Frameless Aluminum Shell Forming With Nano-Injection Bonding
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Solution Overview
Problem
Traditional methods for processing mobile terminal device shells using aluminum materials are costly and complex, requiring CNC machining and additional face frames, which also lead to issues with signal shielding and plastic parts falling off.
Innovation Solution
A method for processing frameless shell materials involves cutting, stamping, and curling aluminum sheets to form a U-shaped frame, followed by CNC processing for antenna grooves and screen installation, grinding and cleaning, surface T processing for micro-pores, and finally nano-injection molding for plastic parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CNC machining is used to carve the shell from an aluminum block, then the shell shape precision is improved, but the production cost increases and assembly complexity increases
Solution Approach 1:
The shell is divided into a U-shaped frame portion and a face frame portion that are processed separately and then assembled together. The U-shaped frame is formed by stamping and curling aluminum sheets, while the face frame is added separately to complete the shell structure, simplifying the overall assembly process.
Solution Approach 2:
The U-shaped frame and face frame are combined through assembly to form the complete shell structure. This merging of separately processed components achieves the desired shell shape while reducing manufacturing complexity and cost compared to machining the entire shell from a single block.
2Ease of operation
If a face frame is added to assemble the screen, then the screen mounting function is improved, but the production cost increases
Solution Approach 1:
The shell is segmented into functional portions where the U-shaped frame provides structural support and the face frame specifically handles screen mounting. This segmentation allows each portion to be optimized for its function while being produced through cost-effective stamping processes rather than expensive CNC machining.
3Strength
If metal materials are used for the shell, then the structural strength is improved, but signal shielding occurs requiring additional slots and antennas
Solution Approach 1:
The shell is divided into the U-shaped frame portion and face frame portion, allowing strategic placement of signal slots and antenna openings in the face frame area where they do not compromise the structural integrity of the main U-shaped frame. This segmentation enables signal transmission functionality while maintaining overall structural strength.
4Ease of operation
If nano-injection molding is used to draw out antennas, then the antenna integration is improved, but the plastic parts easily fall off
Solution Approach 1:
The surface of the U-shaped frame undergoes T processing (oxidation) before nano-injection molding to create micro-pores on the surface. This preliminary surface treatment enhances the adhesion between the plastic antenna components and the aluminum frame, preventing the plastic parts from falling off during use.
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
This method reduces production costs, simplifies assembly, enhances the integration of plastic parts with the aluminum shell, and prevents plastic parts from falling off, thereby addressing the limitations of existing technologies.
Implementation Method 1
stamping the cut sheet material by using a stamping machine, and during the stamping process, thickening a frame and curling the frame into an inner U-shaped frame
Implementation Method 2
surface T processing: oxidizing the surface of the U-shaped frame to form micro-pores on the surface of the U-shaped frame
Implementation Method 3
nano-injection molding: nano-injection molding the antenna groove and other plastic parts on the surface of the U-shaped frame
Data Source
AI summary
A method for processing frameless shell materials, relating to the technical field of mobile terminal device shell processing, is provided and includes the following steps: S1 cutting a sheet material, S2 stamping and curling, S3 CNC processing, S4 grinding and cleaning, S5 surface T processing, and S6. nano-injection molding. The present disclosure adopts a stamping method and replaces traditional metal block CNC processing, which can reduce production costs. During the stamping process, the aluminum sheet is edge-curled and thickened to enhance the strength of the shell material. By cutting a step-shaped groove for screen installation, a frameless design is achieved, thereby reducing production costs and assembly procedures. The anodizing of the U-shaped frame surface allows the plastic to fully penetrate the aluminum shell surface, thereby enhancing integration and preventing plastic parts from falling off the U-shaped frame.