TW201414597A - Method of manufacturing a workpiece with multiple metal layers - Google Patents

Abstract

A method of manufacturing a workpiece with multiple metal layers is disclosed as including steps (a) providing a mold with at least a runner 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 which is roughened and/or includes an 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 in which the second metal layer engages with the roughened surface of the first metal layer or with the engagement structure of the surface of the first metal layer, and the molten second metal enters the cavity of the mold at a speed of at least 70 metres per second (m/s).

Description

Method of manufacturing a workpiece having a multilayer metal layer

This application is a continuation-in-part of U.S. Patent Application Serial No. 13/651,980, filed on Oct. 15, 2012, which is filed on October 20, 2011. Part of the continuation of U.S. Patent Application Serial No. 13/277,673, the entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire entire content

The present invention relates to a method of making a workpiece having a plurality of layers of metal, such as a sheet. For the purposes of the present invention, the terms "metal" and "majority metal" are used herein to also include "metal alloys" and "alloys of most metals." It should also be understood that for the purposes of the present invention, the metal layers may be comprised of one or the same metal.

With the rapid development of the communications, consumer electronics and computer industries (also known as the "3C industry"), consumers are not only looking forward to the good performance of these products (also known as "3C products") (such as processing speed and storage capacity) And look forward to one of these products' advanced and durable beauty surfaces. Therefore, a metal housing with good strength and light weight will become more and more important for 3C products. These characteristics have also become, for example, in the home industry and other industries in the automotive industry. Consumer demand or expectation of the product. In most products, it is necessary to overmolding at least one layer on another metal layer, for example, to form a cover or a plate. There is therefore a need to improve the bond or bond strength between two metal layers that has become an important product requirement.

One of the electronic manufacturers is known that the color plastic case is easily broken and damaged by external impact, and one of the single metal layers may be rusted due to environmental factors or may not be on the case due to limitations of material properties. Subsequent surface treatment is implemented. Therefore, a housing having a multilayer metal layer having a thin thickness, good cosmetic performance, good strength against external impact, and good corrosion resistance is required to solve various disadvantages of a single metal layer casing. In the prior art, a housing for a consumer electronic device formed from a bimetallic layer or a mechanical laminate of a material is often produced by vacuum evaporation or ion sputtering at high manufacturing costs. However, since the conventional housing is intended to accept surface treatment including wet procedures, such as plating and anodizing, it is less resistant to corrosion.

In the prior art, solid state welding procedures (e.g., cold welding, friction welding, and ultrasonic welding) can be used to bond a thin plate to a cast metal part. However, this solid state welding procedure can significantly increase the complexity and cost of the process. Accordingly, those of ordinary skill in the art of the invention are still seeking an effective method of manufacturing a workpiece having multiple layers of metal layers at a lower cost and less complex.

In addition, electronic products (such as tablet PCs and smart mobile phones) and home appliances are constantly being required to be as compact and small as possible. Consumers have the same requirements for the automotive industry and the household products industry. Consumers are in the same There is an increasing demand for the functionality and capabilities of these products. Manufacturers are therefore seeking to manufacture the bodies of such products as tightly as possible while maintaining various methods for accommodating sufficient space for the necessary components. Existing methods do not allow a thin metal layer to be injected into a metal layer and bond/bond the metal layer to form a multilayer metal layer workpiece. In addition, as these products become more compact and finer, problems arise in, for example, the refurbishment required to achieve the necessary features and the processing of computer numerical control (CNC) work.

As these products become more compact and finer, problems occur in the handling of workpieces such as covers, outer casings, casings and supports, as the post-treatment will exert on the workpieces that would deform the workpieces The pressure.

It is therefore an object of the present invention to provide a method of fabricating a workpiece having a plurality of metal layers, one of the molds and a workpiece having a plurality of metal layers, or at least one useful alternative to the commercial and public.

According to a first aspect of the present invention, there is provided a method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a mold having at least a first pass, a gate, and a cavity; (b) Providing a first metal layer composed of a first metal in a cavity of the mold, the first metal layer having a surface that is roughened and/or includes at least one joint structure; and (c) a A molten second metal is injected on the surface of the first metal layer to form a second metal layer on the first metal layer, wherein the roughened surface of the second metal layer and the first metal layer or The joining structure of the surface of the first metal layer is joined, wherein the molten second metal enters the cavity of the mold at a rate of substantially at least 70 meters per second (m/s).

According to a second aspect of the present invention, a mold includes a first mold member and a second mold member, wherein the first mold member and the second mold member are at the first mold member and the second mold member The modules are separated from each other in an open configuration and are used to move the half-finished workpiece between the first module and the second module in a closed configuration relative to each other, and wherein at least the first module Included as a wall member, and when the mold is in the closed configuration and holds half of the workpiece, the wall member is pressed into at least a portion of the semi-finished workpiece to form a gap between the wall member and the semi-finished workpiece Sealed and the seal prevents a fluid from flowing through the seal.

According to a third aspect of the present invention, a workpiece having a plurality of metal layers formed by injecting at least one second metal layer onto a first metal layer, wherein the first metal layer and the second metal layer are provided Each of the metal layers includes at least one bonding structure.

According to a fourth aspect of the present invention, a mold includes a first mold member and a second mold member, wherein the first mold member and the second mold member are at the first mold member and the second mold member The modules are separated from each other in an open configuration, and are engaged with the first module and the second module to form a relative movement between one of the mold cavities for accommodating one of the ones of the workpieces, wherein the first A mold member includes a passageway that allows molding material to be supplied into the mold cavity, and wherein the mold does not have a passage for allowing molding material to flow out of the mold cavity.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a first metal layer composed of a first metal; (b) pretreating the a first metal layer; (c) placing the pretreated first metal layer in a mold; and (d) a melting A molten second metal is injected on the surface of the pretreated first metal layer to form a second metal layer on the pretreated first metal layer.

