JP2018171655A - Method and device for progressively forging mobile device casing - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a field of manufacturing a metal component, more specifically, a technique concerning a manufacturing process for forming a mobile device casing.SOLUTION: A method and a device for progressively forging a mobile device casing are provided. This method can include a step at which an initial mobile device casing, which is cut from an extrusion sheet, is progressively fed through plural stations of a transfer metal mold assembly. This method can include also a step at which a series of forging is executed for the initial mobile device casing in order to progressively form a mobile device casing of which at least one three-dimensional feature part is formed in at least one cavity of the progressively formed mobile device casing.SELECTED DRAWING: Figure 1A

Description

[Cross-reference to prior application]
The present application claims priority to Chinese Patent Application No. 201710209105 filed Mar. 31, 2017 entitled “Method and Apparatus for Progressive Forging of Mobile Device Casing” currently pending. .

  Embodiments of the present invention generally relate to the field of manufacturing metal parts, and more specifically to a manufacturing process for forming a mobile device casing.

  Housing for handheld devices (eg, mobile phones, gaming devices, music players, medical devices, etc.), tablet computer devices, laptop computer device bodies, laptop computer keyboards, laptop computer device displays, and other mobile devices Mobile device housings such as typically include a glass cover that is attached to the housing using an adhesive and / or screws to form a housing, or secured to the housing to form the housing It is sandwiched between glass or ceramic covers. The housing supports and protects the mobile device assembly, such as printed circuit boards, processors, memory, batteries, cooling fans, camera lenses, glass displays, flexible cables, hinges, brackets, and various mobile devices. Including supporting and protecting other parts typically included in the casing.

  One conventional manufacturing process for forming a mobile device casing includes fully machining a housing from a metal block. Machining operations include further machining of all features (eg, mobile device casing sidewalls, mounting holes, embossments, relief surfaces, etc.). However, machined housings typically increase the time and cost of manufacturing mobile device casings.

  Another exemplary approach for manufacturing a mobile device casing includes pressing or “deep drawing” a metal sheet to form a housing. After pressing, the features are then machined in a manner similar to the full machining process that forms the mobile device casing. Pressing the metal sheet to form the mobile device casing results in a housing having a uniform material thickness throughout the housing. Typically, the material thickness is the same sheet thickness as the original sheet material that was pressed. Then, additional machining operations are required that increase the time and cost in forming the mobile device casing to achieve features and / or different material thicknesses when forming the mobile device casing. Furthermore, there may be a relief surface with a very thin material thickness after machining, thereby adversely affecting the rigidity of the housing.

  Embodiments of the invention are illustrated by way of example and not limitation in the figures of the accompanying drawings.

FIG. 3 illustrates one embodiment of a system for progressively forging a mobile device casing having a three-dimensional feature formed in at least one cavity of the casing. FIG. 6 illustrates another embodiment of a system for progressively forging a mobile device casing having a three-dimensional feature formed in at least one cavity of the casing. 1 is a block diagram of a method 200 for progressively forging a mobile device casing having at least one three-dimensional feature formed in at least one cavity of a housing. FIG. FIG. 6 is a cross-sectional view of different stages of a gradual forging operation to form a bowl-shaped mobile device casing. FIG. 6 shows an embodiment of a front view of a fully formed bowl-shaped mobile device casing. FIG. 6 shows another embodiment of a front view of a fully formed bowl-shaped mobile device casing. FIG. 6 shows one embodiment of a side view of a fully formed bowl-shaped mobile device casing. FIG. 6 is a cross-sectional view of different stages of a gradual forging operation to form an i-frame mobile device casing. FIG. 6 illustrates one embodiment of a front view of a fully formed i-frame mobile device casing. FIG. 6 illustrates one embodiment of a front perspective view of a progressively forged mobile device casing having a three-dimensional feature in at least one cavity of the mobile device casing. FIG. 6 illustrates one embodiment of a perspective view of the back side of a progressively forged mobile device casing. FIG. 6 illustrates one embodiment of a front perspective view of a progressively forged laptop bottom casing having a three-dimensional feature in at least one cavity of the laptop monitor casing. FIG. 6 shows one embodiment of a perspective view of the back side of a progressively forged laptop bottom casing. FIG. 6 shows one embodiment of a perspective view of the front side of a progressively forged laptop screen casing having a three-dimensional feature in at least one cavity of the laptop monitor casing. FIG. 6 shows an embodiment of a perspective view of the back side of a progressively forged laptop screen casing. FIG. 6 illustrates one embodiment of a front perspective view of a progressively forged laptop body casing having a three-dimensional feature including a keyboard housing within at least one cavity of the laptop monitor casing. FIG. 6 shows an embodiment of a perspective view of the back side of a progressively forged laptop body casing. FIG. 6 illustrates one embodiment of a perspective view of the front side of a progressively forged i-frame mobile device casing having a three-dimensional feature in at least a first cavity of the mobile device casing. FIG. 6 illustrates one embodiment of a perspective view of the back side of a progressively forged i-frame mobile device casing having a three-dimensional feature in at least a second cavity of the mobile device casing. FIG. 10A illustrates one embodiment of a front view of a progressively forged mobile device casing having a honeycomb feature that is forged within at least a portion of the cavity of the mobile device casing. FIG. 10B is an enlarged view of one embodiment of the honeycomb feature. FIG. 6 is another enlarged view of one embodiment of a honeycomb feature. It is sectional drawing of one Embodiment of a honeycomb characteristic part. FIG. 6 is a cross-sectional view of one embodiment of a progressively forged mobile device casing. FIG. 11B illustrates the granular structure and flow of portions of the progressively forged mobile device casing of FIG. 11A.

