Metal Housing Surface Patterning Using ECM Replica Jigs

Solution Overview

Problem

Existing methods for creating convex and concave patterns on electronic device housings, particularly those made from difficult-to-cut materials like stainless steel or titanium, are inefficient and time-consuming, often requiring mechanical tools or chemical etching.

Innovation Solution

The use of electrochemical machining (ECM) to form convex and concave patterns on electronic device housings, where a jig with a second convex and concave pattern is used to create a corresponding first pattern on the housing, allowing for uniform pitch and height.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical tools or chemical etching are used to create convex and concave patterns on housing, then the patterns can be formed on difficult-to-cut materials, but the processing time is prolonged and uniformity is difficult to achieve

Engineering Contradiction:

Improveuniformity of convex and concave patternVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces mechanical cutting tools with electrochemical machining (ECM) to form convex and concave patterns on the housing. This substitution eliminates mechanical contact and tool wear, enabling uniform pattern formation on difficult-to-cut materials like stainless steel and titanium without prolonged processing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameters from mechanical force and chemical etching to electrochemical dissolution controlled by electrical current density. By controlling the ECM parameters (current, electrolyte flow, electrode gap), uniform convex and concave patterns are achieved with precise control over depth and spacing, significantly reducing processing time compared to traditional methods.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If mechanical tools are used to process housing exterior surface, then the patterns can be created, but it is difficult to evenly process the surface and prolonged time is necessary

Engineering Contradiction:

Improveease of pattern formationVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces mechanical cutting tools with electrochemical machining (ECM) to form convex and concave patterns on the housing. This substitution eliminates mechanical contact and tool wear, enabling uniform pattern formation on difficult-to-cut materials like stainless steel and titanium without prolonged processing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a cathode electrode that is a negative replica of the desired convex and concave pattern. During ECM, the electrode copies its shape onto the housing surface through controlled electrochemical dissolution, ensuring precise and repeatable pattern formation without requiring complex mechanical tooling.

Inventive Principle:

Principle #26Copying

3Productivity

If traditional processing methods are used, then the housing can be manufactured, but the cost and time for manufacturing are high

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent employs continuous electrochemical machining where the electrolyte flows continuously through the tool housing, allowing constant removal of dissolved metal and maintaining steady current density throughout the process. This continuous action enables high-speed pattern formation without intermittent stopping, significantly improving manufacturing efficiency compared to batch mechanical processing.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent replaces mechanical cutting tools with electrochemical machining (ECM) to form convex and concave patterns on the housing. This substitution eliminates mechanical contact and tool wear, enabling uniform pattern formation on difficult-to-cut materials like stainless steel and titanium without prolonged processing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

ECM enables the efficient and uniform formation of convex and concave patterns on electronic device housings, reducing manufacturing time and cost compared to traditional methods, while also allowing for the use of difficult-to-cut materials.

Implementation Method 1

a first convex and concave pattern which is formed by electro chemical machining (ECM) using a jig on which a second convex and concave pattern is formed

Methodology Applied

Scientific EffectElectrochemical dissolution: Electrolysis

Implementation Method 2

an anodizing process of forming an oxide coating layer on the housing

Methodology Applied

Scientific EffectAnodizing: Anodising

Data Source

PatentUS12232287B2Electronic device including housing

Publication Date: 2025.02.18 SAMSUNG ELECTRONICS CO LTD

AI summary

According to various embodiments of the disclosure, an electronic device may include: a housing, a processor disposed inside the housing, the housing may include a metal member comprising a metal and including a first convex and concave pattern formed in a shape corresponding to a shape of a second convex and concave pattern formed on a jig, wherein the jig is formed for use in electro chemical machining (ECM), and the first convex and concave pattern may have at least a portion formed at a substantially uniform pitch and a substantially uniform height.