Metallic Cover Edge Structure Crack Prevention
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Solution Overview
Problem
Conventional metallic covers for electronic devices with sharp-cornered edges are prone to cracks and discoloration due to material deformation during manufacturing, and the anodizing process affects the appearance, leading to a decrease in quality.
Innovation Solution
A metallic cover made from aluminum alloys with specific yield strength, elongation ratio, and hardness ranges, formed using a curved-cornered edge structure that is then pressed into a sharp-cornered edge and polished before anodizing, to minimize deformation and maintain appearance quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a sharp-cornered edge structure is formed by pressing a preformed cover, then the appearance quality is improved, but cracks occur in the edge structure due to material deformation
Solution Approach 1:
The patent changes the material parameters by selecting aluminum alloys with specific mechanical properties (yield strength: 80-150 MPa, elongation ratio: 15-28%, hardness: 45-70 HV0.2). This parameter optimization allows the material to undergo the pressing process to form sharp-cornered edges without cracking, resolving the contradiction between shape quality and structural integrity.
2Ease of manufacture
If conventional aluminum alloy is used for metallic cover, then the manufacturing process is simple, but the material is prone to deformation and cracking during forming
Solution Approach 1:
The patent optimizes the material parameters by selecting aluminum alloys with specific yield strength (80-150 MPa), elongation ratio (15-28%), and hardness (45-70 HV0.2). These parameter changes enable the material to maintain manufacturing simplicity while achieving the precision required for sharp-cornered edge structures without cracking.
3Strength
If anodizing process is applied to metallic cover, then the surface hardness is improved, but color discrepancy occurs between edge structure and other parts
Solution Approach 1:
The patent changes the material composition parameters by selecting specific aluminum alloys (such as 5052-O, 6061-T4) with controlled elemental compositions. This material parameter optimization ensures uniform anodizing response across the entire surface, achieving both surface hardness improvement and color uniformity between the edge structure and other parts.
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
The solution effectively reduces cracks and discolorations, maintaining the appearance quality of the metallic cover by using materials with suitable properties and processing techniques, ensuring a durable and aesthetically pleasing finish.
Implementation Method 1
drawing an aluminum alloy sheet that has a yield strength in the range from about 80 MPa to about 150 Mpa, an elongation ratio in the range from about 15% to about 28%, and a hardness in the range from about 45 HV0.2 to about 70 HV0.2 to form a preformed cover
Implementation Method 2
pressing the curved-cornered edge structure of the preformed cover into a sharp-cornered edge structure by a forming die
Implementation Method 3
polishing the preformed cover
Implementation Method 4
anodizing the polished preformed cover to form the metallic cover
Data Source
AI summary
An exemplary metallic cover (20) includes a bottom base (21) and a plurality of side walls (22, 23, 24, 25). The side walls extend from bottom base. The bottom base and each of the side walls are connected by an edge structure (26). The metallic cover is made of a metallic material that has a yield strength in the range from about 80 MPa to about 150 MPa, an elongation ratio in the range from about 15% to about 28%, and a hardness in the range from about 45 HV0.2 to about 70 HV0.2. A method for making the metallic cover is also provided.