Metal Segment Support Insulator Structure for Bending Resistance
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Solution Overview
Problem
Electronic devices with metal segments face challenges in maintaining durability and preventing bending, especially as the number of antenna modules increases, due to lack of effective reinforcement and insulation between metal segments.
Innovation Solution
Incorporating a support insulator that engages with engagement portions of metal segments and provides insulation, combined with a filler that encloses the insulator and fills the gaps between the segments, enhancing the stiffness and preventing bending while maintaining a consistent gap between the metal segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If metal segments are placed close together to reduce gaps, then device complexity is reduced, but the metal segments become prone to bending and warping
Solution Approach 1:
A support insulator is introduced as an intermediary component between adjacent metal segments. This insulator engages with engagement portions on both metal segments, providing mechanical support that prevents bending and warping while maintaining electrical isolation. The support insulator acts as a mediator that enables the metal segments to be positioned close together without direct contact, thus reducing device complexity while maintaining structural integrity.
2Strength
If metal segments are spaced apart to prevent bending, then bending resistance improves, but device complexity increases due to larger gaps requiring filler material
Solution Approach 1:
The support insulator serves as a space-efficient intermediary that provides the necessary spacing for bending prevention without requiring large gaps. By engaging with engagement portions on adjacent metal segments, the insulator creates an optimized distance that prevents warping while minimizing the volume of filler material needed to enclose the insulator and fill remaining spaces.
3Device complexity
If metal segments are directly connected to reduce gaps, then device complexity is reduced, but electrical insulation between segments is lost
Solution Approach 1:
The support insulator is designed to perform multiple functions simultaneously: it provides mechanical support to prevent bending and warping of metal segments, maintains electrical insulation between adjacent segments, and enables close positioning to reduce device complexity. This multi-functional component eliminates the need for separate insulation elements while preventing electrical interference.
Data Source
AI summary
An electronic device and method of manufacturing are disclosed. The electronic device includes a first metal segment including a first engagement portion, a second metal segment including a second engagement portion, the second metal segment spaced apart from the first metal segment so as to define a slit with the first metal segment, a support insulator engaging the first and second engagement portions, the support insulator supporting the first and second metal segments, and providing insulation between the first and second metal segments, and a filler enclosing at least a portion of the support insulator, and filling at least a portion of the slit. In the method, the first and second metal segments are arranged to define a slit therebetween, a support insulator is engaged to the isolated first and second metal segments, and the slit is filled with a material enclosing at least part of the support insulator.