US20110303686A1 - Metallic cover - Google Patents
Metallic cover Download PDFInfo
- Publication number
- US20110303686A1 US20110303686A1 US13/215,360 US201113215360A US2011303686A1 US 20110303686 A1 US20110303686 A1 US 20110303686A1 US 201113215360 A US201113215360 A US 201113215360A US 2011303686 A1 US2011303686 A1 US 2011303686A1
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- United States
- Prior art keywords
- metallic cover
- bottom base
- side walls
- edge
- thickness
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/02—Details
- H05K5/03—Covers
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/04—Metal casings
Definitions
- the present invention generally relates to metallic covers, and more particularly to a metallic cover used for electronic devices and a method for making the metallic cover.
- a metallic cover has a more appealing appearance and a better surface feel than a plastic cover, thus metallic covers are popularly used for electronic devices such as mobile phones.
- the metallic cover 10 includes a rectangular bottom base 11 , a first side wall 12 , a second side wall 13 , a third side wall 14 , and a fourth side wall 15 .
- the side walls 12 , 13 , 14 , 15 perpendicularly extend from a periphery of the rectangular bottom base 11 .
- Each of the side walls 12 , 13 , 14 , 15 connects to its adjacent side walls, thus the side walls 12 , 13 , 14 , 15 cooperatively define a cavity (not labeled) for receiving electronic components (not shown).
- Each of the side walls 12 , 13 , 14 , 15 and the bottom base 11 are connected at an edge (not labeled).
- the edge is generally a rounded edge so that the metallic cover 10 can easily be made by metal drawing method.
- an edge of another typical cover for connecting the side walls and the bottom base may be a beveled edge instead of the rounded edge.
- a typical method for making a metallic cover with a beveled edge includes two following steps: drawing a metal sheet into a preformed cover; pressing the preformed cover into a metallic cover with a beveled edge by a forming die.
- the edges of the metallic cover are prone to cracks, when using the above method, thus decreasing quality of the metallic covers.
- the described metallic covers are generally made by thin metal sheet.
- a thickness of the side walls of the metallic covers is the same as that of the bottom base of the metallic covers.
- the strength of the side walls of the metallic covers is relatively low.
- a thickness of each side wall of the metallic cover should be greater than that of the bottom base of the metallic cover.
- the unequal-thickness metallic cover is generally made by a die-casting method.
- the appearance of the unequal-thickness metallic cover made by the die-casting method is not good, thus the unequal-thickness metallic cover needs to be polished to improve the quality of the appearance of the unequal-thickness metallic cover.
- unequal-thickness metallic covers can also be manufactured by computerized numerical control (CNC) milling machines.
- CNC computerized numerical control
- a first typical method for making an unequal-thickness metallic cover will now be described.
- a relatively thick raw metallic block is provided.
- the raw metallic block has to go through several milling processes so as to get a preformed body.
- the preformed body is made into a metallic cover by a process of finish machining.
- the above method for making unequal-thickness metallic covers takes a great deal of time, for example, it needs more than ten hours for a process to make one unequal-thickness metallic cover of a mobile phone. Because the unequal-thickness metallic cover goes through several milling processes, the efficiency of the described method is low, thereby increasing the cost of the unequal-thickness metallic covers.
- a metallic cover made of aluminum alloy e.g., an aluminum alloy of grade AL5052 using the above milling method shows a metallographic photograph of a portion of the side walls of the metallic cover under 23 ⁇ 5 Celsius degrees (° C.) and 40-80% relative humidity (RH) conditions.
- the internal structure of the metallic cover is magnified by 200 ⁇ .
- the metallographic structure of the metallic cover is relatively incompact.
- a Vickers hardness of the metallic cover under 23 ⁇ 5° C., 40-80% RH and 0.5 kilograms (kgs) is in a range from 68 to 70.
- a metallic cover in one aspect, includes a bottom base and a side wall extending from the bottom base.
- the side wall is formed by cold forging so that a thickness of the side wall is greater than that of the bottom base.
- a method for making the metallic cover described above includes: drawing a metallic sheet into a preformed cover having a bottom base and a plurality of side walls, and the bottom base and each of the sidewalls connected at a rounded edge; forging the preformed cover by a first forming die to thicken the side walls, and a first slanted pressing surface formed on an end of each of the side walls; forging the preformed cover by a second forming die to further thicken the side walls, and a second slanted pressing surface intersecting with the first slanted pressing surface formed on the end of each of the side walls, and the rounded edge of the preformed cover pressed into a beveled edge; and machining the end of each of the side walls of the preformed metallic cover so that the preformed metallic cover is made into the metallic cover.
- FIG. 1 is an isometric view of a metallic cover in accordance with a preferred embodiment of the present invention.
- FIG. 2 is a partial, cross-sectional view of an edge of the metallic cover of FIG. 1 .
