Housing, terminal device, and housing manufacturing method
12558873 ยท 2026-02-24
Assignee
Inventors
Cpc classification
C23C28/028
CHEMISTRY; METALLURGY
B32B15/017
PERFORMING OPERATIONS; TRANSPORTING
H04M1/0283
ELECTRICITY
H04M1/0202
ELECTRICITY
B32B15/01
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
This application provides a housing, a terminal device, and a housing manufacturing method. The housing includes a magnesium-based metal matrix. A first aluminum-based metal layer and a second aluminum-based metal layer are respectively disposed on two sides of the magnesium-based metal matrix, a first transition layer is disposed between the magnesium-based metal matrix and the first aluminum-based metal layer, an appearance layer is disposed on a surface of a side that is of the first aluminum-based metal layer and that is away from the first transition layer, a second transition layer is disposed between the magnesium-based metal matrix and the second aluminum-based metal layer, and an electrical connection layer is disposed on a surface of a side that is of the second aluminum-based metal layer and that is away from the second transition layer.
Claims
1. A housing, comprising: a magnesium-based metal matrix; a first aluminum-based metal layer and a second aluminum-based metal layer are respectively disposed on two sides of the magnesium-based metal matrix; a first metal layer comprising copper, titanium, nickel, cobalt, tantalum, zinc, or silver, the first metal layer disposed between the magnesium-based metal matrix and the first aluminum-based metal layer; an anodic oxidation layer, an electrophoresis layer, or an ink-jet printing layer disposed on a surface of a side that is of the first aluminum-based metal layer and that is away from the first metal layer; a second metal layer comprising copper, titanium, nickel, cobalt, tantalum, zinc, or silver, the second metal layer disposed between the magnesium-based metal matrix and the second aluminum-based metal layer; and a conductive surface defining electrical connection pads disposed on a surface of a side that is of the second aluminum-based metal layer and that is away from the second metal layer.
2. The housing according to claim 1, wherein the layer disposed on the surface of the side that is of the first aluminum-based metal layer and that is away from the first metal layer comprises the ink-jet printing layer.
3. The housing according to claim 1, wherein a material of the magnesium-based metal matrix comprises a wrought magnesium alloy.
4. The housing according to claim 1, wherein a material of the first metal layer is selected from at least one of pure titanium, a titanium alloy, pure nickel, a nickel alloy, pure cobalt, a cobalt alloy, pure tantalum, a tantalum alloy, pure zinc, a zinc alloy, pure silver, or a silver alloy, and wherein a material of the second metal layer is selected from at least one of pure titanium, a titanium alloy, pure nickel, a nickel alloy, pure cobalt, a cobalt alloy, pure tantalum, a tantalum alloy, pure zinc, a zinc alloy, pure silver, or a silver alloy.
5. The housing according to claim 1, wherein a material of the first metal layer and a material of the second metal layer are a same material.
6. The housing according to claim 1, wherein a material of the first aluminum-based metal layer is selected from at least one of a 1-series aluminum alloy, a 5-series aluminum alloy, a 6-series aluminum alloy, or a 7-series aluminum alloy.
7. The housing according to claim 1, wherein a material of the second aluminum-based metal layer is selected from at least one of a 1-series aluminum alloy to an 8-series aluminum alloy.
8. The housing according to claim 1, wherein a thickness of the housing is T, a thickness of the magnesium-based metal matrix is greater than 0.25 T and less than or equal to 0.95 T, and Tis a positive number.
9. The housing according to claim 1, wherein a thickness of the housing is T, and a sum of a thickness of the first aluminum-based metal layer and a thickness of the second aluminum-based metal layer is greater than or equal to 0.05 T and less than or equal to 0.75 T.
10. The housing according to claim 9, wherein the thickness of the first aluminum-based metal layer is greater than or equal to the thickness of the second aluminum-based metal layer.
11. The housing according to claim 1, wherein a thickness of the housing is T, and a thickness of the first metal layer is greater than 0 and less than or equal to 0.2 T.
12. The housing according to claim 1, wherein a thickness of the housing is T, and a thickness of the second metal layer is greater than 0 and less than or equal to 0.2 T.
13. The housing according to claim 1, wherein a thickness of the anodic oxidation layer, the electrophoresis layer, or the ink-jet printing layer ranges from 5 m to 60 m.
14. The housing according to claim 1, wherein a material of the conductive surface comprises a partial computer numerical control (CNC) machined or laser engraved surface comprising at least one of a material of the first aluminum-based metal layer, a copper sheet, or electrically conductive foam.
15. The housing according to claim 1, wherein a thickness of an electrical connection layer comprising the electrical connection pads ranges from 0.05 mm to 3 mm.
16. A terminal device, comprising: a housing comprising a magnesium-based metal matrix, wherein a first aluminum-based metal layer and a second aluminum-based metal layer are respectively disposed on two sides of the magnesium-based metal matrix, a first nickel layer is disposed between the magnesium-based metal matrix and the first aluminum-based metal layer, an anodic oxidation layer, an electrophoresis layer, or an ink-jet printing layer is disposed on a surface of a side that is of the first aluminum-based metal layer and that is away from the first nickel layer, a second nickel layer is disposed between the magnesium-based metal matrix and the second aluminum-based metal layer, and an electrical connection layer is disposed on a surface of a side that is of the second aluminum-based metal layer and that is away from the second nickel layer.
17. The terminal according to claim 16, wherein the layer disposed on the surface of the side that is of the first aluminum-based metal layer and that is away from the first nickel layer comprises the ink-jet printing layer.
18. The terminal according to claim 16, wherein a material of the magnesium-based metal matrix comprises a wrought magnesium alloy.
