BACKGROUND
Many devices include components that are manufactured in a variety of manners. For example, certain devices or components are formed of plastic using injection molding, while others may be formed of a metal that may be forged, machined, or otherwise shaped. The method of forming the component may be selected based on such factors as strength or surface shape desired.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of various examples, reference is now made to the following description taken in connection with the accompanying drawings in which:
FIG. 1 illustrates an example system for stamping metal components;
FIG. 2 illustrates another example system for stamping metal components;
FIGS. 3-5 illustrate various phases of the stamping of a metal component using the example system of FIG. 2;
FIG. 6 illustrates another example system for stamping metal components;
FIG. 7 illustrates another example system for stamping metal components; and
FIG. 8 is a flow chart illustrating an example method for stamping of metal components.
DETAILED DESCRIPTION
Various mechanisms may be used for forming different components or devices. For metal components, certain features can be achieved through stamping of a metal component. Stamping can often result in defects on the surface of a component. The defects can include significant non-uniformity of the stamped surface. For certain components and materials, the non-uniformity of the surface can, in turn, result in non-uniformity in color or appearance of the surface. Further, for certain components, the non-uniformity may be significantly noticeable to the touch by a user.
In various examples described herein, metal components may be stamped to form a desired shape or feature. For example, the body of a laptop computer may have a cover with features which can be stamped. In one example, a laptop cover is provided with a recess to allow a user to insert a finger to open the cover. In various examples, stamping systems allow improved stamping of metal components, such as laptop covers, with reduced surface defects. In this regard, an example stamping system includes a first stamping portion provided with a first surface having a shape which corresponds to the desired shape of the component to be stamped, such as a flat shape for the finger recess of the laptop cover. A second stamping portion is provided with a second surface to oppose the first surface. The metal component to be stamped may be positioned between the first stamping portion and the second stamping portion, with the portion of the metal component to have the desired shape positioned between the first surface and the second surface. The second surface is provided with a metal flow receiving feature which includes a non-flat surface. The non-flat surface allows the amount of metal to flow into the metal flow receiving feature to be attenuated during stamping of the metal component between the first stamping portion and the second stamping portion. For example, a stamping force may be adjusted to cause an optimal amount of metal to flow into the metal flow receiving feature to provide a substantially defect-free stamped surface on the metal component. In various examples, the non-flat surface of the metal flow receiving feature may include various shapes such as an arc or a sawtooth pattern.
Referring first to FIG. 1, an example system for stamping metal components is illustrated. The example system 100 includes a first stamping portion 110 and a second stamping portion 120. The first stamping portion 110 is provided with a first surface 112. The first surface 112 is shaped to form a corresponding stamped surface on a metal component to be stamped (not shown in FIG. 1). In this regard, the first surface 112 of the first stamping portion 110 is formed to any shape that may be desirable for the stamped surface of the metal component. In the example of FIG. 1, the first surface 112 of the first stamping portion 110 is shown as a substantially flat or linear surface.
The second stamping portion 120 is provided with a second surface 122 to oppose the first surface 112 of the first stamping portion 110 during stamping of the metal component, with the metal component being positioned between the first surface 112 of the first stamping portion 110 and the second surface 122 of the second stamping portion 120. In various examples, the second surface 122 of the second stamping portion 120 includes a metal flow receiving feature 124. The metal flow receiving feature 124 includes a non-flat surface to attenuate an amount of metal flowing therein during stamping of the metal component between the first stamping portion 110 and the second stamping portion 120. In this regard, the first surface 112 of the first stamping portion 110 produces a desired shape, while any variations in the amount of metal that is flowed as a result of the stamping is attenuated on the opposite side of the metal component. In some examples, the amount of metal flowing into the metal flow receiving feature 124 can vary based on the stamping pressure, while the first surface 112 of the first stamping portion produces a consistent amount of flow on the stamped side of the metal component.
The first stamping portion 110 and the second stamping portion 120 of the example system 100 may be formed of any of a variety of materials. In one example, the first stamping portion 110 and the second stamping portion 120 are each formed of steel. Generally, the first stamping portion 110 and the second stamping portion 120 may be formed of a material having a hardness that is greater than the hardness of the metal component to be stamped.
