Die Cast Middle Frame Asymmetric Groove Design
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Solution Overview
Problem
Conventional middle frames in electronic devices have a thick flat part due to die casting processes, which increases the overall thickness of the device and leads to material flow blocking and cold material issues during molding.
Innovation Solution
A middle frame design with a flat part and recessed grooves that are integrally molded using a die casting process, where the recessed grooves are angled to reduce material flow blocking and facilitate thinner production, and the grooves are configured to accommodate different parts of the electronic device, thereby reducing the overall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the middle frame is molded through die casting with conventional groove design, then the manufacturing cost is reduced and molding efficiency is improved, but the flat part thickness becomes large which affects the overall device thickness
Solution Approach 1:
The groove cross-section is designed with asymmetric angles where the first side wall and second side wall form different angles with the flow direction. This asymmetric design creates a gradual enlargement of the opening in the flow direction, reducing material flow blocking and preventing cold spots, thereby enabling thinner flat part thickness while maintaining efficient die casting production
Solution Approach 2:
The patent optimizes the angular parameters of the groove side walls relative to the flow direction. By changing the angles of the first and second side walls, the material flow characteristics are improved, reducing flow blocking and allowing the flat part thickness to be reduced while maintaining manufacturing efficiency
2Volume of moving object
If the groove opening is enlarged perpendicular to the flow direction, then the groove can accommodate more components, but material flow blocking increases causing cold spots and requiring larger flat part thickness
Solution Approach 1:
The patent transitions from enlarging the groove opening purely in the perpendicular direction to a dimensional approach that includes the flow direction. By enlarging the opening gradually in the flow direction through angled side walls, the groove provides adequate accommodation space while maintaining smooth material flow and preventing cold spots
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 design reduces the thickness of the middle frame and electronic device, improves bonding stability, and minimizes the risk of material cold spots during molding, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
a die casting molding process, in which a molten material fills a mold cavity at a high speed under a high pressure, and the material solidifies under the pressure to form a die casting member
Data Source
AI summary
A middle frame includes a flat part and a first recess part that are integrally molded, where the first recess part is recessed relative to a first surface of the flat part to form a first groove, where an opening is located on the first surface; the first recess part includes a bottom wall, a first side wall, and a second side wall, where an orientation of the bottom wall is the same as that of the first surface, the first side wall and the second side wall separately intersect the bottom wall, and the first side wall is connected to the second side wall; and an opening formed by the first side wall and the second side wall is gradually enlarged in a first direction parallel to a flow direction of a die casting material in a die casting molding process of the middle frame.