Formable Insert Attachment in Electronic Device Covers
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Solution Overview
Problem
Existing methods for attaching formable inserts, such as fabrics or leathers, to electronic device covers often result in a weak bond, leading to detachment and visible parting lines, which can be aesthetically unappealing and damage the insert.
Innovation Solution
A method involving a first frame with a smaller dimensional profile than the final part, allowing a foldable insert to be attached and then undermolded with resin to seal its perimeter edge, eliminating the need for secondary trimming and enhancing durability by embedding the edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insert molding is used to attach the insert to the cover, then the insert can be integrated with the cover, but the attachment is weak and the insert can detach
Solution Approach 1:
The insert is attached to the first frame before the second frame is molded, allowing the insert to be positioned and secured in advance. This preliminary attachment ensures the insert remains firmly bonded throughout the molding process and prevents detachment during device assembly and use.
Solution Approach 2:
The insert is embedded within the frame structure, with the first frame and second frame forming a nested configuration that encapsulates the insert. This nesting approach provides mechanical interlocking and distributes stress across the entire frame-insert-frame assembly, significantly enhancing attachment reliability.
2Reliability
If insert molding is used, then the insert can be attached to the cover, but a visible parting line forms between the insert and cover
Solution Approach 1:
The frame is divided into two separate frames: a first frame to which the insert is attached, and a second frame that overlays and conceals the insert edges. This segmentation allows the parting line to be positioned within the second frame rather than at the visible interface between insert and cover, eliminating the aesthetic defect while maintaining attachment integrity.
3Ease of manufacture
If the insert is attached directly to the cover, then the process is simple, but the edges of the insert fray or become damaged
Solution Approach 1:
The second frame acts as a protective shell that overlays and encases the edges of the insert. This thin film structure provides mechanical protection to the insert edges during molding and device assembly, preventing fraying and damage while adding minimal thickness and maintaining manufacturing efficiency.
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 provides a robust attachment of the formable insert, prevents fraying, and hides the parting line from the exterior surface, enhancing the aesthetic appeal and durability of the electronic device cover.
Implementation Method 1
injected a second material into the mold tool to encase the perimeter edge of the foldable insert and seal within the second frame a portion of the perimeter edge of the foldable insert
Data Source
AI summary
Formable inserts and related methods are disclosed herein. An example of forming a cover with a formable insert includes forming a first frame portion of the cover, attaching a formable insert to the first frame portion of the cover, and forming a second frame portion of the cover subsequent to the formation of the first frame portion to capture a perimeter edge of the formable insert in the second frame portion of the cover.