  A method of progressively forging a mobile device casing having one or more three-dimensional features is described. As described herein, a mobile device casing is a handheld device (eg, mobile phone, gaming device, medical device, music player, etc.), tablet computer, laptop computer display, laptop computer body, laptop computer. It can be a casing for one of the keyboard bodies, as well as the casing of other mobile devices. In an embodiment, the mobile device casing is a bowl-shaped casing having a cavity formed on the front side of the mobile device casing and further having one or more three-dimensional features forged into the cavity in the front face thereof. be able to. In an embodiment, the mobile device casing can be an i-frame (eg, i-shaped) mobile device casing having a front cavity and a back cavity each having a three-dimensional feature formed therein. In either embodiment, the mobile device casing is formed progressively over a series of progressive forging operations, as described in more detail herein.

  In an embodiment, the initial mobile device casing is cut from an extruded sheet of material such as aluminum, steel, or other suitable metallic material. This initial mobile device casing is then subjected to a specific series of forgings to progressively form a mobile device casing having one or more three-dimensional features within at least one cavity of the mobile device casing. . This series of gradual forgings can be used to transfer the initial mobile device casing (eg, blank cut from a metal sheet, blank cut from an extruded sheet, etc.) through multiple stations of the transfer mold assembly. It can be implemented by such a system. Multiple stations from multiple stations perform a series of incremental forgings to form mobile device casings such as mobile phone housings, tablet computer housings, laptop monitor housings, laptop body housings. In one embodiment, the gradual forging step can be performed at room temperature. In another embodiment, one or more of these progressive stages includes preheating the partially formed mobile device casing to a predetermined temperature for a minimum duration before performing the forging operation. In embodiments, a combination of room temperature forging and preheating forging stages can be used for a series of progressive forging operations.

  Forging of mobile device casings uses a progressive forging operation over a series of forging stages to manage the plastic deformation that displaces the material with each forging operation. By utilizing the plastic deformation of the initial mobile device casing material over a series of forging stages, the use of the material to manufacture the casing will be significantly reduced. Further, gradual forging results in work hardening of the resulting mobile device casing, thus improving mechanical properties such as rigidity and tensile strength of the fully formed mobile device casing. That is, the non-uniform stress distortion of the casing and the material of the feature formed therein is reduced, and the particle structure is more dense due to the work hardening effect. For example, FIG. 11A shows a cross-sectional view of a progressively forged mobile device casing 1100 that includes a curved wall section 1102, a three-dimensional feature 1104 in the cavity of the mobile device casing, and another curved wall section 1106. Although initial mobile device casing blanks (eg blanks cut from extruded sheets, metal sheets, etc.) will have fine equiaxed particles of uniform size before forging, FIG. 11B is derived from a progressive forging operation. The enlarged curved wall portions 1102 and 1106 and the granular structure and flow of the three-dimensional feature 1104 are shown. In an embodiment, after the gradual forging operation described herein, there is a granular structure and flow that is stretched in the direction of deformation of the metal material of the formed mobile device casing, as shown in FIG. The high strength and rigidity of the formed mobile device casing is provided.