19. A housing, comprising: a magnesium-based metal matrix; a first aluminum-based metal layer and a second aluminum-based metal layer are respectively disposed on two sides of the magnesium-based metal matrix; a copper layer disposed between the magnesium-based metal matrix and the first aluminum-based metal layer; an electrophoresis layer disposed on a surface of a side that is of the first aluminum-based metal layer and that is away from the copper layer; a nickel layer disposed between the magnesium-based metal matrix and the second aluminum-based metal layer; and a conductive surface defining electrical connection pads disposed on a surface of a side that is of the second aluminum-based metal layer and that is away from the nickel layer.
20. The housing of claim 19, wherein the first aluminum-based metal layer and the second aluminum-based metal layer are different materials.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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REFERENCE NUMERALS
(17) 10: Magnesium-based metal matrix; 10a: First side face; 10b: Second side face; 20: First transition layer; 30: First aluminum-based metal layer; 40: Second transition layer; 50: Second aluminum-based metal layer; 60: Appearance layer; 70: Electrical connection layer; 701: Fresh surface of a second aluminum-based metal layer 50; 701a: Partial surface; 701b: Partial surface; and 702: Conductive layer.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(18) To explain the embodiments and advantages of this application clearly, the following further describes this application in detail with reference to the accompanying drawings.
(19) Terms used in the following embodiments are merely intended to describe particular embodiments, but are not intended to limit this application. As used in the specification and appended claims of the application, singular expressions one, a, the, the foregoing, this, and the one are also intended to include expressions such as one or more, unless the contrary is clearly indicated in the context.
(20) Reference to an embodiment, some embodiments, or the like described in this specification indicates that one or more embodiments of this application include a specific feature, structure, or characteristic described with reference to the embodiments. Therefore, statements such as in an embodiment, in some embodiments, in some other embodiments, and in other embodiments that appear at different places in this specification do not necessarily mean reference to a same embodiment, instead, they mean one or more but not all of embodiments, unless otherwise specifically emphasized. The terms include, comprise, have, and their variants all mean include but are not limited to, unless otherwise specifically emphasized.
(21) A magnesium alloy may be used for a housing of an existing terminal device, for example, a rear cover of a mobile phone, a rear cover of a computer, or a middle frame of a mobile phone, to reduce a weight. The following lists parameters such as a dimension, a thickness, a weight, and an appearance of several typical thin and light laptops with magnesium alloy notebook computer housings. Refer to Table 1.
(22) TABLE-US-00001 TABLE 1 PARAMETERS OF TYPICAL THIN AND LIGHT LAPTOPS IN NOTEBOOK COMPUTERS WITH MAGNESIUM ALLOY HOUSINGS Dimension/ Thickness/ Weight/ Brand Product inch mm g Appearance Huawei Matebook X 13 13.6 1000 Paint spraying NEC LaVie Z 13 14.9 875 Paint spraying Acer Swift 5 14 14.9 970 Paint spraying LG LG Gram 14 13.4 980 Paint 14Z950 spraying
(23) Based on parameters of terminal products listed in Table 1, a weight of a light and thin laptop with a magnesium alloy housing is light, and surface processing performed on the magnesium alloy housing is basically paint spraying.
(24) The magnesium alloy housing is obviously worse than an existing commonly used aluminum alloy housing in terms of an appearance texture, wear resistance, reliability, an electrical connection, strength, rigidity, and the like. To improve decorativeness of the magnesium alloy, a surface of the magnesium alloy is covered with a layer of aluminum alloy, to manufacture a magnesium/aluminum laminated composite plate. However, a brittle phase is easily formed between two metals of magnesium and aluminum. Subsequently, a disadvantage such as layering easily occurs during molding of the housing. In a two-layer magnesium-aluminum composite structure, an internal stress and deformation are easily caused because magnesium and aluminum have different shrinkage ratios. In addition, the magnesium alloy exposed on a single side easily galvanically corrodes with the aluminum alloy, and reliability of the electrical connection is poor. Consequently, a housing of a magnesium/aluminum-based laminated composite material cannot have a light weight, a good look, high wear resistance, high reliability, high strength, high rigidity, good corrosion resistance, and good electrical connectivity.
(25) To resolve the foregoing technical problem, an embodiment of this application provides a housing. For example, the housing may be used as a housing, a rear cover, or the like of a terminal device, and includes but is not limited to a rear cover of a mobile phone, a notebook computer housing, or a tablet computer housing.
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(28) Still refer to
(29) Still refer to
(30) In an embodiment of this application, the appearance layer 60 may be an electrophoresis layer or an ink-jet printing layer, and the electrophoresis layer or the ink-jet printing layer may be used to improve a look of the housing. In addition, in an embodiment of this application, a thickness of an appearance layer 60 formed by using an ink-jet printing or electrophoresis process may be between 10 m and 60 m.
(31) In another embodiment of this application, the appearance layer 60 is an anodic oxidation layer. In addition, in an embodiment of this application, a thickness of an appearance layer formed through anodic oxidation may be between 5 m and 16 m.
(32) In an example, the housing is a cover of a notebook computer shown in
(33) The anodic oxidation layer may meet a requirement of the housing for a good look, and may further be used as a corrosion resistance layer. When the anodic oxidation layer is used as a housing of the terminal device, the anodic oxidation layer may prevent corrosion of external moisture, to protect the magnesium-based metal matrix 10 and the first aluminum-based metal layer 30, and improve corrosion resistance of the housing.
