Ceramic Shell Transition Layer for Plastic Bonding
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Solution Overview
Problem
Ceramic materials for smartphone shells are expensive, heavy, and difficult to manufacture with a buckle and middle frame connection, limiting design and increasing production costs due to weak bonding with plastic parts.
Innovation Solution
A processing method involving coating a sol on the inner surface of a ceramic shell, followed by low-temperature sintering to form a transition layer with nano-sized micro-pores, allowing for improved mechanical bonding with plastic parts without special surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic material is used for shell, then scratch resistance and wear resistance are improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent uses a composite structure combining ceramic material and plastic material. The ceramic shell provides scratch resistance and wear resistance, while the plastic shell provides light weight. The two materials are bonded together through a transition layer formed by coating and sintering, creating a composite shell that combines the advantages of both materials.
2Strength
If ceramic material is used for shell, then scratch resistance and wear resistance are improved, but manufacturing difficulty increases
Solution Approach 1:
The patent divides the shell into separate ceramic and plastic parts that are manufactured independently, then bonded together through a transition layer. This segmentation allows each material to be processed using its optimal manufacturing method, reducing overall manufacturing difficulty while maintaining the desired wear resistance properties.
Solution Approach 2:
The patent introduces a transition layer as an intermediary between the ceramic shell and plastic shell. This transition layer, formed by coating and sintering, acts as a bonding agent that facilitates the connection between the two materials, simplifying the manufacturing process and improving bond strength.
3Stability of the object's composition
If ceramic shell is manufactured alone, then structural integrity is improved, but bonding with plastic parts becomes difficult
Solution Approach 1:
The patent introduces a transition layer as an intermediary substance between the ceramic shell and plastic shell. This transition layer, formed by coating and sintering, acts as a bonding agent that facilitates the connection between the two materials, solving the bonding difficulty while maintaining the structural integrity of the ceramic component.
Solution Approach 2:
The patent uses a porous transition layer formed through sintering. The porous structure provides increased surface area and mechanical interlocking opportunities, enhancing the bonding strength between the ceramic and plastic shells while maintaining the structural integrity of the overall assembly.
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
Enhances mechanical bonding between ceramic and plastic parts, reduces production energy consumption, and expands design possibilities by providing mechanical anchor points, while maintaining the ceramic shell's polish and glaze decoration.
Implementation Method 1
sintering the ceramic shell coated with the sol by using a sintering process, forming a transition layer having with nano-sized micro-pores on the inner surface of the ceramic shell
Data Source
AI summary
A shell and a method for processing the shell are provided. The method includes: coating a sol prepared in advance on an inner surface of a ceramic shell prepared in advance; sintering the ceramic shell coated with the sol by using a sintering process, and forming a transition layer having nano-sized micro-pores on the inner surface of the ceramic shell.