According to a sixth aspect of the present invention, a workpiece having a plurality of metal layers is formed by injecting at least one second metal layer onto a first metal layer, wherein the second metal layer has a substantial Thickness of 0.5mm.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a mold having at least a first pass, a gate, and a cavity; (b) Providing a first metal layer composed of a first metal, the first metal layer having a surface comprising at least one bonding structure; (c) pre-treating the first metal layer; (d) pre-treating the first metal layer a metal layer is placed in the mold; and (e) a molten second metal is injected onto the surface of the pretreated first metal layer to form a second metal layer on the pretreated first metal layer, wherein The molten second metal enters the cavity of the mold at a rate of at least substantially 70 meters per second (m/s), wherein the second metal layer includes the bond to the surface of the pretreated first metal layer At least one engagement structure that is structurally joined, wherein the mold includes a first mold member and a second mold member, wherein the first mold member and the second mold member are mutually engageable between the first mold member and the second mold member Separating one of the open configurations, interfacing with the first module and the second module To move relative to each other in a closed configuration state for accommodating the pretreated first metal layer, wherein the first mold member includes a passage permitting supply of the molten second metal, and wherein the mold does not allow the melting The second metal flows out of the passage of the cavity.

According to an eighth aspect of the present invention, a multi-layered gold is provided a workpiece of a layer, the workpiece being formed by a method, and the method comprising the steps of: (a) providing a mold having at least a first pass, a gate and a cavity; (b) providing a first metal a first metal layer having a surface comprising at least one bonding structure; (c) pre-treating the first metal layer; (d) placing the pre-treated first metal layer in the mold And (e) injecting a molten second metal onto the surface of the pretreated first metal layer to form a second metal layer on the pretreated first metal layer, wherein the molten second metal is Entering the cavity of the mold at a velocity of at least 70 meters per second (m/s), wherein the second metal layer includes at least one bonding structure joined to the bonding structure of the surface of the pretreated first metal layer The mold includes a first module and a second module, wherein the first module and the second module are separated from each other by the first module and the second module. Interfacing with the first module and the second module to form a first gold for preserving the pretreatment One of the sub-layers is in a relative movement relative to each other, wherein the first module includes a passage permitting supply of the molten second metal, and wherein the mold does not have a passage permitting the molten second metal to flow out of the cavity.

201,401‧‧‧ devices

202,610,810,910,910',1100‧‧‧Mold

203‧‧‧ cover (first metal layer)

204,404,614,814,914,914',1116,1206‧‧‧second metal layer

205‧‧‧ Pressurized components

206‧‧‧ overflow hole

207,407‧‧‧Mold mold

208‧‧‧Former mold

402‧‧‧First front mold

403‧‧‧First metal layer

405‧‧‧ Pressurized components

406‧‧‧ overflow hole

408‧‧‧Second front mold

612,812,912,912'‧‧‧ semi-finished board

613,913b‧‧‧ surface

813, 913a, 913a'‧‧‧ joint structure

1102‧‧‧Upper mold

1104‧‧‧ wall

1106‧‧‧ Lower mold

1108‧‧‧Semi-finished board; semi-finished metal sheet

1110‧‧‧ Space

1112‧‧‧ hook

1114‧‧‧ upper surface

1200‧‧‧ semi-finished board; first metal layer

1202‧‧‧ Groove

1204‧‧‧ upper surface

1208‧‧‧Threaded bulge

1210‧‧‧Mechanical and structural components

1302‧‧‧ Cover

1304‧‧‧ Groove; thin section

1306‧‧‧Shaded area

2041‧‧‧Liquid second metal

4031‧‧‧Liquid first metal

4041‧‧‧Liquid second metal

A, B, C‧‧ points

D‧‧‧thickness

D‧‧‧depth

S101, S102‧‧‧ steps

S301, S302‧‧‧ steps

S501, S502‧‧‧ steps

S701, S702‧‧‧ steps

1 shows a method of fabricating a workpiece having a plurality of metal layers in accordance with one embodiment of the present invention; and FIG. 2-1 shows a device for fabricating a workpiece having a plurality of metal layers in one of the methods illustrated in FIG. One of the devices is in an open configuration; Figure 2-2 shows the device shown in Figure 2-1, wherein the mold is in a closed configuration; 2-3 is a partial enlarged view of the mold shown in FIG. 2-2; FIG. 3 shows a method of manufacturing a workpiece having a plurality of metal layers according to another embodiment of the present invention; FIG. 4 is a view for implementing FIG. One of the methods shown produces a mold having a workpiece of a plurality of metal layers; and FIG. 5 shows a method of manufacturing a workpiece having a plurality of metal layers in accordance with still another embodiment of the present invention; FIG. 6 is shown in the method of FIG. One of the workpieces having a plurality of metal layers; FIG. 7 shows a method of manufacturing a workpiece having a plurality of metal layers in accordance with still another embodiment of the present invention; and FIG. 8 is a view showing one of the steps of FIG. The first workpiece; FIG. 9A shows a second workpiece having a plurality of metal layers by the method shown in FIG. 7; FIG. 9B shows a third workpiece having a plurality of metal layers manufactured by the method shown in FIG. 7; FIG. 10C shows a procedure in a method according to another embodiment of the invention whereby a liquid second metal is injected into a mold to bond or bond a first metal layer; FIG. 11 is suitable for use in accordance with one of the methods of the present invention Cross section of another mold ; FIG. 12 is a partial cross-sectional view of a first metal layer after bonding with a second metal layer of FIG. 11; Figure 13 is a first metal layer in accordance with yet another embodiment of the present invention after pretreatment and ready to inject a molten second metal; Figure 14A is one of the multilayer metal layers including the first metal layer of Figure 13 FIG. 14B is a partial enlarged view of FIG. 14A; and FIG. 15 is a portion of a cover of a plurality of metal layers having a thin bay covered by a second metal layer. Top view.