(34) Further, the housing may further include an electrical connection layer 70. The second aluminum-based metal layer 50 may provide an aluminum matrix for the electrical connection layer 70. The electrical connection layer 70 is disposed on a surface of a side that is of the second aluminum-based metal layer 50 and that is away from the second transition layer 40. For example, as shown in
(35) In an embodiment of this application, a material of the electrical connection layer 70 is at least one of a partial fresh surface of the first aluminum-based metal layer 30, a copper sheet, or electrically conductive foam. When a partial surface of the first aluminum-based metal layer 30 is used as the electrical connection layer 70, for example, a partial surface of the inner side (that is, the side that is of the second aluminum-based metal layer 50 and that is away from the second transition layer 40) of the cover shown in (C) in
(36) One layer is usually removed from the surface of the second aluminum-based metal layer 50 by using the CNC process or the laser engraving process. A thickness of one layer removed by using the CNC process ranges from 0.1 mm to 1 mm, and a thickness of one layer removed by using the laser engraving process is approximately 0.05 mm.
(37) In a specific implementation, if a requirement for conductivity of the electrical connection layer 70 is low, for example, the electrical connection layer 70 is used for grounding, the partial surface of the first aluminum-based metal layer 30 may be selected as the material of the electrical connection layer 70. If a requirement for conductivity of the electrical connection layer 70 is high, the copper sheet or the electrically conductive foam may be selected as the material of the electrical connection layer 70.
(38) In an embodiment of this application, the magnesium-based metal matrix 10 provides a light magnesium-based material for the housing, and may be used to reduce a weight of the housing. When a material of the magnesium-based metal matrix 10 is selected, a wrought magnesium alloy that may be processed under pressure may be selected, including but being not limited to at least one of a magnesium-aluminum alloy, a magnesium-zinc alloy, or a magnesium-lithium alloy.
(39) In an example description, a model of the magnesium-aluminum alloy may be, for example, AZ31B, AZ61, AZ80, or AZ91D, and a model of the magnesium-zinc magnesium alloy may be, for example, ZM21.
(40) In an embodiment of this application, for example, a thickness of the housing is T. A thickness T4 of the magnesium-based metal matrix 10 is greater than 0.25 T and less than or equal to 0.95 T, and T is a positive number. When a proportion of the thickness of the magnesium-based metal matrix 10 to the housing ranges from 0.25 to 0.95, weight reduction, strength, and costs may be balanced, so that the housing meets different scenario requirements.
(41) In an embodiment of this application, the first aluminum-based metal layer 30 provides an aluminum matrix for the appearance layer 60. When a material of the first aluminum-based metal layer 30 is selected, an aluminum-containing metal on which anodic oxidation may be performed may be selected, including but being not limited to at least one of a 1-series aluminum alloy to a 7-series aluminum alloy.
(42) Optionally, the material of the first aluminum-based metal layer 30 is selected from at least one of a 5-series aluminum alloy or a 6-series aluminum alloy. In an example description, a model of the 5-series aluminum alloy may be 5252, 5052, or the like, and a model of the 6-series aluminum alloy may be 6013.
(43) In an embodiment of this application, the second aluminum-based metal layer 50 provides the aluminum matrix for the electrical connection layer 70, to avoid galvanic corrosion caused by an electrical connection directly performed on the magnesium-based metal matrix. When a material of the second aluminum-based metal layer 50 is selected, an aluminum-containing metal that may be plastically processed and deformed may be selected, including but being not limited to at least one of a 1-series aluminum alloy to an 8-series aluminum alloy. Optionally, the material of the second aluminum-based metal layer 50 is selected from at least one of a 5-series aluminum alloy or a 6-series aluminum alloy.
(44) In an embodiment of this application, for example, the thickness of the housing is T. A sum of a thickness T2 of the first aluminum-based metal layer 30 and a thickness T6 of the second aluminum-based metal layer 50 is greater than or equal to 0.05 T and less than or equal to 0.75 T. When a proportion of the sum of the thickness of the first aluminum-based metal layer 30 and the thickness of the second aluminum-based metal layer 50 to the thickness of the housing is 0.05 to 0.75, overall strength of the housing can be improved while a requirement for a light weight is met.
(45) In an embodiment of this application, the thickness T2 of the first aluminum-based metal layer 30 is greater than or equal to the thickness T6 of the second aluminum-based metal layer 50. The thickness T2 of the first aluminum-based metal layer 30 is larger, and an aluminum matrix with a larger thickness may be provided for manufacturing the appearance layer 60, to meet various manufacturing requirements of a good-look appearance. For example, a high gloss chamfer may be manufactured at the first aluminum-based metal layer 30.
(46) It should be understood that, in some other embodiments of this application, the thickness T2 of the first aluminum-based metal layer 30 may alternatively be less than the thickness T6 of the second aluminum-based metal layer 50.
(47) In an embodiment of this application, when a material of the first transition layer 20 is selected, a material that can increase an interface bonding force of the magnesium-aluminum composite structure may be selected, including but being not limited to at least one of pure copper, a copper alloy, pure titanium, a titanium alloy, pure nickel, a nickel alloy, pure cobalt, a cobalt alloy, pure tantalum, a tantalum alloy, pure zinc, a zinc alloy, pure silver, or a silver alloy. In an example description, a model of the copper alloy may be, for example, T1, T2, TP1, TP2, TU1, or TU2, a model of the titanium alloy may be, for example, TA1 or TA2, a model of the nickel alloy may be, for example, N2, N4, N5, N6, N7, or N8, a model of the cobalt alloy may be, for example, L-605 or HA-188, a model of the tantalum alloy may be, for example, Ta10W, Ta2.5W, or Ta-40Nb, a model of the zinc alloy may be, for example, ZZnAl4Cu1Mg and ZZnAl4Cu3, and a model of the silver alloy may be, for example, AgCe0.5, AgCu5, or AgCu4NiRe.