  In addition, a gradual forging operation over a series of forging stages can result in one or more cavities in the mobile device casing (eg, a front cavity in a bowl-shaped mobile device casing and a front and / or back cavity in an i-frame mobile device casing) One or two or more three-dimensional features can be formed in the interior. The formed three-dimensional features are similar in shape to the final form of these features, and the walls of the progressively forged mobile device casing are thinner than in the conventional approach. Thus, since only the refinement, not the formation of parts and / or walls, is performed in completing the structure of the mobile device casing, the machine cycle time and cost when finishing the mobile device casing is significantly reduced. Furthermore, the thin wall thickness reduces the total weight of the mobile device casing and thus the weight of the resulting mobile device. In the embodiment, 3000, 5000, 6000, and 7000 series aluminum or stainless steel is used in the forging process described in this specification, and has superior rigidity and tensile strength compared to a casing formed by a conventional method. A mobile device casing with strength and granular structure will be provided.

  FIG. 1A illustrates one embodiment of a system 100 for progressively forging a mobile device casing having one or more three-dimensional features within at least one cavity of the mobile device casing. In one embodiment, the system 100 performs one or more forging operations at room temperature (cold forging) in various press forging stages (eg, stages 120-1 to 120-N). Performing a gradual forging operation using the system shown in FIG. 1A reduces non-uniform stress strain in the forged mobile device casing and can utilize an aluminum alloy with a tempering degree of 4 and below. . In addition, when the uniform hardness of the mobile device casing is part of the final product design, a solution heat treatment and subsequent artificial aging can be performed on that part after any of the steps shown in FIG. 1A. it can.

  In one embodiment, the extruded metal sheet 110 is progressively moved in a series of transfer molds over a series of progressive forging stages (eg, stages 120-1 through 120-N) to form the mobile device casing 150. It is formed. In embodiments, the formed mobile device casing 150 can be bowl-shaped, i-frame, or other form of mobile device casing. The press plate of the transfer mold performing the forging operation is coated with a titanium nitride (“TiN”) coating to increase its hardness and to extend its tool life as well as to improve forging efficiency. Or manufactured from high speed steel or carbide tool steel. In one embodiment, the TiN coating is periodically removed from the transfer mold machine (ie, approximately every 300,000 presses) and a new TiN coating is added to the forged press plate. In one embodiment, additional stamping operations, including cutting, puncturing, stamping, coining, or other suitable processes, in additional stages, including additional machine (not shown) to further form the mobile device casing. To be implemented. However, the final shape of the mobile device casing 150 and the three-dimensional features included therein are close to the final shape of the completed mobile device casing.

  With respect to one embodiment, the aluminum alloy, stainless steel, or other metallic material used to form the bowl-shaped mobile device casing can vary in various factors, such as design requirements, desirable material properties, mobile device casing Selection can be based on low contamination of raw materials (ie, contamination such as silicon, copper, zinc) and low natural magnetism of the mobile device casing. For one embodiment, an aluminum alloy in the form of an extruded sheet 110 is first used to provide a blank for forming a mobile device casing. The thickness and profile of the extruded sheet 110 may vary depending on the specific product design.

  The progressive mold assembly utilized to form the mobile device casing 150 by a series of progressive forging operations can include multiple stations from stages 120-1 to 120-N. To complete each of the multiple progressive forgings, the initial mobile device casing (eg, extruded sheet 110) is advanced from station to station. Each station can perform forging from more than one state, as well as other machining operations. Certain forging operations form parts within the mobile device casing, either partially or wholly, as the mobile device casing is advanced through a series of stages. A series of progressive forgings manage one or more of the mobile device casings at a particular stage to manage the material movement caused by the forging operation and ensure uniform thickness of the resulting fully formed mobile device casing 150. A specific part is formed either partially or entirely in the cavity. Further, the order of forging operations and formation of the different parts ensures that the three-dimensional features within one or more cavities of the mobile device casing are accurately and properly formed.

