Thermoplastic Resin Chassis Member Edge Joining
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Solution Overview
Problem
Conventional chassis members for electronic apparatuses face challenges in manufacturing efficiency due to the difficulty in forming joints between fiber-reinforced resin plates, which limits the use of large-sized laminates and efficient cutting and joining processes, resulting in low productivity and joining strength.
Innovation Solution
A chassis member design featuring a laminate with an interlayer between fiber-reinforced resin plates made of thermoplastic resin, where a frame body is joined to a thin plate portion on the edge of the laminate, formed using thermoplastic resin, enhancing manufacturing efficiency and joining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resin is used in the matrix resin of fiber-reinforced resin plates, then the joining strength of the frame body and laminate is improved, but the manufacturing efficiency and productivity deteriorate because it is very difficult to squash the edge of the fiber-reinforced resin plates to form joints
Solution Approach 1:
The patent changes the material parameter from thermosetting resin to thermoplastic resin for the matrix resin of fiber-reinforced resin plates. This parameter change enables the material to be softened by heat and pressure, allowing edges to be squashed and formed into thin plate portions for joining, thereby improving manufacturing efficiency while maintaining joining strength through the thermoplastic material's ability to bond when heated and pressed.
2Stability of the object's composition
If thermosetting resin is used in the matrix resin of fiber-reinforced resin plates, then the structural integrity is improved, but the ease of manufacture deteriorates because it is very difficult to squash the edge of the fiber-reinforced resin plates
Solution Approach 1:
The patent changes the material parameter from thermosetting resin to thermoplastic resin, which fundamentally alters the material's response to heat and pressure. Thermoplastic resin can be softened and reshaped during manufacturing, making it easy to squash edges and form thin plate portions for joints, while still providing structural integrity through proper material selection and processing.
3Loss of substance
If a large-sized laminate is formed and cut out to create fiber-reinforced resin plates, then the material utilization is improved, but the manufacturing efficiency deteriorates because joints cannot be formed on the edges
Solution Approach 1:
The patent applies preliminary action by forming the thin plate portion (joining structure) on the edge of the laminate during the same heating and pressing process used to create the laminate itself. This preliminary formation of joining structures eliminates the need for separate post-processing steps, allowing both efficient material utilization and high manufacturing productivity to be achieved simultaneously.
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 improves manufacturing efficiency and joining strength by allowing for the formation of a thin plate portion on the laminate edge, enabling high-strength and lightweight chassis members with increased contact area, thus addressing the limitations of conventional methods.
Implementation Method 1
the resin material is heated and pressed, thereby a thin plate portion is formed on an edge of the laminate
Implementation Method 2
the resin material is heated and pressed, thereby a thin plate portion is formed on an edge of the laminate
Data Source
AI summary
A chassis member capable of improving manufacturing efficiency is disclosed. The chassis member includes a laminate in which an interlayer is provided between a pair of fiber-reinforced resin plates made of reinforced fiber impregnated with thermoplastic resin. A frame body formed of thermoplastic resin is joined to an edge of the laminate. The edge of the laminate is provided with a thin plate portion thinner than the other portion. The frame body is joined to the thin plate portion.