(48) Because the first transition layer 20 exists between the first aluminum-based metal layer 30 and the magnesium-based metal matrix 10 in the housing, for example, shear and peel strength of a laminated composite structure obtained after the aluminum alloy and the magnesium alloy are directly compounded usually does not exceed 20 MPa. In this embodiment of this application, shear and peel strength obtained after the first aluminum-based metal layer 30, the first transition layer 20, and the magnesium-based metal matrix 10 are compounded is greater than or equal to 30 MPa. In this way, shear and peel strength of the housing can be improved. In an embodiment of this application, a thickness T3 of the first transition layer 20 is greater than 0 and less than or equal to 0.2 T.
(49) In an embodiment of this application, when a material of the second transition layer 40 is selected, a material that can increase a bonding force of the magnesium-aluminum composite structure may be selected, including but being not limited to at least one of pure copper, a copper alloy, pure titanium, a titanium alloy, pure nickel, a nickel alloy, pure cobalt, a cobalt alloy, pure tantalum, a tantalum alloy, pure zinc, a zinc alloy, pure silver, or a silver alloy.
(50) In an example description, a model of the copper alloy may be, for example, T1, T2, TP1, TP2, TU1, or TU2, a model of the titanium alloy may be, for example, TA1 or TA2, a model of the nickel alloy may be, for example, N2, N4, N5, N6, N7, or N8, a model of the cobalt alloy may be, for example, L-605 or HA-188, a model of the tantalum alloy may be, for example, Ta10W, Ta2.5W, or Ta-40Nb, a model of the zinc alloy may be, for example, ZZnAl4Cu1Mg and ZZnAl4Cu3, and a model of the silver alloy may be, for example, AgCe0.5, AgCu5, or AgCu4NiRe.
(51) Because the second transition layer 40 exists between the second aluminum-based metal layer 50 and the magnesium-based metal matrix 10 in the housing, shear and peel strength of the housing can be improved. For example, shear and peel strength obtained after the second aluminum-based metal layer 50, the second transition layer 40, and the magnesium-based metal matrix 10 are compounded is greater than or equal to 30 MPa. In an embodiment of this application, a thickness T5 of the second transition layer 40 is greater than 0 and less than or equal to 0.2 T.
(52) In an embodiment of this application, different materials or a same material may be selected as the material of the first transition layer 20 and the material of the second transition layer 40. Compared with a case in which different materials are used for the first transition layer 20 and the second transition layer 40, in this implementation in which a same material is used for the first transition layer and the second transition layer, a process can be simplified.
(53) Therefore, in the housing of this application, the magnesium-based metal matrix 10 may be used to reduce a weight of the housing. The first transition layer 20 covers the first side face of the magnesium-based metal matrix 10, the side that is of the first transition layer 20 and that is away from the magnesium-based metal matrix 10 is covered with the first aluminum-based metal layer 30, and both the shear and peel strength between the first transition layer 20 and the magnesium-based metal matrix 10 and the shear and peel strength between the first transition layer 20 and the first aluminum-based metal layer 30 are greater than the first shear and peel strength. Compared with the aluminum-magnesium composite material in which the two metals of the magnesium-based metal and the aluminum-based metal are directly bonded in the conventional technology, in the solution of this application, the first transition layer may be used to increase the interface bonding force between the magnesium-based metal matrix 10 and the first aluminum-based metal layer 30. In this way, the housing is not easily deformed. The second side face of the magnesium-based metal matrix 10 is covered with the second transition layer 40, the side that is of the second transition layer 40 and that is away from the magnesium-based metal matrix 10 is covered with the second aluminum-based metal layer 50, and both the shear and peel strength between the second transition layer 40 and the magnesium-based metal matrix 10 and the shear and peel strength between the second transition layer 40 and the second aluminum-based metal layer 50 are greater than the first shear and peel strength. Compared with the aluminum-magnesium composite material in which the two metals of the magnesium-based metal and the aluminum-based metal are directly bonded in the conventional technology, in the solution of this application, the second transition layer 40 may be used to increase the interface bonding force existing after the magnesium-based metal matrix 10 and the second aluminum-based metal layer 50 are compounded. In this way, the housing is not easily deformed. The first aluminum-based metal layer 30 and the second aluminum-based metal layer 50 may provide high wear resistance, high reliability, high strength, high rigidity, and good corrosion resistance for the housing. In addition, the first aluminum-based metal layer 30 may provide an aluminum matrix for the appearance layer 60, the appearance layer 60 may provide a good look for the housing, the second aluminum-based metal layer 50 may provide an aluminum matrix for the electrical connection layer 70, and the electrical connection layer 70 may provide good electrical connectivity for the housing. Therefore, the housing in this application can have a light weight, a good look, high wear resistance, high reliability, high strength, high rigidity, good corrosion resistance, and good electrical connectivity.
(54) Based on a same technical concept, an embodiment of this application further provides a housing manufacturing method. As shown in
(55) S11: Perform molding processing on a laminated composite plate, to form a molded composite plate. The laminated composite plate includes a magnesium-based metal matrix, a first transition layer is disposed on a first side face of the magnesium-based metal matrix, a first aluminum-based metal layer is disposed on a side that is of the first transition layer and that is away from the magnesium-based metal matrix, a second transition layer is disposed on a second side face of the magnesium-based metal matrix, and a second aluminum-based metal layer is disposed on a side that is of the second transition layer and that is away from the magnesium-based metal matrix.
