineering Contradiction:

Improvespatter protectionVSAvoidmodule structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The protective function is extracted as a separate, removable cover component rather than being integrated into the housing structure. This allows the cover to be independently manufactured and attached, simplifying the overall design while providing effective protection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The protective cover functions as a thin metallic shell that envelops the plastic housing. This shell provides comprehensive protection against hot spatter while adding minimal structural complexity, as it simply conforms to the existing housing shape.

Inventive Principle:

Principle #30Flexible shells and thin films

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 solution effectively prevents damage to plastic electronics modules by shielding them from hot spatter, maintaining operational integrity, and ensuring immediate availability through standard manufacturing processes.

Implementation Method 1

the cover top wall can include a plurality of ribs on an inner surface of the top wall that establish and maintain a thermally insulative air gap between the cover top wall and the plastic module

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12336131B2Weld spatter protective cover device for plastic module and module including a protective cover device

Publication Date: 2025.06.17 ROCKWELL AUTOMATION ASIA PACIFIC BUSINESS CTR PTE

AI summary

A spatter protection cover for an electronics module includes a top wall that covers a top surface of a plastic module housing. The cover can include side walls and end walls that cover the side surfaces and end surfaces of the plastic housing. The cover can be a one-piece metallic construction that fits over the plastic module housing or can be defined by separate cover sections that can be adhesively applied to the plastic module housing. The top wall of the cover can include connector openings and/or indicator openings for aligning with connectors and indicator lights, respectively, of the plastic module housing. The cover can include ribs that establish and maintain a select thermally insulative air gap between the top wall of the cover and the top surface of the plastic module housing.