Figure 1 shows a method of making a workpiece having a plurality of metal layers in accordance with the present invention. In general, in this method, a first metal layer of one of the semi-finished plate forms formed by a first metal is placed in a mold. A liquid (melted) second metal is then injected into the mold and on the plate to form a second metal layer on the first metal layer (S101). A second metal layer in the mold is then pressurized (S102) in the mold to bond the second metal layer to the first metal layer. It should of course be understood that a liquid third metal (which may be the same as or different from the first and second metals) may be injected onto the first metal layer or the second metal layer to form a A workpiece of a layer of metal.

The injection operation includes many different characteristics such as high pressure and high speed injection molding, watering and/or flow. The pressure and the velocity of the second metal injected into the mold and the short time that the second metal covers the first metal layer help to improve the adhesion and bonding strength between the first metal layer and the second metal layer. Removing the bubbles in the second metal in a liquid state and improving the compactness of the second metal layer such that after cooling and solidifying the second metal layer Only a very small amount of porosity is left, thus achieving the strength of a composite metal. This also prevents the formation of first-class marks due to the flow of the liquid second metal at the time of injection. Pressurizing the second metal layer also causes an excess liquid second metal to overflow.

Figures 2-1 and 2-2 show an apparatus 201 for implementing one of the methods illustrated in Figure 1 for fabricating a workpiece of a multilayer metal layer. The device 201 includes a mold 202 having a front mold 208 and a rear mold 207. The mold 202 is shown in an open configuration in Figure 2-1, wherein the front mold 208 and the rear mold 207 are separated from one another. A semi-finished metal cover 203 (constituting a first metal layer) composed of a first metal is disposed on the mold 207 after the mold 202. 2-2 shows the mold 202 in a closed configuration wherein the semi-finished cover 203 is held between the front mold 208 and the back mold 207. When the mold 202 is in the closed configuration, a liquid second metal 2041 (a metal different from the first metal layer 203) is injected into the half-finished cover 203 of the mold 202 so as to be in the cover. A second metal layer 204 is formed on 203.

2-3 is a partial enlarged view of FIG. 2-2 and shows that the mold 202 includes a pressure applied to the second metal layer 204 in the mold 202.

In another embodiment, a space is provided between the rear mold 207 and the pressurizing assembly 205 such that the liquid second metal 2041 can be injected into the space. In addition, the mold 202 additionally includes an overflow hole 206 such that when the pressurizing assembly 205 pressurizes the second metal layer 204, an excess liquid second metal 2041 overflows through the overflow hole 206.

In the foregoing description, although it is mentioned that the first metal is different from the second metal, it is of course foreseeable that the first metal layer and the second metal layer may be composed of a same metal.

In still another embodiment of the present invention, and as shown in FIG. 3, a method of manufacturing a workpiece having a plurality of metal layers includes the steps of: injecting a liquid first metal into one of the mating molds and a first a space between one of the front molds to form a first metal layer on the rear mold (S301); and when the rear mold and a second front mold cooperate with each other and when on the rear mold A metal layer is in a half solid state, and a liquid second metal is injected onto the first metal layer to form a second metal layer on the first metal layer (S302). Also, the first metal layer and the second metal layer may be composed of the same or different metals.

The difference between the method shown in FIG. 3 and the method shown in FIG. 1 is mainly that, in the method shown in FIG. 3, the liquid second metal is injected onto the first metal layer and the second metal The layer is formed while the first metal layer is still in a semi-solid molten state. This not only increases the adhesion between the first metal layer and the second metal layer, but also reduces cost and saves time, thus increasing yield.

A device 401 for implementing the method illustrated in Figure 3 is shown in Figure 4. As shown in FIG. 4, the device 401 includes a first front mold 402, and the first front mold 402 can cooperate with a rear mold 407, and a liquid first metal 4031 is injected on the rear mold 407 so that A first metal layer 403 is formed on the rear mold 407. The device 401 also includes a second front mold 408, and the second front mold 408 can cooperate with the rear mold 407 to inject a liquid second metal 4041 while the first metal layer 403 is still in a semi-solid molten state. The first metal layer 403 is formed to form a second metal layer 404 on the first metal layer 403.

When the second front mold 408 and the rear mold 407 are cooperatively engaged, a space is provided between the rear mold 407 and a pressurizing assembly 405 so that the liquid second metal 4041 can be injected into the space.

Additionally, the pressurizing assembly 405 in the second front mold 408 can be used to apply a pressure on the second metal layer 404. Moreover, the rear mold 407 further includes an overflow hole 406 such that an excess liquid second metal 4031 can overflow through the overflow hole when the pressurizing assembly 405 applies a pressure on the second metal layer 404. 406.

The device 401 further includes a moving assembly for relatively moving the rear mold 407 between the first front mold 402 and the second front mold 408. For example, after injecting the liquid first metal 4031, the rear mold 407 can be moved from the first front mold 402 to the second front mold 408; or after injecting the liquid first metal 4031, the first front The mold 402 is removed and the second front mold 408 is moved to a position where it cooperates with the rear mold 407 to inject the liquid second metal 4041 onto the first metal layer 403. With this configuration, the injection of the liquid first metal 4031 and the liquid second metal 4041 are all performed in the same device 401, thus simplifying the manufacturing process.