  In an embodiment, the internal stress of the formed mobile device casing can be removed by annealing. Annealing can be performed before the mobile phone housing is advanced to one or more forging die assembly stages. As discussed above, one or more of the progressive stages of forging are performed at room temperature, and annealing can be used between one or more stages of successive progressive steps. For example, a mobile device casing that is forged by successive gradual steps can be annealed every two steps, every third step, between selected steps, and the like. In one embodiment, annealing is performed by heating the forged mobile device casing to about 390 degrees Celsius and then allowing the housing to cool.

  In an embodiment, one or more of one or more of the mobile device casing wall height and / or three-dimensional feature height may be increased due to material malleability caused by work hardening during the cold forging process. Hot forging by preheating is used between the forging stages.

  FIG. 1B illustrates another embodiment 160 of a system 160 for forging a mobile device casing having one or more three-dimensional features formed in one or more cavities of the mobile device casing. . The system shown in FIG. 1B can be used when preheating of the partially formed mobile device casing is desired before one or more subsequent forging stages. As in the case described above, solid solution heat treatment followed by artificial aging can be used for the partially formed mobile device casing when the final product design requires a uniform hardness of the mobile device casing with respect to the aluminum case material. Heat treatment hardening and subsequent tempering can be used when uniform hardness is desired for the steel device mobile device casing by the final product design.

  As shown in FIG. 1B, a partially formed mobile device casing is formed between one or more of the forging stages 120-1, 120-2, 120-N up to one or more furnaces 140-1, 140-. To move up to 2,140-M, robots 130-1, 130-2, 130-P or other mechanical pick and place means are used. In an embodiment, these furnaces preheat the partially formed mobile device casing before moving back to the subsequent press forging stage. In one embodiment, the partially formed mobile device casing is heated to a predetermined temperature, such as 300 ° C. Furthermore, after the temperature reaches a predetermined temperature, the mobile device casing is held in the furnace for a minimum duration, such as 30-45 minutes, before being transferred back to the press forging stage. Since the partially formed mobile device casing is preheated prior to one or more subsequent forging operations, the side wall height and / or the height of the three-dimensional features within the one or more cavities can be increased over conventional approaches. It can be increased sufficiently.

  Since moving in and out of the furnace and various press forging stages (e.g. up to 120-2, 120-3, 120-N) is a time-critical operation, this movement can be done with a robot arm or other machine. Means. That is, in order to prevent heat loss during movement in and out of the furnace and the various press forging stages, this movement can be achieved for example under a maximum movement duration not longer than 8 seconds. Robot arms and / or other mechanical means are used. Next, the next forging operation is performed in the press next to the press forging stage. These forging operations can include partially or wholly forming existing or additional parts of the mobile device casing, as described herein.

  FIG. 2 shows a block diagram of a method 200 for progressively forging a mobile device casing having at least one three-dimensional feature formed in at least one cavity of the housing. The progressive mold assembly used in the method shown in FIG. 2 can include a plurality of stations, and the mobile device casing is advanced from station to station, optionally with one or more of a plurality of stages. Preheated between. The method includes performing a series of progressive forgings using the transfer mold assembly.

  The method begins by progressively feeding an initial blank for a mobile device casing to a first forging stage of a series of progressive forging stages to form a mobile device casing (block 202). A forging operation is then performed on the mobile device casing in a series of forging operations to progressively form a mobile device casing having one or more three-dimensional features in at least one cavity of the mobile device casing. (Block 204). As described herein, a series of progressive forging operations can be performed, and block 204 can be repeated any number of times corresponding to the number of different progressive forging operations. Further, as described herein, additional operations, such as preheating before one or more forging operations, annealing after forging, performing a solid solution heat treatment, etc., are included in the progressive forging stage. One or more before / after can be performed.

  After the gradual forging operation is complete, the mobile device casing can be moved to a finishing stage where the mobile device casing is finished (block 206). As described above, the steps of finishing the mobile device casing include cutting off excess material, punching, piercing, or drilling holes, performing one or more cleaning steps, coating steps, and others. Can include one or more of the following finishing operations.