(56) Both shear and peel strength between the first transition layer and the magnesium-based metal matrix and shear and peel strength between the first transition layer and the first aluminum-based metal layer are greater than first shear and peel strength, the first shear and peel strength is shear and peel strength between two metals of a magnesium-based metal and an aluminum-based metal in an aluminum-magnesium composite material, and both shear and peel strength between the second transition layer and the magnesium-based metal matrix and shear and peel strength between the second transition layer and the second aluminum-based metal layer are greater than the first shear and peel strength.
(57) In an example description, molding processing in S11 may include but is not limited to at least one of thin plate stamping molding, thick plate forging and CNC molding, and thick plate full CNC molding.
(58) S12: Perform surface processing on the molded composite plate, to form an appearance layer on a surface of the first aluminum-based metal layer.
(59) In a possible implementation, surface processing is performed on a side of the first aluminum-based metal layer of the molded composite plate, to form an appearance layer on a surface of the first aluminum-based metal layer.
(60) In an embodiment of this application, anodic oxidation processing is performed on a side of the molded composite plate, to form an anodic oxidation layer on the surface of the first aluminum-based metal layer. Through anodic oxidation processing, an appearance of the housing can meet a requirement for a good look, and corrosion resistance of the housing can be further improved.
(61) In another embodiment of this application, electrophoresis processing or ink-jet printing processing is performed on the molded composite plate, to form the appearance layer on the surface of the first aluminum-based metal layer.
(62) S13: Process a side of the second aluminum-based metal layer of the molded composite plate, to form an electrical connection layer on a surface of the second aluminum-based metal layer.
(63) In an embodiment of this application, at least one of a CNC process, a laser engraving process, a copper sheet spot welding process, or electrically conductive foam attaching is performed on the molded composite plate, to form the electrical connection layer on the surface of the second aluminum-based metal layer. The partial computer numerical control (CNC) machining or laser engraving surface of the first aluminum-based metal layer is used as the electrical connection layer, to meet a requirement of the housing for electrical connectivity. A spot-welded copper sheet of the first aluminum-based metal layer is used as the electrical connection layer, to meet the requirement of the housing for higher electrical connectivity.
(64) In an embodiment of this application, the laminated composite plate may be manufactured in the following method: The first aluminum-based metal layer, the first transition layer, the magnesium-based metal matrix, the second transition layer, and the second aluminum-based metal layer that are sequentially stacked may be compounded in a laminar form by using at least one of a rolling process, a forging process, an extrusion process, and a diffusion welding process, to form the laminated composite plate.
(65) In an embodiment of this application, as shown in
(66) S11: Form the first transition layer on a surface of a side of the first aluminum-based metal layer and/or a first side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(67) For example, before S11, processing, for example, surface sanding processing may be first performed on the first aluminum-based metal layer, the magnesium-based metal matrix, and a transition metal sheet, to remove a surface oxide layer, and air-drying is performed after ultrasonic cleaning.
(68) S111 may be implemented in any one of the following manners:
(69) Manner A1: Form the first transition layer on the surface of the side of the first aluminum-based metal layer through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(70) For example, if a thickness of a first transition layer in a housing that needs to be manufactured is T3, the first transition layer whose thickness is T3 may be formed on the surface of the side of the first aluminum-based metal layer.
(71) Manner A2: Form the first transition layer on the first side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(72) For example, if a thickness of a first transition layer in a housing that needs to be manufactured is T3, the first transition layer whose thickness is T3 may be formed on the first side face of the magnesium-based metal matrix.
(73) Manner A3: Form the first transition layer on a surface of a side of the first aluminum-based metal layer and a first side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(74) For example, if a thickness of a first transition layer in a housing that needs to be manufactured is T3, a first transition layer whose thickness is x1 may be formed on a surface of a side of the first aluminum-based metal layer, and a first transition layer whose thickness is y1 may be formed on the first side face of the magnesium-based metal matrix. A sum of x1 and y1 is equal to T3. Both x1 and y1 are positive numbers. A value relationship between x1 and y1 is not limited in this application, x1 may be greater than y1, or may be equal to y1, or may be less than y1.
(75) S112: Form the second transition layer on a surface of a side of the second aluminum-based metal layer and/or a second side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(76) S112 may be implemented in any one of the following manners:
(77) Manner B1: Form the second transition layer on the surface of the side of the second aluminum-based metal layer through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(78) For example, if a thickness of a second transition layer in a housing that needs to be manufactured is T5, the second transition layer whose thickness is T5 may be formed on the surface of the side of the second aluminum-based metal layer.
(79) Manner B2: Form the second transition layer on the second side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(80) For example, if a thickness of a second transition layer in a housing that needs to be manufactured is T5, the second transition layer whose thickness is T5 may be formed on the second side face of the magnesium-based metal matrix.
(81) Manner B3: Form the second transition layer on a surface of a side of the second aluminum-based metal layer and a second side face of the magnesium-based metal matrix through at least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding.
(82) For example, if a thickness of a second transition layer in a housing that needs to be manufactured is T5, a second transition layer whose thickness is x2 may be formed on a surface of a side of the second aluminum-based metal layer, and a second transition layer whose thickness is y2 may be formed on a second side face of the magnesium-based metal matrix. A sum of x2 and y2 is equal to T5. Both x2 and y2 are positive numbers. A value relationship between x2 and y2 is not limited in this application, x2 may be greater than y2, or may be equal to y2, or may be less than y2.
(83) S113: Stack the first aluminum-based metal layer, the magnesium-based metal matrix, and the second aluminum-based metal layer, to form the first aluminum-based metal layer, the first transition layer, the magnesium-based metal matrix, the second transition layer, and the second aluminum-based metal layer that are sequentially stacked.
