Wireless Device Case Assembly with Plastic-Filled Metal Hollows
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Solution Overview
Problem
The existing wireless communication devices with metal and plastic case assemblies face issues of interface mismatch due to material differences, leading to increased production costs and complexity in achieving a smooth appearance, especially as the number of antennas increases.
Innovation Solution
A case assembly comprising a metal case with hollow portions for antennas and a plastic cladding body that covers the outer side and partially covers the inner side, filling the hollow portions, which reduces the need for grinding and painting processes and allows the metal case to function as an antenna.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal case is used to improve structural strength and durability, then the case has better durability and structural strength, but the metal case blocks wireless signals requiring hollow areas to be filled with plastic
Solution Approach 1:
The plastic filling body is nested within the hollow portion of the metal case, with the plastic material inserted into the signal-blocking hollow areas to provide signal transmission pathways while maintaining the metal case's structural integrity. This nesting approach allows the plastic to be contained within the metal case structure, combining the strengths of both materials without requiring separate assemblies.
Solution Approach 2:
The case assembly combines metal and plastic materials in a composite structure, where the metal case provides structural strength and durability, while the plastic filling body provides signal transmission capabilities in the hollow portions. This composite material approach allows the case to simultaneously achieve mechanical strength and wireless signal compatibility.
2Adaptability or versatility
If the number of antennas is increased to improve wireless communication capability, then more antennas can transmit and receive signals, but the hollowed-out area of the metal case increases resulting in a larger and more complicated interface
Solution Approach 1:
The plastic filling body is divided into multiple filling portions, each corresponding to a specific hollow portion created by an antenna. Each filling portion independently fills its associated hollow area, allowing the interface between metal and plastic to be segmented into manageable sections rather than forming one large complex interface. This segmentation simplifies the overall interface complexity while supporting multiple antennas.
3Manufacturing precision
If additional grinding and painting processes are applied to improve the interface appearance between metal case and plastic, then the interface becomes smooth and aesthetically pleasing, but the production cost increases
Solution Approach 1:
The plastic filling body is pre-formed with a surface that matches the contour of the metal case's outer surface before assembly. This preliminary shaping of the plastic component ensures that when it is inserted into the hollow portion, the interface between metal and plastic is already smooth and flush, eliminating the need for subsequent grinding or painting processes and reducing manufacturing costs.
Data Source
AI summary
A case assembly and a wireless communication device are provided. The case assembly includes a metal case and a plastic cladding body. The metal case includes an inner side and an outer side, the inner side is opposite to the outer side, the metal case includes a hollow portion and an antenna portion, the hollow portion is adjacent to a side of the antenna portion. The plastic cladding body is disposed on the metal case, and completely covers the outer side of the metal case, partially covers the inner side of the metal case, and fills the hollow portion. The wireless communication device includes a case assembly and a radio frequency signal module. The radio frequency signal module is electrically connected to the antenna portion of the case assembly. Thus, the structural rigidity of the wireless communication device and its case assembly is kept, and the production cost is reduced.