A workpiece having three or more layers may be formed by repeating the above steps.

The metal layers of the first metal layer and the second metal layer may be formed of stainless steel, iron, zinc, aluminum, magnesium, chromium, titanium, copper, ruthenium, nickel, and alloys of these metals. A first metal layer having a smaller specific gravity may be formed first, followed by forming a second metal layer having a larger specific gravity. Alternatively, a first metal layer having a larger specific gravity may be formed first, followed by forming one One of the smaller specific gravity of the second metal layer. For example, if the first metal layer is formed of a zinc alloy and the second metal layer is formed of an aluminum alloy, a composite metal strength can be achieved and can be on the second metal (aluminum alloy) layer. A subsequent anodized surface treatment is performed. 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, such that subsequent processing such as direct current plating or vacuum evaporation can be performed on the second metal. One of the layers is conveniently implemented on the surface, thus further forming a subsequent metal or non-metal layer.

A workpiece having a plurality of metal layers not only manufactured according to one of the methods of the present invention has the strength and elasticity of a composite metal, and may be subjected to subsequent surface treatment (for example, heat treatment, anodized surface treatment, galvanic plating, etc.) on the metal workpiece as needed. Vacuum coating/film processing, coating treatment, coating treatment, and corrosion-resistant treatment) to further increase the adhesion between the metal layers, the strength and corrosion resistance of the workpiece, and the formation of the workpieces The design of the cover is more flexible.

In accordance with yet another embodiment of the present invention, a method of fabricating a workpiece having multiple layers of metal layers is shown in FIG. The method shown in Fig. 5 includes a step of placing a half-finished metal workpiece (e.g., a plate formed of a first metal layer) in a mold, wherein the surface of one of the finished workpieces is roughened (S501). Next, a liquid second metal is injected onto the roughened surface of the semi-finished workpiece to form a second metal layer on the semi-finished plate, wherein the liquid second metal covers and fills the rough of the semi-finished plate Surface (S502). The roughened surface of the semi-finished sheet may be formed on one of the cosmetic or inner surfaces of the semi-finished panel. A liquid third metal may be injected on the second metal layer to borrow Repeat the above operation to form a three-layer metal plate.

Figure 6 shows a panel having a plurality of metal layers produced by the method shown in Figure 5. As shown in FIG. 6, a semi-finished plate 612 formed of a first metal is placed in a mold 610. One surface 613 of the semi-finished plate 612 is roughened. A liquid second metal is injected onto the roughened surface 613 of the semi-finished plate 612 to form a second metal layer on the semi-finished plate 612 that is sufficiently covered and fills the roughened surface 613 of the semi-finished plate 612. 614. This configuration increases the adhesion strength between the semi-finished plate 612 and the second metal layer 614. The semi-finished plate 612 and the second metal layer 614 may be composed of the same metal or different metals. The roughened surface 613 of the semi-finished plate 612 can be formed by a combination of a plurality of recesses, holes, grooves, balls or protrusions, or the like. The roughened surface 613 of the semi-finished plate 612 can be formed mechanically and/or chemically. With this configuration, at least the semi-finished board 612 and the second metal layer 614 are prevented from being separated from each other.

Figure 7 shows a method of yet another embodiment of the present invention. The method includes placing a semi-finished plate formed of a first metal in a mold, wherein one surface of the semi-finished plate has at least one joint structure (S701), and a liquid second metal is injected into the semi-finished plate Surfacely, a second metal layer is formed on the semi-finished plate, wherein the liquid second metal covers, fills, and bonds the bonding structure on the surface of the semi-finished plate (S702). The engagement structure of the semi-finished sheet may be formed on one of the cosmetic surfaces or an inner surface of the semi-finished panel. A liquid third metal may be injected onto the second metal layer to form a three layer metal sheet by repeating the operation.

Figure 8 shows a panel having a plurality of metal layers produced in accordance with the method illustrated in Figure 7. As shown in Figure 8, it will be completed by a first metal. Plate 812 is placed in a mold 810. One surface of the semi-finished plate 812 is formed with at least one joint structure 813. The joint structure 813 can be a hook, a buckle, a groove, a protrusion, a groove or a combination of these structures. A liquid second metal is injected onto the semi-finished plate 812 to form a joint structure 813 on the semi-finished plate 812 that is sufficiently covered, filled, and joined to the surface of the semi-finished plate 812. With this configuration, at least a portion of the second metal layer 814 is confined to a space defined by the joint structure 813 to secure the semi-finished plate 812 with the second metal layer 814. This configuration prevents at least the semi-finished plate 812 from being separated from the second metal layer 814.

At the time of molding, the molten molding material (for example, a molten metal) is injected from an injection nozzle of a molding machine to flow through an injection port, then flows through a first pass, and then flows through a gate, and the molten mold The material enters the mold cavity of the mold through the gate. More specifically, an injection port allows passage of the molten molding material from the injection nozzle to the cavity. A first-class system is fluidly coupled to the injection port and directs the flow of molten molding material from the injection port to the cavity. The runner is engaged with the gate and the gate acts as an inlet, and the molten molding material in the runner enters the cavity through the inlet.

