Electronic Surface Co-Removal Across Multi-Material Interfaces
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Solution Overview
Problem
Electronic device components assembled from different materials often have excess insulating material extending beyond interfaces, leading to aesthetic issues, increased risk of device damage, and reduced structural integrity due to manufacturing imperfections and varying material properties.
Innovation Solution
A process is developed to create a continuous, cosmetically pleasing surface on electronic device components by using an intermediate insulating material between conductive elements, which is processed post-assembly to remove excess material and smooth out interfaces, employing a single tool or process that dynamically adjusts settings based on the material properties of the elements involved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple conductive elements are connected using an insulating intermediate element, then electrical functionality is achieved, but excess material extends beyond the interface adversely affecting appearance and user experience
Solution Approach 1:
The patent applies preliminary action by performing cosmetic co-removal of excess insulating material immediately after the molding process while the component is still in the manufacturing line. This prevents excess material from becoming a persistent problem and eliminates the need for separate post-processing steps, thereby maintaining surface continuity without compromising electrical functionality.
Solution Approach 2:
The patent extracts the harmful excess insulating material from the component surface through a dedicated removal process. By selectively removing only the excess material that extends beyond the interface between conductive elements, the patent eliminates the adverse effects on appearance and user experience while preserving the functional insulating element.
2Reliability
If different materials with different properties are used for conductive elements and insulating intermediate element, then electrical and structural requirements are met, but varying material properties complicate the manufacturing process
Solution Approach 1:
The patent applies universality by using a single cosmetic co-removal process that can handle multiple different materials (metal, plastic, ceramic, glass, composite) simultaneously. The process is designed to be material-agnostic, allowing it to remove excess material from various insulating materials without requiring separate processing steps for each material type, thereby simplifying manufacturing despite varying material properties.
Solution Approach 2:
The patent applies parameter changes by adjusting process parameters (such as removal depth, speed, and intensity) based on the specific material properties being processed. This allows the same cosmetic co-removal process to effectively handle different materials with varying properties, maintaining ease of manufacture while meeting electrical and structural requirements.
3Productivity
If excess insulating material is left on the component surface, then manufacturing is simpler, but the material catches on user's hand or clothing and increases risk of dropping the device
Solution Approach 1:
The patent applies preliminary action by performing cosmetic co-removal of excess material as an integrated step within the manufacturing process itself, rather than as a separate post-processing operation. This eliminates excess material that would otherwise catch on user's hand or clothing, improving user experience and device safety without significantly complicating manufacturing.
Solution Approach 2:
The patent converts the potentially harmful excess material into a benefit by using the same molding process that creates the excess material to also define the precise location and amount to be removed. The excess material serves as a built-in guide for the cosmetic co-removal process, ensuring consistent results while eliminating the harmful effects of protruding material.
4Device complexity
If a single tool is used to process multiple different materials, then device complexity is reduced, but the tool must dynamically adjust settings based on material properties
Solution Approach 1:
The patent applies feedback by implementing a system that automatically detects the material type being processed and dynamically adjusts the cosmetic co-removal parameters in real-time. This feedback mechanism allows a single tool to handle multiple materials effectively, reducing device complexity while maintaining optimal processing conditions through automated parameter adjustment based on material properties.
Data Source
AI summary
This is directed to providing a cosmetic finish on a component constructed by connecting several elements. A single manufacturing process, such as machining or grinding, can be applied to the connected elements to remove material from some or all of the elements and to form a smooth and continuous surface across interfaces between the individual elements of the component. In some cases, settings of the material removal process can be adjusted based on the material of the component elements. For example, the settings can be adjusted based on the manufacturing or mechanical properties of each element material.