  Although not illustrated, a finished mobile device casing having one or more three-dimensional features that are forged in one or more cavities of the casing is then another stage of the mobile device assembly process (e.g., Steps to install components such as displays, sensors, processors, input devices, cameras, etc. on the finished mobile device casing.

  FIG. 3A shows cross-sectional views of different stages of a gradual forging operation to form a bowl-shaped mobile device casing. The mobile device casing is referred to as a bowl shape because the mobile device includes a rounded sidewall and a cavity that comprises substantially all of the front surface of the mobile device casing. An initial flat rectangular sheet 302 of metal material (an extruded sheet of aluminum alloy or steel alloy) has an initial width 306 and an initial material thickness 304. The choice of material thickness and sheet profile depends on the specific design requirements of the finished bowl-shaped mobile device casing. Further, the sequence of forging operations and the formation of various parts (eg, three-dimensional features) ensures that the intricate details of the mobile device casing are properly formed.

  A forging operation is performed on the initial sheet 302 to obtain a partially formed bowl-shaped mobile device case 310. The first forging stage raises the side wall height from thickness 304 to height 312 and reduces both plate thickness 314 and full width 316. After the second forging stage, the partially formed bowl-shaped mobile device case 320 further lifts the side wall height 322 and one or more three-dimensional features 328 in the cavity in the front of the mobile device casing, while simultaneously Both 324 and width 326 are supplied to a mold that also reduces. As described herein, plastic deformation is used to displace the material during subsequent progressive forging stages. Then, after the third forging stage, a fully formed bowl-shaped mobile device casing 330 is formed, the side wall height 322 and the three-dimensional feature height 338 are increased, while the casing 330 width 336 and plate thickness 334 are increased. Is reduced. In an embodiment, the three-dimensional features need not have the same height as the sidewalls, and each three-dimensional feature has a different height specified by one or more design constraints of the finished mobile device casing. be able to.

  FIG. 3B shows one embodiment of a front view of a fully formed bowl-shaped mobile device casing 350. A section line X-X 340 of the formed mobile device casing 330 is shown in the front view of the casing 350, which also has a width 336 and a height 358. In addition, section line X-X340 shows the three-dimensional feature of FIG. 3C that can include additional three-dimensional features 360 and other features in the front cavity of the bowl-shaped mobile device casing. In an embodiment, in order to give the casing a bowl-shaped appearance, the side wall 354 of the bowl-shaped mobile device casing is formed to be curved during a gradual forging operation. FIG. 3D shows the wall height 370 of the fully formed bowl-shaped mobile device casing.

  FIG. 4A shows cross-sectional views of different stages of a gradual forging operation to form an i-frame mobile device casing. Similar to FIG. 3A described above, an initial flat rectangular sheet 402 of metal material (an extruded sheet of aluminum or steel alloy) has an initial width 406 and an initial material thickness 404. As discussed above, the choice of material thickness and sheet profile depends on the specific design requirements of the finished i-frame mobile device casing. Furthermore, the order of forging operations and formation of different parts (eg, three-dimensional features) ensures that the intricate details of the mobile device casing are properly formed.

  After a first forging operation in a series of progressive forging stages, a partially formed i-frame mobile device case 410 having a sidewall height raised from an initial sheet thickness 404 to a sidewall height 412 is formed. Further, the other thickness of the plate is reduced to thickness 418 and thickness 413. Other material transfer and forging operations result in a three-dimensional feature having a height 414 and the plate width is increased to width 416.

  After a second forging operation in a series of forging stages, the sidewall height is reduced to height 421, both reduced plate thicknesses 423 and 424, increased feature height 422, and width 426 are increased. A partially formed i-frame mobile device casing 420 is further formed that includes a width. As in FIG. 3A, plastic deformation techniques are used to displace the material and manage material movement through the progressive forging stage to achieve the desired and / or uniform thickness of the fully formed mobile device casing. The

  The i-frame mobile device casing 430 is then completely formed after a third forging operation in a series of forging stages. In particular, the height of the side wall is increased to a height 431, the height of the three-dimensional feature is increased to a height 432, the overall width of the casing is increased to a width 436, the plate thickness is reduced to a thickness 433, Nearby features are formed. As described above, the three-dimensional features need not have the same height, but can have different heights based on one or more design requirements. FIG. 4B illustrates a fully formed i-frame mobile device casing 450 having a width 436, height 408, and one or more three-dimensional features formed in a cavity on the front and / or back side of the mobile device casing. Fig. 4 shows an embodiment of the front view.

