HK1174004B - Method and device for manufacturing cover including multiple metal layers - Google Patents

Abstract

A method and a device for manufacturing a cover including multiple metal layers are provided. The method includes: injecting a second metal in liquid form which is a metal different from a first metal layer onto a semi-finished cover disposed in a mold and formed of the first metal layer, so as to form a second metal layer on the first metal layer; and pressing the second metal layer with a pressure in the mold. Not only does the multi-layer metal cover manufactured according to the method have the strength and elasticity of a composite metal, but also subsequent surface treatment may be performed on the metal cover as required, such as heat treatment, anodizing surface treatment, Galvanic plating, vacuum coating/film treatment, coating treatment, painting treatment, and corrosion resistant treatment, to further improve the adhesiveness between metal layers, the strength and the corrosion resistance, and make the design of the cover more flexible.

Description

Method and apparatus for manufacturing a housing comprising a plurality of layers of metal

Technical Field

The present invention relates to a method and an apparatus for manufacturing a case containing metal, and more particularly, to a method and an apparatus for manufacturing a case containing a plurality of metal layers.

Background

With the change of electronic products, the demands of consumers for electronic products are increasing, not only considering their physical performances, such as processing speed, storage capacity, communication transmission of mobile phones, etc., of palm computers or tablet computers, but also their appearance and durability. The appearance of fine texture and a metal housing with high strength, high ductility but light weight would be a new trend for consumer electronics.

The multi-color plastic shell of the traditional electronic product is easy to be broken by external force impact, while the single-layer metal shell can be rusted due to environmental factors or cannot be subjected to subsequent surface treatment due to the limitation of material properties. It is desirable to replace the problems of a single layer of metal with a plurality of layers of metal, which are resistant to tarnishing, scratch-resistant, high-strength, and elegant. However, the prior art uses vacuum evaporation or ion sputtering to prepare the housing of consumer electronic device with double-layer metal or material by mechanical lamination, but the manufacturing cost is quite high.

Disclosure of Invention

The present invention is to eliminate the problems caused by the disadvantages of the prior art, and to manufacture a housing comprising a plurality of metal layers in a low-cost and high-yield manner, and to prepare the material according to the amount, which is more environment-friendly and saves the waste compared with the current market technology. Meanwhile, the double-layer or multi-layer different metal can be designed to completely or partially wrap the substrate according to the requirement of the product so as to simultaneously achieve the requirement of appearance and mechanical property, thus saving the work of developing a large amount of different alloy materials and saving the earth resources.

The method and the device can achieve good adhesion among a plurality of layers of metal, improve the metal density and the surface flatness, and are beneficial to the subsequent metal surface treatment.

One embodiment of the present invention provides a method of manufacturing a case comprising a plurality of metal layers, comprising injecting a second liquid metal different from a metal of a first metal layer in a mold onto the case formed with the first metal layer in the mold to form a second metal layer on the first metal layer; and extruding the second metal layer in the die by using extrusion force.

Another embodiment of the present invention provides an apparatus for manufacturing a case including a plurality of metal layers, including a mold for injecting a second liquid metal different from a metal of a first metal layer onto the case formed of the first metal layer placed in the mold to form a second metal layer on the first metal layer, wherein the mold includes a pressing member for applying a pressing force to the second metal layer located in the mold.

In another embodiment, the present invention provides a method for manufacturing a housing comprising a plurality of metal layers, comprising injecting a first liquid metal into a first front mold and a back mold matching the first front mold to form a first metal layer; and injecting a second liquid metal onto the first metal layer in a semi-solid state in a second front mold matched with the rear mold to form a second metal layer on the first metal layer.

In another embodiment of the present invention, an apparatus for manufacturing a housing comprising a plurality of metal layers is provided, which comprises a first front mold, which is coupled to a rear mold for injecting a first liquid metal to form a first metal layer; and a second front mold, cooperating with the rear mold, for injecting a second liquid metal onto the first metal layer in a semi-solid state, so as to form a second metal layer on the first metal layer.

Drawings

Figure 1 shows the method of a preferred embodiment of the invention.

FIG. 2-1 shows the device of a preferred embodiment of the present invention in an open state.

Fig. 2-2 show the closed state of the device according to a preferred embodiment of the invention.

Fig. 2-3 shows a partial enlargement of fig. 2-2.

FIG. 3 shows a method according to another preferred embodiment of the present invention.

Fig. 4 shows an apparatus according to another preferred embodiment of the present invention.

Detailed Description

One embodiment of the method of the present invention is shown in fig. 1, and the method includes injecting a second liquid metal different from a metal of a first metal layer into a mold onto a case formed of the first metal layer placed in the mold to form a second metal layer on the first metal layer (S101), and pressing the second metal layer in the mold with a pressing force (S102). This action is repeated and a third liquid metal may be injected over the second metal, and so on.

