The present invention relates to a method of manufacturing a workpiece, such as a plate, with multiple metal layers. For the purpose of this invention, where the context allows, the terms “metal” and “metals” shall also include “alloys of metal” and “alloys of metals” respectively. It should also be understood that, for the purpose of this invention, the metal layers may be made of a same metal or different metals.
With the rapid development in the communication, consumer electronic and computer industries (so called “3C industries”), consumers not only expect good performance of such products (so called “3C products”) (such as processing speed and storage capacity), but also a high class and durable cosmetic surface of such products. A metal casing with good strength and light weight will thus become more and more important to 3C products. Such characteristics have also become the consumer requirements or expectation of products in other industries, such as the household industry and automotive industry. In most products, there is a need to over-mold at least one metal layer onto another metal layer, for example to form a cover or a plate. There is therefore a need to improve the joining or bonding strength between two metal layers, which has become a significant production requirement.
A conventional colorful plastic casing of an electronic product is easily broken and damaged by external impact, while a casing of a single metal layer may rust due to environmental factors, or subsequent surface treatment cannot be performed on the casing due to the limitation of material properties. Therefore, casings with multiple metal layers with thin thickness, good cosmetic performance, good strength for resisting external impact, and good corrosion resistance are needed to solve the various shortcomings of casings of a single metal layer. In the prior art, a casing for a consumer electronic apparatus which is formed of double metal layers or of a mechanical laminate of materials is usually prepared by vacuum evaporation or ion sputtering, which entails high manufacturing cost. However, as such a prior art casing is not good for receiving surface treatment involving wet process, such as plating and anodizing, it is less corrosion resistant.
In conventional techniques, solid-state welding processes (such as cold welding, friction welding and ultrasonic welding) may be used for bonding a veneer to a cast metal part. However, such solid-state welding processes may significantly increase the complexity and cost of the processing flow. Therefore, persons skilled in the art are still looking for effective methods of manufacturing a workpiece with multiple metal layers which is less costly and less complex.
In addition, there is an ever-increasing requirement for electronic products (such as tablet computers and smart phones) and domestic electrical appliances to be as compact and slim as possible. Consumers also make the same requirements on products in the automotive industry and household product industry. Consumers are at the same time making a higher and higher demand on the functions and capability of such products. Manufacturers are thus looking for ways to make bodies of the products as compact as possible while retaining sufficient space for housing the necessary components. Existing methods do not allow a thin layer of metal to be injected onto and bonded/engaged with a layer of metal to form a workpiece with multiple metal layers. In addition, as such products get compacter and slimmer, problems arise as regards post-treatment, such as trimming and computer numerical control (CNC) works, which are required for achieving the necessary features.
As such products get more and more compact and slim, problems arise as regards post-treatment (such as trimming) of such workpieces as covers, housings, casings and chassis, because such post-treatment will exert pressure on the workpieces, which may deform the workpieces.
It is thus an object of the present invention to provide a method of manufacturing a workpiece with multiple metal layers, a mold and a workpiece with multiple metal layers in which the aforesaid shortcomings are mitigated or at least to provide a useful alternative to the trade and public.
According to a first aspect of the present invention, there is provided a method of manufacturing a workpiece with multiple metal layers, the method including the steps of (a) providing a mold with at least a runner, a gate and a cavity, (b) providing in the cavity of the mold a first metal layer made of a first metal, the first metal layer having a surface, the surface being roughened and/or including at least one engagement structure, and (c) injecting a molten second metal onto the surface of the first metal layer to form a second metal layer on the first metal layer wherein said second metal layer engages with said roughened surface of said first metal layer or with said engagement structure of said surface of said first metal layer, wherein said molten second metal enters said cavity of said mold at a speed of at least substantially 70 meters per second (m/s).
According to a second aspect of the present invention, there is provided a mold including a first mold piece and a second mold piece, wherein said first mold piece and said second mold piece are movable relative to each other between an open configuration in which said first mold piece and said second mold piece are detached from each other and a closed configuration for holding a semi-finished workpiece between said first mold piece and said second mold piece, and wherein at least said first mold piece includes a wall member which, when said mold is in said closed configuration and holds a semi-finished workpiece, punches into at least part of said semi-finished workpiece to form a seal between said wall member and said semi-finished workpiece which prevents flow of a fluid through said seal.