  In one embodiment, the front and / or back side of either the bowl-shaped mobile device casing or the i-frame mobile device casing has a honeycomb cell feature with an additional forging operation performed on the fully formed mobile device casing. Can be added / formed. FIG. 10A illustrates one embodiment of a front view of a progressively forged mobile device casing 1000 having a width 1002 and a length 1004 and further having a honeycomb feature in at least the region 1010. One or more honeycomb features can be formed on other regions of the mobile device casing 1000 without conflicting with the discussion herein. In an embodiment, the honeycomb feature 1010 is forged into at least a portion of the mobile device casing cavity, a portion of the sidewall, a portion of the back side, and the like. The addition of honeycomb cell features increases the rigidity and robustness of the formed mobile device casing. FIG. 10B shows an enlarged view 1014 of the honeycomb feature 1010 formed near the side wall 1012 of the mobile device casing. FIG. 10C shows another enlarged view including one embodiment of dimension 1020 for the honeycomb feature along section AA of FIG. 10A. FIG. 10D shows a cross-sectional view of one embodiment of a honeycomb feature including the relative height and depth of the honeycomb feature thickness and plate thickness. The specific dimensions such as cell spacing, depth, and volume shown in FIGS. 10C and 10D are exemplary and are expressed in relative sizes of these respective dimensions to meet various design requirements. Can be changed based on. In addition, although FIGs. 10B-10D show hexagonal cell shape details, cell features that are forged into mobile device casings to increase strength and rigidity of other dimensions and shapes, such as circles, octagons, etc. Can be used as a part. Furthermore, the addition of honeycomb features through a forging operation in a series of gradual forgings increases the cost, quality control issues, and commercial costs of producing such features using die casting or machining methods. Without having infeasibility, honeycomb cell features can be added to the front and / or back side of the mobile device casing with high accuracy and accuracy.

  As described herein, a progressive forging operation is utilized to form a bowl-shaped mobile device casing or i-frame mobile device casing, such as the cellular telephone casing shown in FIGS. 3B-3D and 4B. Can do. However, the techniques described herein can be used to form other mobile device casings with forged three-dimensional features within at least one cavity of the mobile device casing. 5A and 5B illustrate a front view and a back view 550 of a progressively forged tablet / fablet casing 500 (eg, having a larger dimension than a mobile phone casing) in one embodiment. Similar to the mobile phone casing, the tablet / fablet casing 500 has rounded side walls 502 and 552 and a plurality of three-dimensional features 504 that are forged within the cavity of the tablet / fablet casing 500.

  In another embodiment, an inner view 600 and an outer view 650 of a progressively forged laptop body computer casing having rounded sidewalls 602 and 652 and a three-dimensional feature 604 are shown in FIGS. 6A and 6B. Similarly, FIGS. 7A and 7B show a laptop computer casing for the display. The interior view 700 includes a three-dimensional feature 704 and a rounded sidewall 702, while the exterior view 750 also has a rounded sidewall. FIGS. 8A and 8B illustrate another embodiment of a progressively forged laptop body computer casing 800 for a keyboard having rounded sidewalls 802 and 852 and a three-dimensional feature 804.

  In yet another embodiment, FIG. 9A shows the front side of a progressively forged i-frame mobile device casing 900 for a tablet computer or a fablet computer device. The housing 900 includes a three-dimensional feature 904 formed in at least a first cavity of the mobile device casing 900. The i-frame mobile device casing 900 has an i-frame body (eg, similar to FIG. 4B) and includes a rounded sidewall 902 around the periphery of the mobile device casing 900. FIG. 9B shows a perspective view of the back side of a progressively forged i-frame mobile device casing having additional three-dimensional features 954 formed in a second cavity on the back side of the housing 950 and a side wall 902 around the periphery of the housing. FIG. 950 is shown.

