Composite Aluminum Alloy Case Plate for Strength and Anodized Finish
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Solution Overview
Problem
Conventional aluminum alloy cases for electronic products, such as smartphones, face issues with mechanical strength, aesthetic appearance, and abrasion resistance due to the limitations of 5XXX and 6XXX series alloys, which result in poor performance when surface anodized and dyed.
Innovation Solution
A composite aluminum alloy plate is created by stacking a high mechanical strength 6XXX to 8XXX series alloy as the intermediate layer and a 1XXX to 5XXX series alloy as the external layer, with the latter being anodized and dyed to enhance aesthetic appearance and chemical stability, and the layers are processed through hot rolling, cold rolling, and tempering to achieve desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If 5XXX series aluminum alloy is used for case manufacturing, then corrosion resistance and weldability are improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies composite materials by stacking two different aluminum alloy plates (5XXX series and 6XXX/7XXX series) to create a composite structure. The 5XXX series layer provides corrosion resistance and aesthetic appearance after anodizing, while the 6XXX/7XXX series layer provides high mechanical strength. This composite structure resolves the contradiction by combining materials with complementary properties.
2Strength
If 6XXX series aluminum alloy is used for case manufacturing, then mechanical strength is improved, but aesthetic appearance after anodizing and dyeing deteriorates
Solution Approach 1:
The patent uses a composite structure where the 6XXX series aluminum alloy layer provides mechanical strength support, while a separate 5XXX series aluminum alloy layer provides the aesthetic appearance through anodizing and dyeing. The 5XXX series alloy forms a thicker, more uniform oxide film that accepts dye better, resolving the contradiction between strength and aesthetics.
Solution Approach 2:
The patent applies local quality by assigning different functional properties to different layers of the composite structure. The outer 5XXX series layer is optimized for aesthetic appearance and surface treatment, while the inner 6XXX/7XXX series layer is optimized for mechanical strength. Each layer performs its specific function locally, resolving the contradiction.
3Strength
If 7XXX series aluminum alloy is used for case manufacturing, then mechanical strength is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction by creating a composite structure where the 7XXX series aluminum alloy layer provides high mechanical strength, while a separate 5XXX series layer provides abrasion resistance through a thicker oxide film formed during anodizing. The composite structure allows each material to excel at its specific function.
4Ease of manufacture
If single-layer aluminum alloy plate is used, then manufacturing process is simple, but cannot simultaneously achieve high mechanical strength, good aesthetic appearance, and high abrasion resistance
Solution Approach 1:
The patent applies composite materials by stacking two aluminum alloy plates with different properties. Although this increases material complexity, the manufacturing process remains relatively simple using existing rolling and anodizing technologies. The composite structure enables simultaneous achievement of high mechanical strength, good aesthetic appearance, and high abrasion resistance that cannot be obtained with single-layer alloys.
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 composite alloy plate achieves improved mechanical strength, aesthetic appearance, chemical stability, insulation, high-temperature resistance, and abrasion resistance, while maintaining suitable tensile strength and elongation, effectively addressing the limitations of single-series alloy cases.
Implementation Method 1
when the case is surface anodized, an oxide film is formed on the aluminum alloy by ways of electric currents
Implementation Method 2
the first aluminum alloy plate and the second aluminum alloy plate are stacked and compounded by hot rolling
Implementation Method 3
the composite aluminum alloy plate is laminated in a desired thickness by cold rolling
Implementation Method 4
the composite aluminum alloy plate is stabilized in a tempering treatment
Data Source
AI summary
A composite aluminum alloy plate for a case of an electronic product contains: a first aluminum alloy plate and a second aluminum alloy plate. The first aluminum alloy plate is made of first aluminum alloy material, and the second aluminum alloy plate is made of second aluminum alloy material. The first aluminum alloy material is selected from any one of 6XXX series aluminum alloy to 8XXX series aluminum alloy, and the second aluminum alloy material is selected from any one of 1XXX series aluminum alloy to 5XXX series aluminum alloy. The first and second aluminum alloy plates are stacked and compounded by hot rolling so as to produce the composite aluminum alloy plate having an external layer, an intermediate layer, and an internal layer. Thereafter, the composite aluminum alloy plate is laminated by cold rolling and is stabilized in a tempering treatment.