According to a third aspect of the present invention, there is provided a workpiece with multiple metal layers, said workpiece being formed by injecting at least a second metal layer onto a first metal layer, wherein each of said first metal layer and second metal layer includes at least one engagement structure.
According to a fourth aspect of the present invention, there is provided a mold including a first mold piece and a second mold piece, wherein said first mold piece and said second mold piece are movable relative to each other between an open configuration in which said first mold piece and said second mold piece are detached from each other and a closed configuration in which said first mold piece and said mold piece are engaged with each other to form a cavity for containing a semi-finished workpiece, wherein said first mold piece includes a passageway allowing supply of molding material into said cavity, and wherein said mold is without a channel allowing flow of molding material out of said cavity.
According to a fifth aspect of the present invention, there is provided a method of manufacturing a workpiece with multiple metal layers, said method including steps (a) providing a first metal layer made of a first metal, (b) pre-treating said first metal layer, (c) placing said pre-treated first metal layer in a mold, and (d) injecting a molten second metal onto said surface of said pre-treated first metal layer to form a second metal layer on said pre-treated first metal layer.
According to a sixth aspect of the present invention, there is provided a workpiece with multiple metal layers, said workpiece being formed by injecting at least a second metal layer onto a first metal layer, wherein said second metal layer is of a thickness of not more than substantially 0.5 mm.
According to a seventh aspect of the present invention, there is provided a method of manufacturing a workpiece with multiple metal layers, said method including steps (a) providing a mold with at least a runner, a gate and a cavity, (b) providing a first metal layer made of a first metal, said first metal layer having a surface, said surface including at least one engagement structure, (c) pre-treating said first metal layer, (d) placing said pre-treated first metal layer in said mold, and (e) injecting a molten second metal onto said surface of said first pre-treated metal layer to form a second metal layer on said pre-treated first metal layer, wherein said molten second metal enters said cavity of said mold at a speed of at least substantially 70 meters per second (m/s), wherein said second metal layer includes at least one engagement structure which engages with said engagement structure of said surface of said pre-treated first metal layer, wherein said mold includes a first mold piece and a second mold piece, wherein said first mold piece and said second mold piece are movable relative to each other between an open configuration in which said first mold piece and said second mold piece are detached from each other and a closed configuration in which said first mold piece and said second mold piece are engaged with each other to form said cavity for containing said pre-treated first metal layer, wherein said first mold piece includes a passageway allowing supply of said molten second metal, and wherein said mold is without a channel allowing flow of said molten second metal out of said cavity.
According to an eighth aspect of the present invention, there is provided a workpiece with multiple metal layers formed of a method including steps (a) providing a mold with at least a runner, a gate and a cavity, (b) providing a first metal layer made of a first metal, said first metal layer having a surface, said surface including at least one engagement structure, (c) pre-treating said first metal layer, (d) placing said pre-treated first metal layer in said mold, and (e) injecting a molten second metal onto said surface of said first pre-treated metal layer to form a second metal layer on said pre-treated first metal layer, wherein said molten second metal enters said cavity of said mold at a speed of at least substantially 70 meters per second (m/s), wherein said second metal layer includes at least one engagement structure which engages with said engagement structure of said surface of said pre-treated first metal layer, wherein said mold includes a first mold piece and a second mold piece, wherein said first mold piece and said second mold piece are movable relative to each other between an open configuration in which said first mold piece and said second mold piece are detached from each other and a closed configuration in which said first mold piece and said second mold piece are engaged with each other to form said cavity for containing said pre-treated first metal layer, wherein said first mold piece includes a passageway allowing supply of said molten second metal, and wherein said mold is without a channel allowing flow of said molten second metal out of said cavity.