In order to further increase the bonding/bonding strength between the first metal layer and the second metal layer, in an embodiment of the invention, the liquid second metal is injected from the injection nozzle at a speed, and the speed causes the The liquid second metal exits the flow path through the gate of the mold at a rate of at least 70 meters per second (m/s) and enters the mold cavity of the mold. This speed will be referred to as the "gate speed". In one embodiment, to achieve a pre-gate velocity of 70 m/s, it is configured such that the liquid second metal leaves at a speed of at least 3.5 m/s. The injection port enters the flow channel. The following speed of the latter will be referred to as "outlet port speed".

Figure 9A shows a panel having a plurality of metal layers in accordance with one embodiment of the present invention. A semi-finished plate 912 formed of a first metal is first placed in a mold 910. One surface 913b of the semi-finished plate 912 is roughened to form a plurality of recesses, holes, grooves, balls and/or protrusions, and is in the form of a hook, a buckle, a trench, a protrusion, and/or a groove. At least one engagement structure 913a of the groove is also formed on the surface 913b. A liquid second metal is injected on the roughened surface 913b of the semi-finished plate 912 and the at least one joint structure 913a at a gate speed of at least 70 m/s to form a sufficient coverage on the semi-finished plate 912. Filling the roughened surface 913b and bonding the second metal layer 914 of the at least one bonding structure 913a of the semi-finished plate 912 to increase the bonding or bonding strength between the semi-finished plate 912 and the second metal layer 914 and The second metal layer 914 is confined within a space defined by the (equal) joint structure 913a.

Figure 9B shows a plate having multiple layers of metal layers in accordance with another embodiment of the present invention. A semi-finished plate 912' formed of a first metal is first placed in a mold 910'. One surface of the semi-finished plate 912' is formed with at least one engaging structure 913a' in the form of a hook, a buckle, a groove, a protrusion and/or a groove. A liquid second metal is injected on the joint structure 913a' of the semi-finished plate 912' at a gate speed of at least 70 m/s to form a sufficient covering, filling and joining on the semi-finished plate 912'. The second metal layer 914' of the bonding structure 913a' of the semi-finished board 912'. This configuration increases the bond or bond strength between the semi-finished plate 912' and the second metal layer 914' and limits the second metal layer 914' to a space defined by the (etc.) joint structure 913a' . more In detail, since the mutual engagement and/or interlocking between the second metal layer 914' and the joint structure 913a' prevents the semi-finished plate 912' and the second metal layer 914' from being separated from each other, the reinforcement is strengthened. Bonding or bonding between the semi-finished plate 912' and the second metal layer 914'. More specifically, it can be said that the semi-finished plate 912' and the second metal layer 914' each have at least one joint structure joined to each other.

The semi-finished plate (or the metal foil layer) and the second metal layer may be composed of the same metal or different metals, and the metal may be stainless steel, iron, zinc, aluminum, magnesium, chromium, titanium, copper, tantalum, nickel or Its alloy.

The roughened surface of the semi-finished sheet (i.e., the first metal layer) in the above embodiment may be chemically and/or mechanically formed. For example, if the first metal layer is formed of aluminum (Al), a plurality of pores for bonding with the molten second metal may be formed on the surface of the first metal layer using an anodizing procedure. In detail, the second metal in the molten state can be trapped in the pores such that the second metal will be consolidated on the first metal layer after cooling and solidification.

The board can be used as an electronic device, or a cover or an insert of any other product/device of the other industry that requires better bonding, bonding or bonding strength in a multilayer metal construction.

The first metal layer and the second metal layer may be joined together by combining or confining a portion of the second metal layer in a space defined by one of the bonding structures.

In the above method, a gate speed of at least 70 m/s may be used, and a higher than 3 m/s, 3.5 m/s, 4.0 m/s, 4.5 m/s, 5.5 m/s, The second metal 614, 814, 914, 914' is injected onto the surface of the semi-finished sheet (first metal layer) at an exit velocity of 6.0 m/s, 6.5 m/s or more. In this manner, the second metal layer can have an extremely thin dimension such that the recesses, holes, grooves, balls or protrusions of the roughened surface and the (etc.) hooks of the joint structure, etc. The buckle, the (etc.) groove, the (etc.) protrusion, and the (etc.) groove may be well covered (or covered) and filled by the second metal. In a preferred embodiment, the second gate speed is adjusted (eg, by adjusting the speed at which the second metal layer is ejected by the injection nozzle), or based on a 3D design of a product that will become important in the future. The thickness of the metal layer may be no greater than 0.5 mm (eg, 0.5 mm, 0.3 mm, 0.2 mm, or 0.1 mm).

As can be seen from the above, the high flow velocity of the second metal layer is an important parameter for the temperature of the second molten metal when the second molten metal flows from the injection nozzle to the cavity. Local melting on the surface of the two metals to be joined or bonded can only produce a weak bond. Therefore, post-procedures (e.g., laser welding, resistance welding, and some other welding procedures known in the market) are needed to enhance the bond or bond strength between the two metal layers. In the present invention, a bolt-type locking mechanism (or bolt-type locking space) is disposed on the first metal layer to guide the molten state. The second metal is retained by a designated space defined by the bolt-type locking mechanism. As the joint structures 913a and 913a' shown in Figs. 9A to 9B and as described above.

In detail, the purpose of injecting the liquid second metal into the mold at a high speed is to ensure that the second metal fills the cavity in a very short time and thus when the second metal fills the mold to form In the second metal layer, the second metal is still in the melting stage. As shown in the examples shown in Figs. 10A to 10C Shown by the person shown in FIG. 10A (when the molten second metal leaves the injection port and enters the flow path at point A), as shown in FIG. 10B (when the molten second metal passes through the flow path and Just entering the gate, at point B), until the total time through the one shown in Figure 10C (when the molten second metal fills the mold cavity, at point C) is no more than 0.02 s, and total The displacement is 130mm. In the case of this 0.02 s time, after the molten second metal enters the mold cavity of the mold, it takes less than 0.005 s for the molten second metal to fill the cavity. In this example, the molten second metal exits the injection port and enters the flow path at a rate of 3.5 m/s, and the molten second metal exits the gate into the mold cavity at a speed of 70 m/s.

