Electroformed Timepiece Shell with Precious Metal Inserts
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Solution Overview
Problem
Conventional methods for producing structural timepiece components by electroforming struggle to achieve sufficient rigidity and mechanical resistance, particularly in thin components like hollow shells, which are prone to deformation or tearing when assembled with other components.
Innovation Solution
A method involving the use of a sacrificial substrate with inserted precious metal inserts, where electroforming is performed to create a shell that covers both the substrate and inserts, allowing for reinforced areas with sufficient rigidity and functional geometries that are difficult to achieve through conventional machining, using a combination of precious metals like gold and sacrificial materials like copper or polymer-based substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electroforming is used to produce thin structural timepiece components, then material usage is reduced and surface quality is improved, but mechanical rigidity and resistance to deformation are insufficient
Solution Approach 1:
The invention combines precious metal electroformed shell with a sacrificial substrate core to create a composite structure. The substrate provides mechanical strength and rigidity while the electroformed precious metal layer provides the desired appearance and uses minimal precious material. After electroforming, the substrate is destroyed leaving a rigid hollow component with sufficient mechanical properties.
Solution Approach 2:
The invention changes the physical state and properties of the substrate material through the electroforming process. The substrate transitions from a solid sacrificial material to a form that provides structural support, and is subsequently destroyed to leave the finished component with optimized mechanical properties.
2Strength
If a sacrificial substrate is used as a core during electroforming, then mechanical rigidity is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The substrate is prepared in advance with the correct geometry and features before electroforming begins. Machined inserts and reinforcement elements are pre-positioned on the substrate, and the electroforming process then builds the precious metal shell around these pre-prepared components, simplifying the overall manufacturing sequence.
Solution Approach 2:
The sacrificial substrate acts as an intermediary element that enables the electroforming process to create complex geometries. It serves as a temporary core that provides structural support during manufacturing, and is removed after serving its purpose, leaving the finished component with features that would be difficult to achieve directly.
3Adaptability or versatility
If machined inserts are incorporated into the electroformed component, then functional geometries and reinforcement are achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention merges multiple manufacturing operations into a single electroforming process. Machined inserts, reinforcement elements, and the electroformed shell are combined in one continuous process, eliminating the need for separate machining operations on the finished precious metal component and reducing overall manufacturing complexity.
Solution Approach 2:
The machined inserts and reinforcement elements are strategically placed only in specific locations where functional geometries or additional strength are needed. This localized approach provides the necessary adaptability and reinforcement only where required, rather than throughout the entire component.
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 thin, yet rigid electroformed components with enhanced resistance to torsion, traction, and shearing forces, preventing deformation or tearing, and enabling complex geometries that were previously inaccessible.
Implementation Method 1
an electroforming method is implemented to obtain a bare electroformed component with sections of material deposited on the sacrificial substrate acting as a core
Data Source
AI summary
Method for manufacturing an electroformed timepiece component:the same first alloy including a first precious metal is selected to make both functional inserts and an electroformed shell;these inserts are made;an electroforming substrate having a complementary profile to the inner profile of this component is formed in a second sacrificial material;these inserts are inserted into housings made on this substrate, to form an equipped sacrificial substrate, which is provided with the resists necessary to obtain, by means of an electroforming process, a bare electroformed component, with deposition of material on this substrate, acting as a core to form this electroformed shell, and on each accessible surface of each insert to secure the insert to this electroformed shell;then this sacrificial substrate is destroyed and all of these resists are removed.