The injection includes various modes such as high pressure injection, pouring or flowing. In addition, the extrusion force is beneficial to improving the adhesiveness of the first metal layer and the second metal layer, bubbles in the liquid second metal material are removed, the density of the second metal layer is improved, and the second metal layer is not left with holes after being cooled and solidified, so that the advantage of the strength of the composite metal is achieved. In addition, the liquid flow mark (flow mark) formed when the liquid metal flows during the injection of the second liquid metal can be eliminated. The process of extruding the second metal layer can also overflow the excess second liquid metal material. The metal shell with multiple layers manufactured by the method not only has the strength and elasticity of the composite metal, but also can be subjected to subsequent surface treatment according to requirements, such as heat treatment, anode surface treatment, general water plating treatment, vacuum coating/film treatment, coating treatment, oil spraying treatment, corrosion resistance treatment and the like, so that the adhesion, the strength and the corrosion resistance between the metal layers can be further improved, and the appearance design of the shell is more elastic.

In a preferred embodiment, the first metal layer and the second metal layer may be one of stainless steel, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel, or an alloy thereof, or other metals and alloys, and the first metal layer with low specific gravity may be formed first, and then the second metal layer with high specific gravity may be formed, or the first metal layer with high specific gravity may be formed first, and then the second metal layer with low specific gravity may be formed. For example, forming the first metal layer from a zinc alloy and the second metal layer from an aluminum alloy achieves the strength of the composite metal and allows the second metal layer to be subsequently anodized. For example, the first metal layer is formed of aluminum alloy or magnesium alloy, the second metal layer is formed of stainless steel, and the surface of the second metal layer can be subjected to subsequent direct current plating or vacuum evaporation to further form a subsequent metal or non-metal layer.

In another preferred embodiment of the present invention, an apparatus for manufacturing a housing comprising a plurality of metal layers is disclosed, fig. 2-1 shows an open state of the apparatus 201 according to a preferred embodiment of the present invention, the apparatus 201 comprises a mold 202, a housing (a first metal layer 203) formed of a first metal is placed in the mold 202 (i.e., on a rear mold 207), fig. 2-2 shows a closed state of the apparatus 201, in which a second liquid metal 2041 different from a metal of the first metal layer 203 is injected onto the housing formed of the first metal layer 203 placed in the mold 202 to form a second metal layer 204 on the first metal layer 203.

Fig. 2-3 is a partial enlargement of fig. 2-2. Wherein the mold 202 includes a pressing member 205 for applying a pressing force to the second metal layer 204 located in the mold 202.

In a preferred embodiment, a space may be provided between the rear mold 207 and the extrusion member 205 so that the second liquid metal 2041 can be injected into the space, and an overflow port 206 may be additionally included in the mold 202 so that when the extrusion member 205 extrudes the second metal layer 204, the excess second liquid metal overflows through the overflow port 206.

Yet another preferred embodiment of the present invention relates to a method for manufacturing a case comprising a plurality of metal layers, as shown in fig. 3, the method of the present invention comprises injecting a first liquid metal into a first front mold and a back mold fitted thereto to form a first metal layer (S301); and injecting a second liquid metal on the first metal layer in a semi-solid state in a second front mold cooperating with the rear mold to form a second metal layer on the first metal layer (S302). In addition, three or more layers of metal shells can be formed in the same manner as required.

The difference from the method of FIG. 1 is that when the first metal layer is in a semi-solid state, the second metal layer is formed thereon, which not only improves the adhesion between the first and second metal layers, but also reduces the cost and saves the time, thereby improving the productivity.

In another preferred embodiment of the present invention, an apparatus for implementing the method shown in FIG. 3 is provided, as shown in FIG. 4, the apparatus 401 of this embodiment includes a first front mold 402, which cooperates with a rear mold 407 to inject a first liquid metal 4031 to form a first metal layer 403; and a second front mold 408, which cooperates with the rear mold 407 to inject a second liquid metal 4041 onto the first metal layer 403 in a semi-solid state, so as to form a second metal layer 404 on the first metal layer 403.

In another preferred embodiment of the present invention, when the second front mold 408 and the rear mold 407 are operated cooperatively, a reserved space is provided between the rear mold 407 and the pressing member 405, so that the second liquid metal can be injected into the reserved space.

In addition, a pressing member 405 in the second front mold 408 may be used to apply a pressing force to the second metal layer 404. Furthermore, the rear mold 407 further comprises an overflow port 406, so that when the pressing member 405 applies a pressing force to the second metal layer 404, the excess second liquid metal can overflow through the overflow port 406.