In order to further strengthen the bonding and bonding between the two metal layers, as shown in FIG. 11, a mold 1100 for manufacturing a plate having a plurality of metal layers according to the present invention has an upper mold 1102, and the upper mold 1102 has a morphology. It is a barrier of an endless wall 1104 and the wall 1104 extends away from the surface of one of the upper dies 1102 that directly faces the lower mold 1106. When the upper mold 1102 is in the configuration shown in FIG. 11, that is, the upper mold 1102 is aligned with the lower mold 1106 and is ready for the second metal injection of the molten form to complete the metal plate 1108. When the first metal layer is held between the upper mold 1102 and the lower mold 1106, the wall 1104 is contacted and pressurized to cut into the semi-finished plate 1108 to form a seal, and the seal prevents a fluid (including a Gas and a liquid) flow through the seal. The gas may be air and the liquid may be a liquid molding material, such as a second metal in the molten form. A space 1110 is also formed between the upper mold 1102 and the semi-finished plate 1108. The space 1110 is an injection port and a flow channel that can pass through the mold. The relationship of the gate to the injection nozzle fluid connection. The space 1110 reduces further oxidation of the molten second metal as the molten second metal flows in the mold. Because the second metal of the molten form leaves the gate and enters the high speed of the cavity, and by means of the space 1110 (reducing further oxidation of the second metal of the molten form), the molten second metal may be in the melting After the two metals have entered the space 1110, the roughened surface and/or the joining element on the semi-finished plate 1108 are joined and/or passed through the semi-finished plate 1108 for a very short period of time, such as no more than 0.005 s, thereby enhancing The joint strength between the two metal layers (meaning the semi-finished plate 1108 and the metal layer formed by the cooled second metal). On the other hand, in the absence of the wall 1104 and, therefore, in the case of a fluid-tight seal between the wall 1104 and the semi-finished plate 1108, since the external atmosphere is connected to the cavity through a conventional venting system, The molten second metal will be further cooled and oxidized in the injection process. The surface of the molten second metal will be oxidized and will be extended to the molten second metal. The surface tension of the oxidized molten second metal and/or semi-solid second metal will be higher, resulting in a higher viscosity of the molten second metal which will slow the flow of the molten second metal. Therefore, the molten second metal is difficult to pass or join the joining elements of the semi-finished plate 1108, particularly if the joining elements have a height of less than 0.5 mm and a width of less than 0.5 mm, or the engaging elements have a diameter of at least 0.5 mm. When the depth is reached.

While the joining elements can have a height of at least 0.5 mm, the second metal layer can have a relatively small thickness. As shown in Figure 12, the semi-finished plate 1108 is shown schematically with two engaging elements, each engaging element being a hook 1112, and the hooks 1112 are separated from each other. The hooks 1112 are One of the upper surfaces 1114 of the plate 1108 extends a height of 0.5 mm. A quantity of molten second metal is injected into the space between the hooks 1112 to form a second metal layer 1116 that engages the plate 1108. The thickness of the second metal layer 1116 may be greater than, equal to, or less than the height of the hooks 1112, depending on structural and design requirements. In detail, in FIG. 12, the second metal layer 1116 is shown to have a thickness (eg, 0.4 mm, 0.3 mm, or less than 0.3 mm) that is less than the height of the hooks 1112.

The space 1110 includes a passageway through which a molding material (e.g., molten metal) can be supplied to the mold cavity of the mold when the mold 1100 is in the closed configuration. However, unlike the prior art, there is no passage in the mold 1100 for the excess molding material (ie, the molten metal) to exit the cavity of the mold 1100 via the passage and become a burr that must be trimmed after the molding process and Flashing. On the other hand, when the mold 1100 is used, any excess molten second metal will flow through the first metal layer/plate 1108 and still form part of the product. It is therefore not necessary to carry out any finishing steps after the method according to the invention, since there is no "overflow material" to be repaired.

Although FIG. 11 shows that the wall 1104 is provided by the upper mold 1102, it is envisioned that the wall 1104 can be provided by the lower mold 1106, for example, directly facing one of the upper molds 1102, depending on the design of the products. on.

The method according to one aspect of the invention has at least the following advantages:

(a) the molded product may be ejected after the injection procedure, which is different from the general casting procedure in which the product must be cooled before it is ejected from the cavity; (b) when the molten second metal is still in liquid form When the second gold is melted Covering the first metal layer; (c) reducing further oxidation of the molten second metal before the molten second metal cools, thereby allowing the molten second metal to fully bond or penetrate the semi-finished plate (first a different portion of the roughened surface of the metal layer and/or a bonding element (eg, a trench, a void, a recess). It provides the opportunity to form internal features to form a mesh and reduce many post-processing procedures and CNC work, thus saving more cost; (d) since all molten metal is trapped and there is no overflow of the metal, the first The second metal layer becomes dense and sealed. There is therefore no gap between the metal layers, in particular between the boundaries or between the bonding lines of the metal layers, which can be seen by the end user, thus ensuring cosmetic quality. In addition to being a cosmetic treatment of the product, this also prevents liquids (such as water, DI water, acidic solutions, alkaline solutions, etc.) from penetrating between the metal layers. This at least reduces the likelihood of the product producing an electrical erosion problem.