  In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be apparent, however, that various modifications and changes can be made to these embodiments without departing from the spirit and scope of the described invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

100 System for progressively forging mobile device casing 110 Extruded metal sheet 120-1, 120-N Progressive press forging stage 150 Forming mobile device casing

Claims (21)

A method of progressively forging a mobile device casing,
Progressively feeding the initial mobile device casing cut from the extruded sheet through multiple stations of the transfer mold assembly;
A series of forgings is performed on the initial mobile device casing to progressively form a mobile device casing having at least one three-dimensional feature formed in at least one cavity of the progressively formed mobile device casing. The stage of execution,
A method comprising the steps of:   The progressively formed mobile device casing has a cavity formed in the front side of the bowl-shaped mobile device casing, and one or more three-dimensional features are forged in the front cavity of the bowl-shaped mobile device casing. The method of claim 1 including a bowl-shaped mobile device casing having rounded sidewalls. Performing the series of forgings on the initial mobile device casing progressively forms the bowl-shaped mobile device casing;
Performing a first forging operation in said series of forging stages to form a first partially formed bowl-shaped mobile device casing comprising at least raising the sidewall height, reducing the plate thickness, and reducing the casing width; ,
Further raising at least the side wall height, raising the height of at least one three-dimensional feature in the front cavity of the second partially formed bowl-shaped mobile device casing, further reducing the plate thickness, and reducing the casing width Performing a second forging operation in the series of forging stages to form a second partially formed bowl-shaped mobile device casing including further reducing;
Further lifting at least the side wall height to a final side wall height, further raising the height of the at least one three-dimensional feature in the front cavity of the fully formed bowl-shaped mobile device casing to a final feature height; Performing a third forging operation in the series of forging stages to completely form the bowl-shaped mobile device casing including the steps of further reducing the thickness to a final plate thickness and further reducing the casing width to the final casing width. When,
The method of claim 2, further comprising:   The progressively formed mobile device casing has cavities formed in the front and back sides of the i-frame mobile device casing, and at least one three-dimensional feature is forged in the front cavity of the i-frame mobile device casing. The method of claim 1 including an i-frame mobile device casing that is forged with at least one three-dimensional feature in the cavity on the back side. Performing the series of forgings on the initial mobile device casing progressively forms the i-frame mobile device casing;
A first part comprising raising at least the side wall height, raising the height of at least one three-dimensional feature in the front cavity of the first part-forming i-frame mobile device casing and increasing the casing width; Performing a first forging operation in the series of forging stages to form a formed i-frame mobile device casing;
Further lifting at least the sidewall height to reduce one or more regions of plate thickness and the height of the at least one three-dimensional feature in the cavity on the front side of a second partially formed i-frame mobile device casing. Performing a second forging operation in the series of forging stages to form a second partially formed i-frame mobile device casing comprising further raising the height and further increasing the casing width;
Further lifting at least the sidewall height to a final sidewall height, further lifting the height of the at least one three-dimensional feature in the front cavity to a final feature height, and the one or more regions of plate thickness And further increasing the casing width to a final casing width and forming at least one three-dimensional feature near at least one sidewall of a fully formed i-frame mobile device casing. Performing a third forging operation in the series of forging stages to completely form a device casing;
The method of claim 4, further comprising: Performing the series of forgings on the initial mobile device casing comprises:
A forging operation is performed on the progressively formed mobile device casing to form a honeycomb cell feature on at least a portion of the progressively formed mobile device casing front side, backside, sidewall, or combination thereof. Stage,
Further including
The method according to claim 1. Performing the series of forgings on the initial mobile device casing comprises:
Annealing the mobile device casing after one or more stages in the series of forgings;
Further including
