Roll-Bonded Metal Laminate Waviness Control for Mirror Finishes
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Solution Overview
Problem
Roll-bonded bodies used in mobile electronic apparatuses often exhibit waviness on their surfaces due to insufficient tension during the plate passing process, which hinders the achievement of an excellent mirror surface finish, leading to difficulties in obtaining a high-quality external appearance.
Innovation Solution
A roll-bonded body is produced by bonding a first metal layer and a second metal layer with specific waviness parameters (0.01 to 0.96 μm arithmetic average waviness and 0.2 to 5.0 μm maximum waviness height) and incorporating an intermediate metal layer, with the first metal layer on the outer surface and the second metal layer on the inner surface, to minimize waviness and enhance image clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the plate passing step is conducted with insufficient tension, then the roll-bonded body can be easily handled and processed, but waviness is generated on the surface due to imperfect contact with the roll
Solution Approach 1:
The patent optimizes the tension parameter during the plate passing step to a specific range that balances ease of handling with surface quality. By carefully controlling the tension magnitude, the roll-bonded body maintains sufficient contact with the roll to prevent waviness while remaining manageable during processing.
Solution Approach 2:
The patent applies a tension level that is sufficient to prevent waviness generation during the plate passing step, rather than using minimal tension. This excessive action ensures perfect contact between the roll-bonded body and the roll, eliminating surface defects even though it requires slightly more force than the absolute minimum.
2Adaptability or versatility
If the pitch between rolls in the plate passing step is made long, then the roll-bonded body can move more freely, but the roll-bonded body does not move perfectly along the rolls, generating knock patterns
Solution Approach 1:
The patent optimizes the pitch parameter between rolls to a specific range that ensures the roll-bonded body moves perfectly along the rolls without generating knock patterns. This optimized pitch maintains appropriate movement freedom while preventing surface defects.
3Manufacturing precision
If waviness is removed by increasing polishing amount, then the surface quality is improved, but productivity is lowered and cost increases
Solution Approach 1:
The patent prevents waviness generation during the plate passing step by optimizing tension and pitch parameters. This preliminary prevention eliminates the need for extensive polishing later, maintaining high productivity and low cost while achieving excellent surface quality.
Solution Approach 2:
The patent converts the potential harm of waviness generation into benefit by carefully controlling process parameters. The optimized tension and pitch conditions transform the plate passing step from a waviness-generating process into a waviness-preventing process, eliminating the need for corrective polishing.
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 proposed method effectively suppresses waviness on the surface of the roll-bonded body, enabling the production of mobile electronic apparatus housings with a beautiful metallic luster and excellent image clarity, while maintaining processability and heat radiation properties.
Implementation Method 1
bonding two metal plates to each other by rolling
Implementation Method 2
bonded by rolling
Implementation Method 3
a heat treatment is conducted
Implementation Method 4
the roll-bonded body is passed through one or a plurality of correction rolls while applying a tension to the roll-bonded body
Implementation Method 5
for removing warpage or the like of the roll-bonded body generated in the steps ranging to the heat treatment
Data Source
AI summary
[Problem] To provide: a roll-bonded body which is able to be suppressed in waviness in the surface; and a method for producing this roll-bonded body. [Solution] A roll-bonded body according to the present invention is obtained by bonding a first metal layer and a second metal layer with each other by means of rolling, and is characterized in that the surface of the first metal layer has an arithmetic average waviness (Wa1) 0.01-0.96 and a maximum waviness height (Wz1) of 0.2-5.0 μm.