In another preferred embodiment of the present invention, the apparatus 401 further comprises a moving means for relatively moving the positions of the rear mold 407 and the first front mold 402 and the second front mold 408. For example, the rear mold 407 may be moved from the first front mold 402 position to the second front mold 408 position after the injection of the first liquid metal; or the first front mold 402 is moved after the first liquid metal is injected, the first front mold 402 is removed, and the second front mold 408 is moved to a position of engagement with the rear mold 407 for the second liquid metal injection. By this embodiment, the injection of the first liquid metal and the second liquid metal are performed in the same apparatus, which further saves the process steps.

The present invention can also form three or more layers of metal housing in the same manner as required. For example, a third front mold is additionally added and the three-layer metal housing is completed in the manner described above.

The metal shell with multiple layers manufactured by the method not only has the strength and elasticity of the composite metal, but also can be subjected to subsequent surface treatment according to requirements, such as heat treatment, anode surface treatment, general water plating treatment, vacuum coating/film treatment, coating treatment, oil spraying treatment and corrosion resistance treatment and the like, so that the adhesion, the strength and the corrosion resistance between the metal layers can be further improved, and the appearance design of the shell is more elastic.

Although the technical content and features of the invention have been described above, a person skilled in the art may make many variations and modifications without departing from the teaching and disclosure of the invention. Accordingly, the scope of the present invention is not limited to the disclosed embodiments, but includes other variations and modifications without departing from the scope of the present invention, which is intended to be covered by the appended claims.

Claims (16)

1. A method for manufacturing a housing comprising a plurality of metal layers, comprising:

injecting a second liquid metal different from a metal of a first metal layer in a mold onto a case formed with the first metal layer in the mold to form a second metal layer on the first metal layer; and

pressing the second metal layer in the mold at a pressing force at a location other than where the second liquid metal is injected into the mold while the second metal layer is not yet solidified.

2. The method of claim 1, wherein the second metal layer is in a liquid state when the second metal layer is pressed with a squeezing force.

3. The method of claim 1, wherein the first metal layer is in a semi-solid state when the second liquid metal is injected onto a casing formed with the first metal layer in the mold.

4. The method of claim 1, wherein the material of the first metal layer and the second metal layer comprises one of stainless steel, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel, or an alloy thereof.

5. An apparatus for manufacturing a housing comprising a plurality of metal layers, comprising:

a mold for injecting a second liquid metal different from a metal of a first metal layer onto a case formed with the first metal layer in the mold to form a second metal layer on the first metal layer,

wherein the mold comprises a pressing member located at a position other than where the second liquid metal is injected into the mold to apply a pressing force to the second metal layer located in the mold while the second metal layer is not yet solidified.

6. The device of claim 5, wherein said die includes a overflow port for allowing excess second liquid metal to overflow through said overflow port when said pressing means presses said second metal layer.

7. The apparatus of claim 5, wherein the mold comprises a rear mold having a headspace with the extrusion member such that the second liquid metal can be injected into the headspace.

8. The device of claim 5, wherein the material of the first and second metal layers respectively comprises one of stainless steel, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel, or an alloy thereof.

9. A method for manufacturing a housing comprising a plurality of metal layers, comprising:

injecting a first liquid metal into a first front mold and a rear mold matched with the first front mold to form a first metal layer; and

injecting a second liquid metal onto the first metal layer in a semi-solid state in a second front mold fitted with the rear mold to form a second metal layer on the first metal layer,

further comprising pressing the second metal at a position other than where the second liquid metal is injected into the mold with a pressing force while the second metal layer is not yet solidified.

10. The method of claim 9, wherein the second metal layer is in a liquid state when the second metal layer is pressed with the pressing force.

11. The method of claim 9, further comprising relatively moving the positions of the rear mold and the first front mold and the second front mold.

12. The method of claim 9, wherein the material of the first metal layer and the second metal layer comprises one of stainless steel, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel, or an alloy thereof.

13. An apparatus for manufacturing a housing comprising a plurality of metal layers, comprising:

a first front mold, which is matched with a rear mold and is used for injecting a first liquid metal to form a first metal layer; and

a second front mold, which is matched with the rear mold to inject a second liquid metal on the first metal layer in a semi-solid state so as to form a second metal layer on the first metal layer,

the second front mold further comprises a pressing member located at a position other than the position where the second liquid metal is injected into the mold, for applying a pressing force to the second metal layer while the second metal layer is not yet solidified.

14. The apparatus of claim 13, wherein a space is provided between the rear die and the pressing member to allow the second liquid metal to be poured into the space, and the rear die further comprises a flow-through port to allow excess second liquid metal to flow over the flow-through port when the pressing member presses the second metal layer.

15. The apparatus of claim 13, further comprising a moving means for relatively moving the positions of the rear mold, the first front mold and the second front mold.

16. The apparatus of claim 13, wherein the material of the first and second metal layers respectively comprises one of stainless steel, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel, or an alloy thereof.