The injection operation includes different aspects, such as high-pressure and high speed injection molding, pouring and/or flowing. The pressure, the speed at which the second metal is injected into the mold and the short time duration in which the second metal covers the first metal layer all assist in improving the adhesiveness and strength of bonding between the first metal layer and the second metal layer, removing bubbles in the second metal when in liquid state, and improving the compactness of the second metal layer, so that only very few pores are left after cooling and curing of the second metal layer, thereby achieving the strength of a composite metal. Such may also prevent the formation of a liquid flow mark due to flowing of the second metal in liquid form during injection. Pressing the second metal layer may also enable a surplus of the second metal in liquid form to overflow.
In a further embodiment, a space is provided between the rear mold 207 and the pressing component 205, so that the second metal in liquid form 2041 may be injected into the space. Moreover, the mold 202 additionally includes an overflow port 206, so that a surplus of the second metal in liquid form 2041 overflows through the overflow port 206 when the pressing component 205 presses the second metal layer 204.
Although, in the foregoing discussions, it is mentioned that the first metal is different from the second metal, it is of course envisaged that the first metal layer and the second metal layer may be made of a same metal.
In a yet further embodiment of the present invention, and as shown in
The difference between the method shown in
A device 401 for implementing the method shown in
When the second front mold 408 operates in cooperation with the rear mold 407, a space is provided between the rear mold 407 and a pressing component 405, so that the second metal in liquid form 4041 may be injected into the space.
Moreover, the pressing component 405 in the second front mold 408 may be used for applying a pressure on the second metal layer 404. Furthermore, the rear mold 407 further includes an overflow port 406, so that a surplus of the second metal in liquid form 4031 may overflow through the overflow port 406 when the pressing component 405 applies a pressure on the second metal layer 404.
The device 401 further includes a movement component, for relatively moving the rear mold 407 between 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 to the second front mold 408 after the first metal in liquid form 4031 is injected; or the first front mold 402 is moved away after the first metal in liquid form 4031 is injected, and the second front mold 408 is moved to a position operating in cooperation with the rear mold 407, so as to inject the second metal in liquid form 4041 onto the first metal layer 403. Through this arrangement, the injection of both the first metal in liquid form 4031 and the second metal in liquid form 4041 is performed in the same device 401, thus simplifying the production process.
A workpiece with three or more metal layers may be formed by repeating the above steps.
Each of the first metal layer and the second metal layer may be formed of stainless steel, iron, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel and alloy of these metals. A first metal layer with a smaller specific weight may first be formed, and then a second metal layer with a larger specific weight is formed. Alternatively, a first metal layer with a larger specific weight may first be formed, and then a second metal layer with a smaller specific weight is formed. For example, if the first metal layer is formed of a zinc alloy, and the second metal layer is formed of an aluminum alloy, the strength of a composite metal may be achieved, and subsequent anodizing surface treatment may be performed on the second metal (aluminum alloy) layer. In another example, the first metal layer is formed of an aluminum alloy or a magnesium alloy, and the second metal layer is formed of stainless steel, so that subsequent treatment such as direct current electroplating or vacuum evaporation may be conveniently performed on a surface of the second metal layer, thereby further forming a subsequent metal or non-metal layer.
Not only does the workpiece with multiple metal layers manufactured according to a method of the present invention have the strength and elasticity of a composite metal, but also subsequent surface treatment (such as heat treatment, anodizing surface treatment, Galvanic plating, vacuum coating/film treatment, coating treatment, painting treatment, and corrosion resistant treatment) may be performed on the metal workpiece, as required, to further improve the adhesiveness between the metal layers and the strength and corrosion resistance of the workpiece, and to make the design of covers made of such workpieces more flexible.
A method of manufacturing a workpiece with multiple metal layers, according to a yet further embodiment of the present invention is shown in
In molding, the molten molding material (such as a molten metal) is injected from an injector nozzle of a molding machine to flow through a sprue, then a runner, then a gate, through which the molten molding material enters the cavity of the mold. More particularly, a sprue is a channel allowing flow of the molten molding material from the injector nozzle towards the mold cavity. A runner is a channel in fluid communication with the sprue and guides the molten molding material to flow from the sprue towards the mold cavity. The runner is joined with the gate and the gate acts as an entrance through which molten molding material in the runner enters the mold cavity.