The method according to claim 1.   The method of claim 1, wherein one or more stages in the series of forgings are performed at room temperature.   A solid solution heat treatment and subsequent artificial aging is applied to the partially formed mobile device casing after the one or more stages are performed at room temperature to obtain a uniform hardness of the formed mobile device casing. The method according to claim 8.   The one or more stages in the series of forgings include preheating the partially formed mobile device casing to a predetermined temperature for a minimum duration before performing a forging operation. The method described.   The heat-treatment curing and subsequent tempering, including a preheating step to obtain a uniform hardness of the formed mobile device casing, is applied to the partially formed mobile device casing after the one or more steps. 10. The method according to 10.   The method of claim 1, wherein a press plate of a station of the transfer mold assembly that performs the forging operation is coated with titanium nitride.   The method of claim 1, wherein the mobile device casing is formed from an aluminum alloy.   The method of claim 1, wherein the mobile device casing is formed from a steel alloy.   The mobile device casing includes one of a mobile phone housing, a fablet computer housing, a tablet computer housing, a laptop monitor housing, a laptop body housing, or a laptop keyboard housing. The method according to claim 1. An apparatus for progressively forging a mobile device casing,
A transfer mold assembly for progressively feeding an initial mobile device casing cut from the extruded sheet through a plurality of stations of the transfer mold assembly;
A series of forgings is performed on the initial mobile device casing to progressively form a mobile device casing having at least one three-dimensional feature formed in at least one cavity of the progressively formed mobile device casing. A plurality of stations from the plurality of stations to perform;
The apparatus characterized by including.   The progressively formed mobile device casing has a cavity formed in the front side of the bowl-shaped mobile device casing, and one or more three-dimensional features are forged in the front cavity of the bowl-shaped mobile device casing. The apparatus of claim 16, comprising a bowl-shaped mobile device casing having rounded side walls. The series of forgings performed by the plurality of stations on the initial mobile device casing progressively forms the bowl-shaped mobile device casing;
First forging in said series of forging stages forming a first partially formed bowl shaped mobile device casing, wherein the first forging station includes raising at least the sidewall height, reducing the plate thickness, and reducing the casing width. A first forging station performing the operation;
A second forging station further raises at least the side wall height to raise the height of at least one three-dimensional feature in the front cavity of the second partially formed bowl-shaped mobile device casing to further reduce the plate thickness. And a second forging station for performing a second forging operation in the series of forging stages forming a second partially formed bowl-shaped mobile device casing comprising further reducing the casing width;
A third forging station further raises at least the side wall height to the final side wall height, and determines the height of the at least one three-dimensional feature in the front cavity of the fully formed bowl-shaped mobile device casing to a final feature height. A third in the series of forging stages to completely form the bowl-shaped mobile device casing including further lifting to a final thickness, further reducing the plate thickness to a final plate thickness, and further reducing the casing width to a final casing width. A third forging station for performing the forging operation of
The apparatus of claim 17, further comprising:   The progressively formed mobile device casing has cavities formed in the front and back sides of the i-frame mobile device casing, and at least one three-dimensional feature is forged in the front cavity of the i-frame mobile device casing. The apparatus of claim 16, further comprising an i-frame mobile device casing forged with at least one three-dimensional feature in the cavity on the back side. The series of forgings performed by the plurality of stations on the initial mobile device casing progressively forms the i-frame mobile device casing;
A first forging stage raises at least the sidewall height, raises the height of at least one three-dimensional feature in the cavity on the front side of the first partially formed i-frame mobile device casing, and increases the casing width; A first forging stage for performing a first forging operation in the series of forging stages forming a first partially formed i-frame mobile device casing comprising:
A second forging stage further raises at least the sidewall height, reduces one or more regions of plate thickness, and the at least one 3 in the cavity on the front side of a second partially formed i-frame mobile device casing. Performing a second forging operation in the series of forging stages forming a second partially formed i-frame mobile device casing comprising further raising the height of the dimension feature and further increasing the casing width. A second forging stage;
A third forging stage further lifts at least the sidewall height to a final sidewall height, further lifts the height of the at least one three-dimensional feature in the front cavity to a final feature height, and Further reducing one or more regions, further increasing the casing width to the final casing width, and forming at least one three-dimensional feature near at least one sidewall of the fully formed i-frame mobile device casing. A third forging stage for performing a third forging operation in the series of forging stages to completely form the i-frame mobile device casing comprising:
20. The apparatus of claim 19, further comprising:   The mobile device casing includes one of a mobile phone housing, a fablet computer housing, a tablet computer housing, a laptop monitor housing, a laptop body housing, or a laptop keyboard housing. The apparatus according to claim 16.