Referring now to FIG. 2, another example system for stamping metal components 200 is illustrated. The example system 200 of FIG. 2 is similar to the example system 100 described above with reference to FIG. 1 and includes a first stamping portion 210 and a second stamping portion 220. The example system 200 of FIG. 2 includes a metal component 230 to be stamped. As illustrated in FIG. 2, the metal component 230 may form a surface of an electronic device, such as a laptop, for example. The example metal component 230 of FIG. 2 is provided with a surface feature 238 which may be, for example, a finger recess to allow a user to open a closed laptop. In this regard, the surface feature 238 should be smooth to the touch of a user. It is noted that FIG. 2A illustrates a completed (e.g., stamped) metal component 230, while FIG. 2B illustrates a cross-sectional view of the component 230 before it is stamped.
As with the example system 100 of FIG. 1, the first stamping portion 210 of example system 200 of FIG. 2 is provided with a first surface 212 formed to correspond to a stamped surface 232 of the metal component 230 to be stamped. Thus, the first surface 212 is formed to the desired shape for the stamped surface 232 of the metal component 230 illustrated in FIG. 2A. In this regard, the first surface 212 of the first stamping portion 210 includes a substantially flat portion.
The second stamping portion 220 is provided with a second surface 222, and the metal component 230 is positioned between the first surface 212 of the first stamping portion 210 and the second surface 222 of the second stamping portion 220. As noted above, the metal component 230 includes a stamped surface 232 to be stamped. As illustrated in FIG. 2B, the stamped surface 232 of the metal component 230 faces the first surface 212 of the first stamping portion 210. The metal component further includes a non-stamped surface 234 opposite the stamped surface 232. The non-stamped surface 234 faces the second surface 222 of the second stamping portion 220.
In the example system 200 of FIG. 2, the second surface 222 of the second stamping portion 220 includes a metal flow receiving feature 224 which includes a non-flat surface. As noted above, the non-flat surface of the metal flow receiving feature 224 allows attenuation of the amount of metal flowing therein during stamping of the metal component between the first stamping portion 210 and the second stamping portion 220. In this regard, the first surface 212 of the first stamping portion 210 produces a desired shape (e.g., the flat shape illustrated in FIG. 2), while any variations in the amount of metal that is flowed as a result of the stamping is attenuated on the opposite side of the metal component.
Referring now to FIGS. 3-5, various phases of the stamping of the metal component 230 using the example system 200 of FIG. 2 are illustrated. As illustrated in FIGS. 3-5, the first stamping portion 210 and the second stamping portion 220 are moved toward each other until the stamping is complete. In various examples, the completion of the stamping may occur when the first stamping portion 210 and the stamping portion 220 are no longer in movement relative to each other when a certain stamping pressure is applied. In this regard, the level of stamping pressure may be determined by any of a variety of factors including, but not limited to, the material of the metal component 230, tool damage prevention, accuracy, and smooth motion.
Referring first to FIG. 3, the example system 200 is illustrated as a snapshot at a point at which the first stamping portion 210 and the second stamping portion 220 both make contact with the metal component 230. In the example of FIG. 3, at this point, the first surface 212 of the first stamping portion 210 is in contact with the metal component 230. At this point, the metal component 230 may offer resistance to the relative movement of the first stamping portion 210 and the second stamping portion 220, and sufficient stamping pressure may be used to overcome the resistance and continue to move the first stamping portion 210 and the second stamping portion 220 towards each other.
Referring now to FIG. 4, the example system 200 is illustrated as a snapshot at a point at which the first stamping portion 210 and the second stamping portion 220 continue to move toward each other and deform the metal component 230. As illustrated in FIG. 4, the metal component 230, or the stamped surface 232 thereof, is beginning to acquire the shape of the first surface 212 of the first stamping portion 210.
Referring now to FIG. 5, the example system 200 is illustrated as a snapshot at a point at which the first stamping portion 210 and the second stamping portion 220 have stopped moving toward each other. As noted above, this stoppage point may be determined by the amount of stamping pressure applied. At this stoppage point, the first surface 212 of the first stamping portion 210 forms a substantially identical surface on the stamped surface 232 of the metal component 230. At the same time, the metal flow receiving feature 224 of the second surface 222 of the second stamping portion 220 may accommodate any variations or imperfections in the amount of metal flowing during the stamping process.
In this regard, the non-linear or non-flat surface of the metal flow receiving feature 224 provides regions in which excess metal can flow during stamping. Similarly, the non-flat surface can accommodate varying amounts of metal flowing with variations in stamping pressure. For example, once a minimum level of stamping is achieved to sufficiently form the stamped surface 232 of the metal component 230, additional stamping pressure may result in additional metal flowing into the non-flat metal flow receiving feature 224 while maintaining the desired stamped surface 232. Thus, the non-stamped surface 234 of the metal component may or may not significantly match the second surface 222 of the second stamping portion 220.