(84) When the first aluminum-based metal layer and the magnesium-based metal matrix are stacked, the first transition layer formed in any one of Manner A1, Manner A2, and Manner A3 may be stacked with the first aluminum-based metal layer and/or the magnesium-based metal matrix. Descriptions are separately provided below.
(85) In an example, the first transition layer is formed in Manner A1. As shown in
(86) In another example, the first transition layer is formed in Manner A2. As shown in
(87) In still another example, the first transition layer is formed in Manner A3. As shown in
(88) Based on a same concept, when the magnesium-based metal matrix and the second aluminum-based metal layer are stacked, the second transition layer formed in any one of Manner B1, Manner B2, and Manner B3 may be stacked with the first aluminum-based metal layer and/or the magnesium-based metal matrix. For a specific implementation, refer to related content of stacking the first aluminum-based metal layer and the magnesium-based metal matrix. Details are not described herein again.
(89) An example in which the magnesium-based metal matrix and the first aluminum-based metal layer are stacked to form the first transition layer in Manner A1, and the magnesium-based metal matrix and the second aluminum-based metal layer are stacked to form the second transition layer in Manner B3 is used to describe a stacking process in S113.
(90) As shown in
(91) At least one of chemical plating, electroplating, thermal spraying, ion plating, and diffusion welding is used, so that there can be high bonding strength between the first transition layer and the surface of the side of the first aluminum-based metal layer and/or the first side face of the magnesium-based metal matrix, and there can be high bonding strength between the second transition layer and the surface of the side of the second aluminum-based metal layer and/or the second side face of the magnesium-based metal matrix.
(92) S114: Compound, in a laminar form by using at least one of a rolling process, a forging process, an extrusion process, and a diffusion welding process, the first aluminum-based metal layer, the first transition layer, the magnesium-based metal matrix, the second transition layer, and the second aluminum-based metal layer that are sequentially stacked, to form the laminated composite plate.
(93) The following describes a housing manufacturing process in this application with reference to different embodiments.
Embodiment 1
(94) In an embodiment of this application, as shown in
(95) S201: Pre-manufacture a transition layer 1 and a transition layer 2, where pure Cu foil may be selected as a material of the transition layer 1 and a material of the transition layer 2, and the Cu foil is cut into strips. In the following embodiment, copper may be understood as pure copper.
(96) In an example description, the Cu foil is striped and cut to obtain Cu foil whose thickness is 0.04 mm and dimension is 0.04 mm*250 mm*300 mm. A dimension of the Cu foil is the same as that of a magnesium alloy layer (AZ31B), a plate shape is flat, and a surface is clean and free of contamination such as fat and dirt.
(97) S202: As shown in
(98) In an example description, surface sanding processing is performed on a magnesium alloy sheet (Thickness: 1.2 mm, and Dimension: 1.2 mm*250 mm*300 mm), an aluminum alloy sheet (Thickness: 0.2 mm, and Dimension: 0.2 mm*250 mm*300 mm), and the Cu foil (Thickness: 0.04 mm, and Dimension: 0.04 mm*250 mm*300 mm), to remove a surface oxide layer, ultrasonic cleaning is performed, and then air-drying is performed.
(99) The aluminum alloy layer 2, the transition layer 2, the magnesium alloy layer, the transition layer 1, and the aluminum alloy layer 1 are stacked neatly from bottom to top based on a laminated composite structure. An overall thickness obtained after stacking is 1.6 mm. Then, the laminated composite structure obtained after stacking is fastened through riveting.
(100) S203: Compound, in a laminar form by using a rolling process, the aluminum alloy layer 2 (5252), the transition layer 2 (copper foil), the magnesium alloy layer (AZ31B), the transition layer 1 (copper foil), and the aluminum alloy layer 1 (5252) that are stacked in the laminar form, to form a laminated composite plate.
(101) In an example description, the aluminum alloy layer 2 (5252), the transition layer 2 (copper foil), the magnesium alloy layer (AZ31B), the transition layer 1 (copper foil), and the aluminum alloy layer 1 (5252) that are stacked in a laminar form are heated for 9010 min at a heating temperature of 38010 C., and are hot rolled for a plurality of times to a target thickness of 0.8 mm, and a total deformation amount is 50%.
(102) S204: Perform molding processing on the laminated composite plate, to form a molded composite plate.
(103) In an example description, the laminated composite plate is cut and then stamped, and is formed into a shape of a PC housing.
(104) S205: Perform surface processing on the molded composite plate, to form an anodic oxidation layer on a side that is of the aluminum alloy layer 1 (5252) and that is away from the transition layer 1.
(105) It should be understood that, in S205, it only needs to be ensured that, when anodic oxidation processing is performed on the molded composite plate, the anodic oxidation layer is formed on the side that is of the aluminum alloy layer 1 (5252) and that is away from the transition layer 1. When anodic oxidation processing is performed on the molded composite plate, an anodic oxidation layer may also be formed on a side that is of the aluminum alloy layer 2 (5252) and that is away from the transition layer 2. Whether the anodic oxidation layer is formed on the side that is of the aluminum alloy layer 2 (5252) and that is away from the transition layer 2 does not affect a subsequent step. Even if the anodic oxidation layer is formed on the side that is of the aluminum alloy layer 2 (5252) and that is away from the transition layer 2, it only needs to be ensured that a surface of the anodic oxidation layer on the side that is of the aluminum alloy layer 2 (5252) and that is away from the transition layer 2 is processed in S206, to form an electrical connection layer.
(106) S206: Process a side of the aluminum alloy layer 2 (5252) of the molded composite plate, to form the electrical connection layer on the side that is of the aluminum alloy layer 2 and that is away from the transition layer 2: a surface of 5252 manufactured by using a laser engraving process and a spot-welded copper sheet.
