Variable-Thickness Mobile Enclosure Covers With Reduced Machining
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Solution Overview
Problem
Conventional manufacturing processes for mobile computing device enclosure covers are wasteful and time-consuming, requiring multiple steps to achieve complex shapes, often discarding up to 90% of the material from planar extrusions of aluminum.
Innovation Solution
The method involves extruding a panel with a fixed cross-sectional profile that includes increased thickness features, removing portions at the ends to facilitate folding, and stamping the panel to create a variable thickness enclosure cover, reducing the need for extensive machining and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional manufacturing processes are used to create complex enclosure cover shapes from planar sheet metal, then the desired complex shapes and structural reinforcement are achieved, but material waste increases significantly (up to 90% discarded) and manufacturing time increases due to multiple processing steps
Solution Approach 1:
The extrusion process preliminary forms the panel with variable thickness features built-in during the initial manufacturing stage, rather than adding or removing material later. The extruded panel is formed with increased thickness in specific regions that will become structural reinforcements, eliminating the need for subsequent material addition operations and reducing overall material waste.
Solution Approach 2:
The invention changes the thickness parameter of the panel during extrusion to create variable thickness features. By controlling the extrusion die geometry, the panel is formed with different thicknesses in different regions, allowing structural reinforcement where needed while minimizing material usage in non-critical areas.
2Shape
If conventional manufacturing processes with multiple steps are used to create enclosure covers, then complex shapes are achieved, but manufacturing time and process complexity increase
Solution Approach 1:
The invention merges multiple manufacturing operations into a single extrusion process. The extrusion operation simultaneously creates the panel shape, variable thickness features, and structural reinforcements in one continuous operation, eliminating the need for separate machining, forming, or assembly steps required by conventional processes.
Solution Approach 2:
The extrusion process preliminary forms the panel with variable thickness features built-in during the initial manufacturing stage, rather than adding or removing material later. The extruded panel is formed with increased thickness in specific regions that will become structural reinforcements, eliminating the need for subsequent material addition operations and reducing overall material waste.
3Ease of manufacture
If planar extrusions are used for enclosure covers, then manufacturing is simpler, but structural reinforcement and seamless appearance are compromised
Solution Approach 1:
The invention changes the thickness parameter of the panel during extrusion to create variable thickness features. By controlling the extrusion die geometry, the panel is formed with different thicknesses in different regions, allowing structural reinforcement where needed while minimizing material usage in non-critical areas.
Solution Approach 2:
The invention applies local quality by providing variable thickness only in specific regions of the panel where structural reinforcement is needed. The extrusion die is designed to create increased thickness in localized areas such as corners or edges that require strength, while other areas maintain thinner profiles for weight reduction and material efficiency.
4Ease of operation
If material is removed from increased thickness features at distal ends to accommodate folding, then folding is enabled, but additional processing steps are required
Solution Approach 1:
The removal of material from the distal ends of increased thickness features is performed as a preliminary action before the folding operation. This preprocessing step ensures that the material geometry is appropriate for the subsequent folding operation, enabling clean folds without cracking or distortion while integrating the material removal into the overall manufacturing sequence.
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
This approach minimizes material waste and processing time while achieving structurally reinforced enclosure covers with a seamless appearance, offering improved structural integrity and reduced visual discontinuities.
Implementation Method 1
extruding a panel having a fixed cross-sectional profile with a first increased thickness feature
Implementation Method 2
stamping the extruded panel to fold upward at the perimeter of the extruded panel and define the variable thickness enclosure cover
Data Source
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AI summary
Enclosure covers for mobile computing devices are often formed from planar sections of sheet metal that form opposing outer-most layers thereof. The enclosure covers generally enclose and protect internal components. Enclosure covers for mobile computing devices are typically made from planar extrusions of aluminum with subsequent computer numerical control (CNC) machining and other processing steps to achieve complex shapes. Machining can be particularly wasteful of material and numerous processing steps are time-consuming and costly. The presently disclosed variable thickness enclosure covers sourced from extruded sheets of variable thickness reduce or eliminate machining and other processing steps typically required to achieve a desired complex shape. This is accomplished by extruding a shape closer to the desired shape of the variable thickness enclosure cover than presently known.