Curved Housing Shape Error Reduction via Variable Radius Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electronic devices with curved front surfaces, the housing often experiences shape errors due to limitations in processing techniques, leading to tolerance issues in the coupling between the window and the housing.
Innovation Solution
The design incorporates a housing with a first plate featuring a flat portion, a corner, and a curved edge, along with a side member that includes a metal portion and a polymer portion with a recess, where the polymer portion overlaps the curved edge and is supported by double-sided tape, allowing for precise alignment and reduced shape errors through primary and secondary ball end mill cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a ball end mill tool is used to process the curved surface of the housing, then the housing can be formed with a curved surface shape, but shape errors occur due to the shape limitation of the tool, leading to tolerance issues in the coupling portion
Solution Approach 1:
The curved edge portion is divided into multiple regions with different curvature radii. The first curved edge portion has a first curvature radius while the second curved edge portion has a second curvature radius that is different from the first. This segmentation allows each portion to be processed with appropriate tool paths, reducing cumulative shape errors that would occur if a single ball end mill tool with fixed radius were used for the entire curved surface.
Solution Approach 2:
The curvature radius parameter is changed along the curved edge portion. By varying the curvature radius from the first value to the second value across different sections of the curved edge, the housing can accommodate the limitations of ball end mill tools while maintaining overall curved surface aesthetics. This parameter variation allows optimization of manufacturing precision in critical coupling portions while preserving the desired curved shape.
2Shape
If the housing follows the curved surface shape of the window, then the aesthetic curved appearance is achieved, but shape errors occur in the coupling portion due to tool limitations
Solution Approach 1:
Different quality requirements are applied to different portions of the curved edge. The first curved edge portion maintains a larger curvature radius for aesthetic purposes, while the second curved edge portion has a smaller curvature radius optimized for precise coupling. This local differentiation ensures that the coupling portion meets reliability requirements with tighter tolerances while other portions maintain the desired curved appearance.
Solution Approach 2:
The housing structure is designed in advance with specific curvature radius variations to pre-compensate for ball end mill tool limitations. By planning the curved edge with different curvature radii before manufacturing, the design anticipates and corrects for the inherent shape errors that would occur during machining, ensuring that coupling portions achieve required tolerances while maintaining overall curved surface geometry.
Data Source
AI summary
Disclosed is an electronic device comprising: a housing including a first plate, a second plate and a lateral member for covering a gap between the first plate and the second plate; a touch screen display exposed through a first part of the first plate; a sensor exposed through the first plate; a wireless communication circuit arranged inside the housing; and a processor which is arranged inside the housing and is electrically connected to the touch screen display, the sensor and the wireless communication circuit. In addition, other embodiments are possible.