FIGS. 1-5 illustrate various examples of stamping systems with a metal flow receiving feature corresponding to a non-stamped surface of a metal component. In the example systems 100, 200 described above, the metal flow receiving feature 224 is illustrated as a non-linear or non-flat surface, having a non-linear cross-section, such as an arc. In other examples, the metal flow receiving feature 224 may have any of a variety of other non-linear or non-flat surfaces. In this regard, FIGS. 6 and 7 illustrate some example systems with different metal flow receiving features 224.
Referring first to FIG. 6, the example system 600 includes a first stamping portion 610, a second stamping portion 620 and a metal component 630 being stamped therebetween. Similar to the example systems described above, the first stamping portion 610 of the example system 600 includes a first surface 612 formed to correspond to a stamped surface 632 of the metal component 630.
The second stamping portion 620 is provided with a second surface 622, and the metal component 630 is positioned between the first surface 612 of the first stamping portion 610 and the second surface 622 of the second stamping portion 620. The metal component includes a stamped surface 632 facing the first surface 612 of the first stamping portion 610 and a non-stamped surface 634, opposite the stamped surface 632, and facing the second surface 622 of the second stamping portion 620.
In the example system 600 of FIG. 6, the second surface 622 of the second stamping portion 620 includes a metal flow receiving feature 624 which includes a non-flat surface. In the example system 600 of FIG. 6, the metal flow receiving feature 624 is provided with a waved formation. Viewed in three-dimensions, the metal flow receiving feature 624 may include a series of crests and troughs. During stamping, the crests may contact the metal component 630 and transmit the stamping pressure onto the metal component 630, while the troughs may provide space for a variable amount of metal to flow into. Thus, the metal flow into the metal flow receiving feature 624 may absorb any imperfections in the stamping process, thereby producing a more uniform surface on the stamped surface 232 of the metal component.
Referring next to FIG. 7, the example system 700 includes a first stamping portion 710, a second stamping portion 720 and a metal component 730 being stamped therebetween. Similar to the example systems described above, the first stamping portion 710 of the example system 700 includes a first surface 712 formed to correspond to a stamped surface 732 of the metal component 730.
The second stamping portion 720 is provided with a second surface 722, and the metal component 730 is positioned between the first surface 712 of the first stamping portion 710 and the second surface 722 of the second stamping portion 720. The metal component includes a stamped surface 732 facing the first surface 712 of the first stamping portion 710 and a non-stamped surface 734 opposite the stamped surface 732 and facing the second surface 722 of the second stamping portion 720.
In the example system 700 of FIG. 7, the second surface 722 of the second stamping portion 720 includes a metal flow receiving feature 724 which includes a non-flat surface. In the example system 700 of FIG. 7, the metal flow receiving feature 724 is provided with a sawtooth pattern. During stamping, the sawtooth pattern can simultaneously provide the force on the metal components resulting from the stamping pressure and space for a variable amount of metal to flow into. Thus, the metal flow into the metal flow receiving feature 724 may absorb any imperfections in the stamping process, thereby producing a more uniform surface on the stamped surface 732 of the metal component.
Referring now to FIG. 8, a flow chart illustrating an example method for stamping of metal components is provided. The example method 800 includes positioning a metal component between a first stamping portion and a second stamping portion (block 810). In various examples, the metal component has a stamped surface to be stamped and a non-stamped surface opposite the stamped surface. Further, the first stamping portion has a first surface facing the stamped surface of the metal component, and the second stamping portion has a second surface facing the non-stamped surface of the metal component. The second surface of the second stamping portion includes a metal flow receiving feature. As described above, various examples of the metal flow receiving feature may have a non-flat feature, such as a wave formation or a sawtooth formation, for example.
The example method 800 further includes stamping the metal component between the first stamping portion and the second stamping portion (block 820). As described above, the stamping includes flowing material from the metal component into the metal flow receiving feature. In this regard, the metal flow receiving feature can absorb imperfections, thus allowing the stamped surface to be substantially defect-free.
The foregoing description of various examples has been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or limiting to the examples disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of various examples. The examples discussed herein were chosen and described in order to explain the principles and the nature of various examples of the present disclosure and its practical application to enable one skilled in the art to utilize the present disclosure in various examples and with various modifications as are suited to the particular use contemplated. The features of the examples described herein may be combined in all possible combinations of methods, apparatus, modules, systems, and computer program products.
It is also noted herein that while the above describes examples, these descriptions should not be viewed in a limiting sense. Rather, there are several variations and modifications which may be made without departing from the scope as defined in the appended claims.
Patent Application
20210362211
