Electronic Housing Sidewall Decoration via Segmented In-Mold and Surface Processing
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Solution Overview
Problem
Current in-mold decoration technologies are unable to effectively fix a decoration film onto a sidewall of electronic device housings that are bent from the body, particularly when the sidewall is extended substantially perpendicular to the body, resulting in an inconsistent appearance and texture.
Innovation Solution
A method involving a preformed housing with a decoration film and a decoration layer, where the decoration film is applied using an in-mold injection mold process, and a surface processing treatment is applied to the exposed portion of the sidewall to form a decoration layer, allowing for a seamless and visually matched appearance with the rest of the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an in-mold decoration process is used to form the body and sidewall, then the decoration film can be applied to the housing, but the decoration film cannot be effectively fixed onto a sidewall that is bent perpendicular to the body
Solution Approach 1:
The decoration process is segmented into two separate operations: first applying the decoration film to the body using in-mold decoration, then separately forming the decoration layer on the exposed sidewall portion through surface processing treatment. This segmentation allows each process to optimize for its specific surface geometry.
Solution Approach 2:
The decoration film is applied to the body in advance during the injection molding process, before the sidewall decoration is completed. This preliminary action prepares the base structure and allows subsequent processes to focus specifically on the sidewall portion.
2Device complexity
If a single in-mold decoration process is used for the entire housing, then the process is simple, but the appearance and texture are inconsistent on bent sidewalls
Solution Approach 1:
Different decoration methods are applied to different local regions of the housing: in-mold decoration is used for the body surface, while surface processing treatment is used for the sidewall. This local quality approach ensures optimal appearance consistency for each region's specific geometry.
3Area of stationary object
If the decoration film covers the entire housing including bent sidewalls, then coverage is complete, but the decoration film cannot be effectively fixed and appears inconsistent
Solution Approach 1:
The sidewall portion is extracted from the decoration film coverage area, allowing the decoration film to be applied only to the body where it can be effectively fixed. The decoration layer is then separately formed on the extracted sidewall portion through surface processing treatment.
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
Enables the production of electronic device housings with a specific configuration, ensuring a uniform appearance and reduced production costs by allowing the decoration film and layer to be formed in two individual processes, effectively addressing the limitations of existing IMT.
Implementation Method 1
An in-mold injection mold is provided. An in-mold decoration process is applied to the decoration film to form the body and the sidewall
Implementation Method 2
A surface processing treatment is applied to an exposed portion of the sidewall to form a decoration layer
Data Source
Figure 1~3
Figure 4
Figure 5(a)~5(e)
AI summary
A manufacturing method of a housing includes the following steps: a preformed housing is provided. The preformed housing includes a body and a sidewall connected to the edge of the body, and a decoration film disposed on the body and the sidewall. A portion of the sidewall is exposed from the decoration film. The body includes a first surface. The sidewall includes a second surface. The second surface extends from the first surface. The first surface and the second surface are non-coplanar. A decoration layer is formed on the exposed portion of the sidewall by a surface processing treatment.