(e) when the workpiece is to form a final product outer casing, the surface that will form the outer surface of the final product will be free of traces of the ejected material, thus presenting a more aesthetically pleasing appearance; and (f) The metal layer can be very thin (not more than 0.5 mm), so if a workpiece is to form a product shell, the internal space of the product can be preserved, thus giving the designer greater freedom.

In another embodiment of the invention, and as shown in Figures 13 through 14B, a first metal layer (e.g., half completed plate 1200) is pretreated prior to molding. The plate 1200, which is constructed of a first metal, originally has a generally rectangular cross section. The semi-finished plate 1200 substantially conforms to the shape and wheel of the component it is to form Profile (especially the outer contour). Some of the first metal is removed from the plate 1200 to form one or more recesses, such as thinned grooves 1202, on the upper surface 1204 of the plate 1200. These grooves 1202 have a depth d equal to or less than 0.3 mm, and the thickness D of the first metal layer 1200 is about 0.8 mm.

The pretreated semi-finished plate 1200 is then placed in the cavity of a mold. A molten second metal is then injected onto the upper surface 1204 of the pretreatment plate 1200 to form a second metal layer 1206, and the pretreatment plate 1200 is joined to form a two layer metal workpiece. Some of the second metal is received within the recess 1202 of the plate 1200 to engage the pre-treatment plate 1200 with the second metal layer 1206. Of course, the above steps can be repeated to form a workpiece having more layers of metal. It should be noted that the second metal layer 1206 may cover only a portion of the grooves 1202.

In addition, as shown in FIG. 14A, since the molten second metal is injected at a high speed on the upper surface 1204 of the board 1200, the second metal layer 1206 formed by the second metal can form a second extending away from the board 1200. The structure of one of the major surfaces of the metal layer 1206. The structures may be threaded projections 1208 and other mechanical and structural components 1210.

It has been found practical to pre-treat the configuration of the semi-finished panel 1200 prior to molding (particularly by removing some of the first metal from the panel 1200 to form a plurality of thinned recesses 1202 on the upper surface 1204 of the panel 1200. The two recesses can be advantageously combined with the mold 1100 having the continuous wall 1104 described above because of any excess melting of the second metal (i.e., beyond the minimum amount required to mold on the first metal layer) Melting the second metal) will remain in the mold 1100 to form at least one of the second metal layers 1206 And at least a portion of the second metal layer 1206 forms a useful portion of the final workpiece/product, so there will be no "waste".

One advantage associated with the use of a combination method is that all excess or excess molten second metal (if any) will become part of the final workpiece/product in a planned manner, which will help to strengthen the second metal The characteristics of formation. In addition, the combined process is environmentally friendly and cost effective since it does not have to be post-treated with any overflow material.

As described above, the second metal layer 1206 can cover only a portion of the recess formed on the first metal layer. As shown in FIG. 15, a cover 1302 formed of a first metal is formed with a shallow groove 1304 along the periphery. A molten second metal is then molded over the first metal layer to form a second metal layer such that a portion of the recess 1304 is covered by the molten second metal. The shaded area 1306 shown in Figure 15 is the area of the thin portion 1304 that is not covered by the molten second metal. In the molding process, the groove 1304 receives the molding material (i.e., melts the second metal) and functions as a venting function for the leaking air generated during the molding process.

The present invention seeks to at least alleviate the deficiencies associated with the prior art, and to prepare a material having a plurality of metal layers at a lower cost and higher yield by preparing materials according to real material consumption, and thus is more environmentally friendly and more economical than the currently used technology. . At the same time, two or more layers of different metals can be designed to completely or partially cover a substrate to meet both the appearance and mechanical performance requirements, which will save a lot of work on developing different alloy materials and save global resources.

The method of the invention achieves good adhesion between multiple layers of metal layers Focus on and improve metal tightness and surface smoothness, and contribute to subsequent metal surface treatment.

It should also be understood that for the purposes of the present invention, "a workpiece having a plurality of layers of metal" does not mean that the workpiece consists solely of (most) metal. It is envisioned that a "workpiece having a plurality of metal layers" may be additionally formed from other materials such as plastic materials. For example, the workpiece may be formed of two metal layers bonded/bonded to each other as described above and a plastic layer bonded/bonded to one of the two metal layers. Therefore, the number of layers of related materials or the number of related materials is not limited as long as the workpiece includes two metal layers bonded/joined to each other as described above.

While the technical content and features of the present invention are as described above, various changes and modifications can be made by those skilled in the art without departing from the scope of the invention. Therefore, the scope of the present invention is not limited to the disclosed embodiments, but includes other variations and modifications of the invention as defined by the following claims.

S101, S102‧‧‧ steps

Claims (36)