To further enhance the strength of bonding/engagement between the first metal layer and second metal layer, in an embodiment of the present invention, the second metal in liquid form is injected from the injector nozzle at such a speed that the second metal in liquid form exits the runner and enters the cavity of the mold via the gate of the mold at a speed of at least 70 meters per second (m/s). This speed will hereafter be called the “ex-gate speed”. In one embodiment, to achieve an ex-gate speed of 70 m/s, it is arranged such that the second metal in liquid form exits the sprue and enters the runner at a speed of at least 3.5 m/s. This latter speed will hereafter be called the “ex-sprue speed”.
The semi-finished plate (or the first metal layer) and the second metal layer may be made of the same metal or different metals, and the metal may be stainless steel, iron, zinc, aluminum, magnesium, chromium, titanium, copper, beryllium, nickel or an alloy thereof.
The roughened surface of the semi-finished plate (i.e. first metal layer) in the above embodiments may be formed chemically and/or mechanically. For example, if the first metal layer is formed of aluminum (Al), anodizing process may be used for forming pores on the surface of first metal layer for joining with the molten second metal. In particular, the second metal in molten state may be trapped in the pores, so that the second metal will be fastened onto the first metal layer after cooling and curing thereof.
The plate may be used as a cover or an insert of an electronic device, or any other kinds of products/devices in other industries in which the devices require better joining, bonding or engagement strength on multi-metal construction.
The first metal layer and the second metal layer may be engaged together by bonding or confining a part of the second metal layer in a space defined by the engaging structure.
In above-mentioned methods, the second metal 614, 814, 914 and 914′ may be injected onto the surface of the semi-finished plate (first metal layer) at an ex-gate speed of at least 70 m/s, and with an ex-sprue speed higher than 3 m/s, 3.5 m/s, 4.0 m/s, 4.5 m/s, 5.5 m/s, 6.0 m/s, 6.5 m/s or above. In this way, the second metal layer can be of an extremely thin dimension, so that the recesses, holes, grooves, balls or protrusions of the roughened surface and hook(s), buckle(s), trench(es), protrusion(s) or groove(s) of the engaging structure can be well capped (or covered) and filled by the second metal. In a preferred embodiment, the thickness of the second metal layer may be not more than 0.5 mm (such as 0.5 mm, 0.3 mm, 0.2 mm or 0.1 mm) by adjusting the ex-gate speed (e.g. by adjusting the speed at which the second molten metal is ejected from the injection nozzle), or depending on the 3D-design of product, which may become important in future.
In view of the above, high speed of flow of the second molten metal is a critical parameter in minimizing the fall in temperature of the second molten metal during its flow from the injection nozzle to the mold cavity. Localized melting on the surfaces of the two metals which are going to be joined or bonded together can only result in a weak bonding. As such, post-processes (for examples, laser welding, resistance welding and some other welding processes which are known in the market) are needed to enhance the joining or bonding strength between the two metal layers. In the present invention, a bolted locking mechanism (or bolted locking space) is provided on the first metal layer for guiding the second metal in molten form to be trapped by the designated space defined by the bolted locking mechanism, as the engaging structures 913a and 913a′ depicted in
In particular, a purpose of injecting the second metal in liquid form into the mold at a high speed is to ensure that the second metal fills up the cavity in a very short time, and thus the second metal is still in the molten stage when it fills up the cavity of the mold to form the second metal layer. As shown in the example illustrated in
To further enhance the engagement and bonding between the two metal layers, as shown in
Although the engagement elements may be of a height of at least 0.5 mm, the second metal layer may be of a lesser thickness. As shown in
The mold 1100 includes a passageway through which molding materials (such as molten metals) may be supplied to the cavity of the mold when the mold 1100 is in the closed configuration. As distinct from existing practice, however, there is no channel in the mold 1100 through which excess molding material (i.e. the molten metal) exits the cavity of the mold 1100 to become burrs and flash, which have to be trimmed off after the molding process. On the other hand, when the mold 1100 is used, any excess molten second metal will flow over the first metal layer/plate 1108 and will still form part of the product. It is thus not necessary to carry out any trimming step after the method according to this invention, because there is no “over-flow material” to be trimmed off.
