Resin Layering for Electronic Device Fire Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electronic devices face safety challenges due to overheating and potential fires from short-circuiting, particularly in components like voice coils and electrolytic capacitors, where existing solutions may not adequately balance non-flammability with mechanical strength, durability, and cost considerations.
Innovation Solution
The application of a first resin with high non-flammability and a second resin with lower non-flammability, strategically selected to ensure the oxygen index of the first resin is greater than the second, and their average value meets a safety threshold, along with the inclusion of a fire extinguishing component, to minimize burning risks and prevent fire spread in electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single resin with high non-flammability is applied to the housing, then fire safety is improved, but mechanical strength and durability may be compromised
Solution Approach 1:
The patent applies a composite material structure consisting of a heat-resistant resin layer (first resin) and a general-purpose resin layer (second resin). The heat-resistant resin layer provides fire safety with high non-flammability, while the general-purpose resin layer contributes mechanical strength and durability. This composite structure resolves the contradiction by combining materials with complementary properties rather than relying on a single material to satisfy all requirements.
2Reliability
If a heat-resistant resin with high non-flammability is used, then burning time is reduced, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using heat-resistant resin only in the layer directly contacting the voice coil, where fire risk is highest. The general-purpose resin is used in the outer housing layer where mechanical properties are more critical than fire resistance. This localized application of heat-resistant material optimizes fire safety where needed while controlling overall manufacturing costs.
Solution Approach 2:
The composite structure allows the expensive heat-resistant resin to be used only where necessary for fire safety, while the more cost-effective general-purpose resin is used for the remaining structure. This reduces overall material costs compared to using heat-resistant resin throughout the entire housing.
3Reliability
If fire extinguishing components are added to the resin, then flame retardancy is improved, but mechanical properties may deteriorate
Solution Approach 1:
The patent uses a composite structure where the heat-resistant resin layer containing fire extinguishing components provides flame retardancy, while the general-purpose resin layer maintains mechanical properties. This distributes the functional requirements across different material layers, allowing each layer to optimize its specific function without compromising overall performance.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electronic device (1, 1') includes an element (2, 33), a first member (3, 11), and a second member (4, 5, 12). An electric current flows in the element (2, 33). The element (2, 33) is mounted in the first member or the first member (3, 11) is arranged to face the element (2, 33). In addition, the first member (3, 11) is made of a first resin. The second member (4, 5, 12) is provided adjacent to the first member (3, 11). In addition, the second member (4, 5, 12) is made of a second resin. In addition, one of the first resin and the second resin has lower non-flammability than the other.