Stainless Steel and Fiber Composite Casing Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manufacturing methods for electronic device casings face challenges in achieving a balance of high rigidity, lightness, thinness, and cost-effectiveness, as metal casings require increased thickness for strength, fiber casings are difficult to shape and combine with other structures, and existing methods are costly and inefficient.
Innovation Solution
A manufacturing method that combines stainless steel and fiber materials by shaping stainless steel plates into structural components, applying fiber materials, and using a mold to attach them with adhesive, while controlling vacuum and heat to achieve a strong and lightweight composite material with improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum alloy plate with sufficient thickness is used to meet strength requirements, then the casing has high rigidity and strength, but the casing becomes thicker and heavier
Solution Approach 1:
The patent applies composite materials by combining fiber material (such as carbon fibers, glass fibers, or metal fibers) with metal material (aluminum alloy or stainless steel) to create a fiber-reinforced metal composite casing. The fiber material provides high strength-to-weight ratio and rigidity, allowing the casing to maintain sufficient strength with reduced thickness compared to solid metal construction.
2Length of moving object
If stainless steel plate with thin thickness is used to achieve thin casing, then the casing is thin, but it becomes heavy due to high density
Solution Approach 1:
The patent creates a composite structure where fiber material is combined with metal material to produce a casing that is both thin and lightweight. The fiber reinforcement allows the metal substrate to be thinner while maintaining structural integrity, thereby reducing overall weight compared to solid stainless steel construction.
3Weight of moving object
If fiber material is used to make casing light and thin, then the casing has high rigidity and is lightweight, but it becomes difficult to shape and combine with other structures
Solution Approach 1:
The patent employs a composite material system where fiber material is integrated with metal material, combining the advantages of both: the fiber provides high strength-to-weight ratio and rigidity, while the metal substrate maintains good formability and ease of manufacturing. This composite structure allows the casing to be shaped and combined with other structures more easily than pure fiber material.
4Strength
If conventional manufacturing methods are used to combine metal and fiber materials, then the structure has high rigidity, but the manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent merges the metal material and fiber material into an integrated composite structure during the manufacturing process. By combining these materials in a single manufacturing process rather than assembling separate components, the patent reduces the number of manufacturing steps, lowers production costs, and simplifies the overall manufacturing process while maintaining high structural rigidity.
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 method produces a composite material with high rigidity and strength in limited thickness, offering a cost-effective solution that balances material properties and manufacturing complexity, allowing for versatile application in various products.
Implementation Method 1
coating adhesive on a surface of the stainless structural component away from the female mold, and putting the fiber structure component on the surface of the stainless structural component with adhesive to make the fiber structure component attached to the stainless structural component
Data Source
AI summary
A manufacturing method of composite material includes following steps: shaping a stainless steel plate to a stainless structural component; putting the stainless structural component in a female mold; putting a fiber material over a surface of the stainless structural component away from the female mold; and pressing a male mold towards the female mold to make the fiber material attached to the stainless structural component. The present invention is able to make different materials attached to each other to form a composite material in a simple and efficient manufacturing process, and the composite material is light; thin and has advantages of high rigidity and high strength.