Although
A method according to this invention possesses at least the following advantages:
In a further embodiment of the present invention, and as shown in
The pre-treated semi-finished plate 1200 is then placed within the cavity of a mold. A molten second metal is then injected onto the upper surface 1204 of the pre-treated plate 1200 to form a second metal layer 1206, and to engage with the pre-treated plate 1200 to form a bi-layer metal workpiece. Some of the second metal is received within the bays 1202 of the plate 1200, so as to engage the pre-treated plate 1200 with the second metal layer 1206. It is of course possible to form a workpiece with more layers of metal by repeating the above steps. It should be noted that the second metal layer 1206 may cover only part of the bays 1202.
In addition, and as shown in
It is found in practice that this arrangement of pre-treating the semi-finished plate 1200 (in particular the removal of some of the first metal from the plate 1200 to form two recesses in the form of thin bays 1202 on the upper surface 1204 of the plate 1200) before molding may be advantageously combined with the use of mold 1100 with the endless wall 1104 discussed above. With such a combined method, there will be no “waste material”, as any excess molten second metal (i.e. molten second metal beyond the minimum amount necessary for molding onto the first metal layer) will be kept within the mold 1100 to form at least part of the second metal layer 1206, which forms useful parts of the final workpiece/product.
An advantage associated with adopting such a combined method is that all excess or surplus molten second metal (if any) will become part of the final workpiece/product in a planned manner, which could assist in strengthening the features formed by the second metal. In addition, as it is not necessary to post-treat any overflow material, the combined method is both environmentally-friendly and cost-saving.
As mentioned above, the second metal layer 1206 may cover only part of the bays formed on the first metal layer. As shown in
The present invention seeks to at least mitigate the shortcomings associated with the prior art, and to manufacture a workpiece with multiple metal layers at a lower cost and with a higher yield, by preparing materials according to actual material consumption, thus being more environmentally friendly and cost efficient than the technology currently available. Meanwhile, different metals of double layers or multiple layers may be designed to completely or partially cover a substrate, so as to meet the requirements for appearance and mechanical performance at the same time, which will save a large amount of work in developing different alloy materials and save global resources.
The method of the present invention achieves good adhesiveness between multiple metal layers and improves the metal compactness and the surface smoothness, and facilitates subsequent metal surface treatment.
It should also be understood that, for the purpose of this invention, a “workpiece with multiple metal layers” does not mean that the workpiece is formed exclusively of metal(s). It is envisaged that a “workpiece with multiple metal layers” may be formed additionally of other materials, e.g. plastics material. As an example, such a workpiece may be formed of two metal layers which are bonded/engaged with each other as discussed above and a plastic layer which is bonded/engaged with one of the two metal layers. There is thus no limitation on the number of layers of materials involved or the number of materials involved, so long as the workpiece includes two metal layers which are bonded/engaged with each other as discussed above.
Although the technical contents and features of the present invention are described above, various variations and modifications can be made by persons of ordinary skill in the art without departing from the teaching and disclosure of the present invention. Therefore, the scope of the present invention is not limited to the disclosed embodiments, but encompasses other variations and modifications that do not depart from the present invention as defined by the appended claims.
Number | Date | Country | Kind |
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20110037281.4 | Feb 2012 | CN | national |
This application is a Continuation-In-Part of U.S. patent application Ser. No. 13/651,980 filed on 15 Oct. 2012, which is itself a Continuation-In-Part of U.S. patent application Ser. No. 13/277,673 filed on 20 Oct. 2011, which claims priority in Chinese Patent Application no. 2011 0037281.4, filed Feb. 1, 2011, the contents of these applications being incorporated herein in their entirety by reference.
Number | Date | Country | |
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Parent | 13651980 | Oct 2012 | US |
Child | 13747833 | US | |
Parent | 13277673 | Oct 2011 | US |
Child | 13651980 | US |