- FIG. 3 is a metallographic photograph of part of the edge of the metallic cover magnified by 200 ⁇ .
- FIG. 4 is an isometric view of a preformed metallic cover formed in a method for making the metallic cover of FIG. 1 .
- FIG. 5 is a cross-sectional view of a first forming die used for pressing the preformed metallic cover of FIG. 4 .
- FIG. 6 is an enlarged, side cross-sectional view of a punch of the first forming die of FIG. 5 .
- FIG. 7 is a partial, cross-sectional view of the first forming die which is pressing the preformed metallic cover of FIG. 4 .
- FIG. 8 is a partial, cross-sectional view of the preformed metallic cover after being pressed by the first forming die of FIG. 5 .
- FIG. 9 is a cross-sectional view of a second forming die used for further pressing the preformed metallic cover which has been pressed by the first forming die of FIG. 5 .
- FIG. 10 is an enlarged, side cross-sectional view of a punch of the second forming die of FIG. 9 .
- FIG. 11 is a partial, cross-sectional view of the second forming die which is pressing the preformed metallic cover which has been pressed by the first forming die.
- FIG. 12 is a partial, cross-sectional view of the preformed metallic cover after being pressed by the second forming die of FIG. 9 .
- FIG. 13 is a partial, cross-sectional view of a third finish machining die for making the preformed metallic cover which pressed by the second forming die of FIG. 9 into the metallic cover of FIG. 1 .
- FIG. 14 is an isometric view of a conventional metallic cover.
- FIG. 15 is a metallographic photograph of part of the conventional metallic cover magnified by 200 ⁇ .
- a metallic cover 20 according to a preferred embodiment is shown.
- the metallic cover 20 is used as a cover for a mobile phone.
- the metallic cover 20 includes a rectangular bottom base 21 , a first side wall 22 , a second side wall 23 , a third side wall 24 , and a fourth side wall 25 .
- the side walls 22 , 23 , 24 , 25 perpendicularly extend from a periphery of the rectangular bottom base 21 .
- the side walls 22 , 23 , 24 , 25 cooperatively define a cavity (not labeled).
- the bottom base 21 and each of the side walls 22 , 23 , 24 , 25 are correspondingly connected at an edge 26 .
- the side walls 22 , 23 , 24 , 25 of the metallic cover 20 are formed by cold forging, thus a thickness of each of the side walls 22 , 23 , 24 , 25 of the metallic cover 20 is greater than that of the bottom base 21 of the metallic cover 20 .
- b represents a thickness of the bottom base 21
- t represents a thickness of each of the side walls 22 , 23 , 24 , 25
- h represents a height of each of the side walls 22 , 23 , 24 , 25
- the ratio between t and b (t/b) is preferably in a range from about 1 to about 3
- the ratio between h and b (h/b) is preferably in a range from about 1 to about 2.5
- the metallic cover 20 is preferably made of aluminum alloy.
- the edge 26 is a beveled edge formed by cold forging. The angle formed between an outer surface of the bottom base 21 and an outer surface of each of the sidewalls 22 , 23 , 24 , 25 at the edge 26 is in a range from about 90 degrees to about 135 degrees.
- the bottom base 21 can also be other shapes such as triangular, pentagonal, and hexagonal.
- the edge 26 is not limited to a beveled edge, the edge can also be other shapes, that is, not beveled, formed by cold forging.
- the metallic cover 20 made of aluminum alloy e.g., an aluminum alloy of grade 5052- 0 using cold forging method shows a metallographic photograph of a portion of the metallic cover under 23 ⁇ 5° C. and 40-80% relative humidity (RH) conditions.
- the metallographic photograph of the metallic cover is magnified by 200 ⁇ .
- the metallographic structure of the metallic cover is relatively compact.
- a Vickers hardness of the metallic cover 20 under 23 ⁇ 5° C., 40-80% RH and 0.5 kilograms (kgs) is in a range from 71 to 75. Therefore, the Vickers hardness of the metallic cover 20 formed by cold forging is greater than the Vickers hardness of a metallic cover which is formed by milling method.
- the method for making the metallic cover includes the following main steps: a drawing process; a first cold forging process; a second cold forging process; and a finish machining process.
- a metallic sheet is drawn into a preformed metallic cover 30 .
- the metallic sheet used for making the preformed metallic cover 30 is preferably made of aluminum alloys such as 5052-O aluminum alloy.
- the preformed cover 30 includes a bottom base 31 and a plurality of side walls 32 .
- the side walls 32 cooperatively define a cavity (not labeled) for receiving electronic components (not shown).
- the bottom base 31 and each of the sidewalls 32 are connected at a rounded edge 33 .