A method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a mold having at least a first pass, a gate, and a cavity; (b) providing a mold in the mold cavity of the mold The first metal constitutes a first metal layer, the first metal layer has a surface that is roughened and/or includes at least one bonding structure; and (c) a molten second metal is injected into the first metal Forming a second metal layer on the first metal layer on the surface of the layer, wherein the second metal layer is bonded to the roughened surface of the first metal layer or the surface of the first metal layer Structural bonding wherein the molten second metal enters the cavity of the mold at a rate of at least 70 meters per second (m/s). The method of claim 1, wherein the molten second metal enters the flow path of the mold at a rate of at least 3.5 m/s per second. The method of claim 1, wherein the first metal and the second metal are independently selected from the group consisting of stainless steel, iron, zinc, aluminum, magnesium, chromium, titanium, copper, ruthenium, nickel, and the like. Group of alloys. The method of claim 1, further comprising a step (d) of chemically and/or mechanically forming the roughened surface or the bonded structure of the first metal layer on the surface of the first metal layer . The method of claim 1, wherein the roughened surface of the first metal layer comprises at least one recess, a hole, a groove, a ball, a protrusion or a combination thereof. The method of claim 1, wherein the joining structure comprises at least one hook, a buckle, a groove, a protrusion, a groove or a combination thereof. The method of claim 1, comprising a step (e) of applying a pressure to the second metal layer. The method of claim 1, wherein the workpiece is a cover or an insert of an electronic device. A mold includes a first module and a second module, wherein the first module and the second module are movable relative to each other between an open configuration and a closed configuration. The first module and the second module are separated from each other, and the closed configuration is for holding a half of the finished workpiece between the first module and the second module, and wherein at least the first The mold member includes a wall member, and when the mold is in the closed configuration and holds the workpiece halfway, the wall member is pressed into at least a portion of the semi-finished workpiece to be in the wall member and the semi-finished workpiece A seal is formed therebetween and the seal prevents a fluid from flowing through the seal. The mold of claim 9, wherein the first module is an upper mold. A mold according to claim 9 wherein the wall member is endless. The mold of claim 9 further comprising a passage, and wherein the passage allows a mold when the mold is in the closed configuration and a space is formed between the semi-finished workpiece and the first mold The material is supplied to the space. For example, the mold of claim 9 includes a pressurizing component. A mold according to claim 9 wherein the fluid is a gas and/or a liquid. A mold according to claim 14 wherein the gas is air. A mold according to claim 14 wherein the liquid is a molten molding material. A workpiece having a plurality of metal layers formed by injecting at least one second metal layer onto a first metal layer, wherein each of the first metal layer and the second metal layer comprises at least one bond structure. The workpiece of claim 17, wherein the at least one bonding structure of the first metal layer is bonded to the at least one bonding structure of the second metal layer. The workpiece of claim 17, wherein the joint structure of the first metal layer and the joint structure of the second metal layer are independently selected from the group consisting of a recess, a hole, a groove, and a hook. , a buckle, a groove, a ball and a group of protrusions. The workpiece of claim 19, wherein each of the first metal layer and the second metal layer is composed of a metal, and the metal is independently selected from the group consisting of stainless steel, iron, zinc, and aluminum. a group of alloys of magnesium, chromium, titanium, copper, ruthenium, nickel, and the foregoing metals. For example, the workpiece of claim 17 wherein the workpiece is a plate. The workpiece of claim 21, wherein the board is a cover or an insert of an electronic device. The workpiece of claim 17 wherein the second metal layer has A thickness of no more than 0.5 mm. The workpiece of claim 17, wherein the second metal layer comprises at least a portion extending away from a major surface of the second metal layer. A mold includes a first module and a second module, wherein the first module and the second module are movable relative to each other between an open configuration and a closed configuration. The first module and the second module are separated from each other, and in the closed configuration, the first module and the second module are joined to each other to form a cavity for accommodating a half of the workpiece. Wherein the first module includes a passage that allows the molding material to be supplied into the cavity, and wherein the mold does not have a passage that allows the molding material to flow out of the cavity. A method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a first metal layer composed of a first metal; (b) pretreating the first metal layer; (c) Pre-treating the first metal layer in a mold; and (d) injecting a molten second metal onto the surface of the pretreated first metal layer to pretreat the first metal layer A second metal layer is formed thereon. The method of claim 26, wherein the steps (a) to (d) are performed in the order. The method of claim 27, wherein the step (b) includes The first metal layer removes a portion of the first metal. The method of claim 28, wherein at least one recess is formed on the first metal layer after the step (b). The method of claim 29, wherein at least a portion of the molten second metal is contained in at least a portion of the recessed portion of the pretreated first metal layer to engage the second metal a layer and the first metal layer that has been pretreated. The method of claim 27, wherein the excess molten second metal is retained in the mold to form at least a portion of the second metal layer. A workpiece having a plurality of metal layers formed by injecting at least a second metal layer onto a first metal layer, wherein the second metal layer has a thickness substantially no greater than 0.5 mm. A method of manufacturing a workpiece having a plurality of metal layers, the method comprising the steps of: (a) providing a mold having at least a first pass, a gate, and a cavity; and (b) providing a first metal a metal layer having a surface comprising at least one bonding structure; (c) pretreating the first metal layer; (d) placing the pretreated first metal layer in the mold And (e) injecting a molten second metal onto the surface of the pretreated first metal layer to form a second metal layer on the pretreated first metal layer, wherein the melting Two metals at a level of at least 70 meters per second a velocity of (m/s) entering the cavity of the mold, wherein the second metal layer comprises at least one bonding structure engaged with the bonding structure of the surface of the pretreated first metal layer, wherein the mold The first module and the second module are respectively movable relative to each other between an open configuration and a closed configuration, and the first configuration is in the open configuration. a module and the second module are separated from each other, and in the closed configuration, the first module and the second module are joined to each other to form the pre-treated first metal layer a cavity, wherein the first module includes a passage permitting supply of the molten second metal, and wherein the mold does not have a passage that allows the molten second metal to flow out of the cavity. The method of claim 33, wherein the step (c) comprises removing a portion of the first metal from the surface of the pretreated first metal layer to be pretreated in the first At least one recess is formed on the surface of the metal layer. The method of claim 34, wherein at least a portion of the molten second metal is received in the recess on the surface of the pretreated first metal layer to join the second metal layer The first metal layer is pretreated. A workpiece having a plurality of metal layers is formed according to the method of claim 33 of the patent application.