Injection-Molded Frame Adhered to Metal Casing for Simplified Assembly
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Solution Overview
Problem
The manufacturing of electronic device casings with complex connecting structures is time-consuming and costly due to the need for intricate milling processes, which complicates the assembly and increases production costs as devices become thinner and smaller.
Innovation Solution
A casing assembly comprising a metal casing and an injection-molded frame, where the injection-molded frame is manufactured with connecting structures and adhered to the metal casing using an adhesive, simplifying the assembly process and reducing production costs by eliminating the need for complex structures on the metal casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If complex connecting structures are manufactured on the metal casing via milling process, then the connecting structures can be integrated into the casing, but the manufacturing time and cost increase significantly
Solution Approach 1:
The invention divides the casing into two separate components: a metal casing and an injection-molded frame. The connecting structures are manufactured on the injection-molded frame through injection molding, while the metal casing is manufactured through simpler thermal processing. This segmentation allows each component to be optimized for its specific manufacturing process, reducing overall manufacturing time and complexity.
Solution Approach 2:
The invention combines the metal casing and the injection-molded frame into a unified casing assembly. The injection-molded frame is adhered to the metal casing, creating a composite structure that integrates the advantages of both materials and manufacturing processes. This merging allows the complex connecting structures to be formed on the frame without complicating the metal casing manufacturing.
2Ease of manufacture
If complex connecting structures are manufactured on the metal casing, then the structures can be integrated, but the manufacturing cost increases
Solution Approach 1:
The invention segments the manufacturing process into two distinct parts: manufacturing the metal casing through simple thermal processing, and manufacturing the injection-molded frame with integrated connecting structures through injection molding. This segmentation eliminates the need for complex milling operations on the metal casing, reducing both manufacturing cost and process complexity.
Solution Approach 2:
The invention replaces the mechanical milling process with injection molding. Instead of using complex milling machines to create connecting structures on the metal casing, the design uses injection molding to form these structures on the frame. This substitution of manufacturing methods significantly reduces process complexity and cost.
3Weight of moving object
If the metal casing is made thinner to reduce device weight and size, then the device becomes lighter and more compact, but the strength and structural integrity are compromised
Solution Approach 1:
The invention creates a composite casing structure by adhering the injection-molded frame to the metal casing. This composite structure combines the lightweight properties of the frame material with the high strength of the metal casing. The connecting structures integrated into the frame provide additional structural reinforcement, allowing the overall device to be lighter while maintaining or improving strength.
Solution Approach 2:
The injection-molded frame with its integrated connecting structures provides structural reinforcement that compensates for the reduced thickness of the metal casing. The frame's design, including its connecting structures, creates a more complex load-bearing system that enhances overall structural integrity despite the thinner metal casing.
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 approach simplifies the manufacturing process, reduces production costs, and allows for quicker assembly of electronic devices by forming complex structures on the injection-molded frame rather than the metal casing, facilitating the use of a simpler thermally working process for the metal casing.
Implementation Method 1
coating adhesive to at least one of the metal casing and the injection-molded frame, and adhering the injection-molded frame to the metal casing via the adhesive
Data Source
AI summary
A casing assembly of an electronic device is provided. The casing assembly of the electronic device is configured to connect a connecting assembly. The connecting assembly comprises a metal casing; and an injection-molded frame. The injection-molded frame includes a first surface and a second surface, the first surface is fixed to the metal casing, and the second surface is configured with a plurality of connecting structures. The connecting structures are fixed to the connecting assembly, and the connecting assembly is assembled to the metal casing via the connecting structures.