(107) Housing structure information of the housing obtained in the manufacturing method in this application is shown in Table 2. An overall thickness is approximately 0.8 mm, a comprehensive density is 2.3 g/cm.sup.3, the housing is of a seven-layer structure, a middle AZ31B magnesium alloy matrix whose thickness is 0.6 mm is used to reduce a weight, 5252 whose surface is 0.1 mm functions as an anodic oxidation substrate, and 5252 whose bottom layer has a thickness of 0.1 mm provides a substrate for an electrical connection. An appearance decoration and electrical connection reliability are improved. In addition, aluminum alloys on upper and lower surfaces isolate the magnesium alloy from an outside, to improve corrosion resistance of a magnesium matrix. In the conventional technology, a large quantity of brittle second phases shown in
(108) TABLE-US-00002 TABLE 2 Structure information of a metal housing Sequence number Structural layer Material Thickness 1 Appearance layer Anodic oxidation T1 12 m 2 Aluminum alloy 5252 T2 0.1 mm layer 1 3 Transition layer 1 Copper foil T3 0.02 mm 4 Magnesium alloy AZ31B T4 0.6 mm layer 5 Transition layer 2 Copper foil T5 0.02 mm 6 Aluminum alloy 5252 T6 0.1 mm layer 2 7 Electrical Spot-welded copper T7 0.05 mm connection layer sheet and laser engraving
Embodiment 2
(109) In an embodiment of this application, as shown in
(110) S301: Pre-manufacture a transition layer 1 and a transition layer 2, where Nickel (Ni) may be selected as a material of the transition layer 1 and a material of the transition layer 2, and a 0.05 mm Ni layer is plated on two faces of a front face and a rear face of a magnesium alloy layer (AZ80) in an electroplating manner. Herein, the two faces of the front face and the rear face are a first side face and a second side face. If the front face is the first side face, the rear surface is the second side face; or if the rear surface is the first side face, the front surface is the second side face.
(111) In an example description, a thickness of the magnesium alloy layer (AZ80) is 5 mm, a dimension is 5*230*280 mm.sup.3, a plate shape is flat, and a surface is clean and free of contamination such as fat and dirt.
(112) S302: As shown in
(113) In an example description, surface sanding processing is performed on an aluminum alloy sheet (Thickness: 0.6 mm, and Dimension: 0.6*230*280 mm.sup.3), a magnesium alloy sheet (Thickness: 5 mm, and Dimension: 5*230*280 mm.sup.3), an aluminum alloy sheet (Thickness: 0.4 mm, and Dimension: 0.4*230*280 mm.sup.3), and a Ni sheet, to remove a surface oxide layer, ultrasonic cleaning is performed, and then air-drying is performed.
(114) Based on a structure of a composite housing:
(115) The aluminum alloy layer 2 (6061), the transition layer 2 (Ni), the magnesium alloy layer (AZ80), the transition layer 1 (Ni), and the aluminum alloy layer 1 (6013) are stacked neatly and tightly from bottom to top based on a laminated composite structure, and an overall thickness obtained after stacking is 6 mm. Then, the stacked laminated composite structure is fastened through riveting.
(116) S303: Compound, in a laminar form by using a hot pressing molding process, the aluminum alloy layer 2 (6061), the transition layer 2 (Ni), the magnesium alloy layer (AZ80), the transition layer 1 (Ni), and the aluminum alloy layer 1 (6013) that are stacked in the laminar form, to form a laminated composite plate.
(117) In an example description, the aluminum alloy layer 2 (6061), the transition layer 2 (Ni), the magnesium alloy layer (AZ80), the transition layer 1 (Ni), and the aluminum alloy layer 1 (6013) that are stacked in a laminar form are heated for 12010 min at a heating temperature of 350110 C., and are hot-pressing molded, a molding pressure is 10010 MPa, and a hot pressing time period is 31 min.
(118) S304: Perform CNC molding processing on the laminated composite plate, to form a molded composite plate.
(119) In an example description, the laminated composite plate is cut and then stamped, and is formed into a PC housing.
(120) S305: Perform electrophoresis on the molded composite plate, to form an electrophoresis layer on a side that is of the aluminum alloy layer 1 (6013) and that is away from a first transition layer.
(121) Herein, similar to S205, in S305, it only needs to be ensured that electrophoresis is performed on the molded composite plate, to form the electrophoresis layer on the side that is of the aluminum alloy layer 1 (6013) and that is away from the first transition layer. However, when electrophoresis is performed on the molded composite plate, an electrophoresis layer may also be formed on a surface that is of the aluminum alloy layer 2 (6061) and that is away from the transition layer 2, and S306 is not affected. Even if the electrophoresis layer is formed on the surface that is of the aluminum alloy layer 2 (6061) and that is away from the transition layer 2, in S306, a surface of an electrophoresis layer on a side of the aluminum alloy layer 2 of the molded composite plate is processed, to form the electrical connection layer.
(122) S306: Process a surface of a side of the aluminum alloy layer 2 of the molded composite plate, to form an electrical connection layer on a side that is of the aluminum alloy layer 2 and that is away from the second transition layer: a surface of 6061 manufactured by using a laser engraving process, a spot-welded copper sheet, and attached electrically conductive foam.
(123) Housing structure information of the housing obtained in the manufacturing method in this application is shown in Table 3. An overall thickness is approximately 6 mm, a comprehensive density is 26 g/cm.sup.3, the housing is of a seven-layer structure, a middle magnesium alloy layer AZ80 whose thickness is 5 mm is used to reduce a weight, 6013 whose surface has a thickness of 0.6 mm functions as an electrophoresis substrate, and 6061 whose bottom layer has a thickness of 0.4 mm provides a substrate for an electrical connection. Ni is directly electroplated on two faces of the magnesium alloy matrix AZ80, and is used as a middle transition layer between AZ80 and the aluminum alloy (6013/6061). No large quantity of brittle second phases are generated. An interface bonding force existing after the magnesium alloy layer, the transition layer, and the aluminum-based metal layer are compounded is increased, and shear strength is increased from approximately 15 MPa to 50 MPa.
(124) TABLE-US-00003 TABLE 3 Structure information of a metal housing Sequence number Structural layer Material Thickness 1 Appearance layer Electrophoresis T1 35 m 2 Aluminum alloy 6013 T2 0.6 mm layer 1 3 Transition layer 1 Copper foil T3 0.05 mm 4 Magnesium alloy AZ80 T4 5 mm layer 5 Transition layer 2 Ni T5 0.05 mm 6 Aluminum alloy 6061 T6 0.4 mm layer 2 7 Electrical Spot-welded copper T7 0.05 mm connection layer sheet, laser engraving, and attached electrically conductive foam
(125) Based on any one of the foregoing embodiments, a housing obtained in the manufacturing method in this application includes the magnesium-based metal matrix, the first transition layer, the first aluminum-based metal layer, the appearance layer, the second transition layer, the second aluminum-based metal layer, and the electrical connection layer. A result of comparing the housing and an existing aluminum alloy housing and an existing magnesium alloy housing is shown in Table 4.
(126) TABLE-US-00004 TABLE 4 Result of comparing a housing obtained in a manufacturing method in this application and an existing housing Electrical connection Yield Elastic Laser strength modulus Quantity of Surface processing engraving, a Yield Elastic structural Density Appearance Scratch Coating copper sheet, strength, modulus, Housing layers g/cm.sup.3 effect Texture resistance reliability and foam MPa GPa Housing 7 1.8 to Same as an Same as an Same as an Same as an Same as an Between 45 to manufactured 2.7 aluminum aluminum aluminum aluminum aluminum magnesium 70 in this alloy alloy alloy alloy alloy and aluminum application Existing 3 2.7 Mainly Metal Hardness: Good Reliable High 70 aluminum anodic texture 5H to 6H, and not alloy oxidation good easy to housing corrode Existing 3 1.8 Mainly Plastic Hardness: Poor Unreliable Low 45 magnesium paint texture 2H to 3H, and easy alloy spraying poor to corrode housing
(127) The magnesium-based metal matrix may be used to reduce a weight of the housing. A first transition layer covers a first side face of the magnesium-based metal matrix, a side that is of the first transition layer and that is away from the magnesium-based metal matrix is covered with the first aluminum-based metal layer, and a bonding force between the first transition layer and the magnesium-based metal matrix, shear and peel strength between the first transition layer and the first aluminum-based metal layer, and the shear and peel strength between the first transition layer and the first aluminum-based metal layer are all greater than first shear and peel strength. Compared with an aluminum-magnesium composite material in which two metals of a magnesium-based metal and an aluminum-based metal are directly bonded in the conventional technology, in the solution of this application, the first transition layer may be used to increase a bonding force existing after the magnesium-based metal matrix and the first aluminum-based metal layer are compounded. In this way, the housing is not easily deformed. A second side face of the magnesium-based metal matrix is covered with a second transition layer, a side that is of the second transition layer and that is away from the magnesium-based metal matrix is covered with a second aluminum-based metal layer, both shear and peel strength between the second transition layer and the magnesium-based metal matrix and shear and peel strength between the second transition layer and the second aluminum-based metal layer are greater than first shear and peel strength. Compared with the aluminum-magnesium composite material in which the two metals of a magnesium-based metal and an aluminum-based metal are directly bonded in the conventional technology, in a solution of this application, the first transition layer may be used to increase an interface bonding force existing after the magnesium-based metal matrix and the second aluminum-based metal layer are compounded. In this way, the housing is not easily deformed. The first aluminum-based metal layer and the second aluminum-based metal layer may provide high wear resistance, high reliability, high strength, and high rigidity for the housing. In addition, the first aluminum-based metal layer may provide an aluminum matrix for the appearance layer, the appearance layer may provide a good look for the housing, the second aluminum-based metal layer may provide an aluminum matrix for the electrical connection layer, and the electrical connection layer may provide good electrical connectivity for the housing. Therefore, the housing in this application can have a light weight, a good look, high wear resistance, high reliability, high strength, high rigidity, good corrosion resistance, and good electrical connectivity.
(128) Based on a same technical concept, an embodiment of this application further provides a terminal device. The terminal device may be, for example, a mobile phone, a notebook computer, a tablet computer, or a display. The terminal device includes the housing in the possible implementations in the foregoing embodiments or the housing obtained in the manufacturing method in the foregoing embodiments of this application.
(129) The terminal device in this application includes the housing the possible implementations of this application. Therefore, when the housing has a light weight, a good look, high wear resistance, high reliability, high strength, high rigidity, good corrosion resistance, and good electrical connectivity, the terminal device in this application also has a light weight, a good look, high wear resistance, high reliability, high strength, high rigidity, good corrosion resistance, and good electrical connectivity.
(130) The foregoing descriptions are merely specific implementations of this application, but are not intended to limit the protection scope of this application. Any variation or replacement readily figured out by a person skilled in the art within the technical scope disclosed in this application shall fall within the protection scope of this application. Therefore, the protection scope of this application shall be subject to the protection scope of the claims