- the preformed cover 30 is forged by a first forming die 200 to flatten the side walls 32 , thereby thickening (widening) the side walls 32 , and to form a first slanted pressed surface 321 (see FIG. 8 ) on an end of each of the side walls 32 .
- the first forming die 200 includes an upper die 210 , a lower die 220 , a pressing member 230 , a punch 240 , a first resilient member 250 , and a second resilient member 260 .
- the lower die 220 and the pressing member 230 are disposed adjacent to and on opposite sides of the punch 240 correspondingly.
- the punch 240 , the lower die 220 , and the pressing member 230 cooperatively define a molding groove 270 for receiving the side walls 32 of the preformed metallic cover 30 .
- a thickness of the molding groove 270 is greater than that of each of the side walls 32 of the preformed metallic cover 30 .
- the upper die 210 is disposed above the lower die 220 , the pressing member 230 , and the punch 240 .
- the first resilient member 250 and the second resilient member 260 are both springs.
- the first resilient member 250 is disposed below the lower die 220 .
- the second resilient member 260 is disposed below the pressing member 230 .
- the upper die 210 includes a working surface 2101 formed on a bottom surface for pressing the bottom base 31 of the preformed metallic cover 30 .
- the lower die 220 includes a mounting surface 2201 formed on a top surface for mounting the preformed metallic cover 30 .
- the pressing member 230 includes a side surface 2301 and an upper surface 2302 perpendicular to each other.
- An extending portion 2303 is formed on the side surface 2301 adjacent to the upper surface 2302 .
- the extending portion 2303 includes a pressing surface 2304 for pushing against the side walls 32 of the preformed cover 30 .
- the pressing surface 2304 is perpendicular to the working surface of the upper die
- the punch 240 includes a punching portion 2401 and a restricting portion 2402 that connects to the punching portion 2401 .
- the punching portion 2401 includes a first side surface 2404 , a second side surface 2405 , and a slanted working surface 2406 .
- the first side surface 2404 is parallel to the second side surface 2405 , and the first side surface 2404 and the second side surface 2405 are on opposite sides of the punching portion 2401 correspondingly.
- d 1 represents a distance between the first side surface 2404 and the second side surface 2405
- t represents the final thickness of the sidewall of the metallic cover. The distance d 1 should be in a range from 0.7 t to 0.9 t.
- the distance d 1 is preferably in a range from 0.8 t to 0.85 t.
- An edge of the slanted working surface 2406 connects the first side surface 2404 and an opposite edge of the slanted working surface 2406 connects the second side surface 2405 .
- the edge of the slanted working surface 2406 adjacent to the first side surface 2404 is configured to be higher than the opposite edge of the slanted working surface 2406 adjacent to the second side surface 2405 . In other words, the slanted working surface 2406 slants towards the first side surface 2404 .
- An angle ⁇ 1 defined by the slanted working surface 2406 relative to the first side surface 2404 should be in a range from about 45 degrees to about 70 degrees.
- the angle ⁇ 1 is preferably in a range from about 60 degrees to about 65 degrees.
- the restricting portion 2402 includes a positioning surface 2403 for restricting the motion range of the pressing member 230 .
- a distance between the upper surface 2302 of the pressing member 230 and the mounting surface 2201 of the lower die 220 is greater than the thickness of the bottom base 31 of the preformed metallic cover 30 .
- the pressing surface 2304 of the extending portion 2303 of the pressing member 230 abuts the second side surface 2405 of the punching portion 2401 of the punch 240 .
- the side surface 2301 of the pressing member 230 abuts the restricting portion 2402 of the punch 240 .
- a lower end of the extending portion 2303 of the pressing member 230 is set a predetermined distance away from the positioning surface 2403 of the restricting portion 2402 of the punch 240 .
- the preformed metallic cover 30 is placed on the lower die 220 and the side walls 32 of the preformed metallic cover are received in the molding groove 270 .
- the upper surface 2302 of the pressing member 230 and the bottom base 31 of the preformed metallic cover 30 are pressed by the upper die 210 .
- the first resilient member 250 and the second resilient member 260 becomes compressed.
- the side walls 32 of the preformed metallic cover 30 received in the molding groove 270 presses/pushes against the slanted working surface 2406 of the punch 240 ; material of the side walls 32 displaces (molds) into the molding groove 270 .
- the lower die 220 and the pressing member 230 stop moving.
- material of the side walls 32 of the preformed metallic cover 30 flattens out into the molding groove 270 , thus the side walls 32 of the preformed metallic cover 30 become thicker (wider) than the bottom base 31 .
- the rounded edge 33 of the preformed cover 30 is pressed into a substantially beveled edge.
- the preformed cover 30 is forged by a second forming die 300 to flatten the side walls 32 , thereby further thickening (widening) the side walls 32 , and to form a second slanted pressing surface 322 intersecting with the first slanted pressing surface 321 on the end of each of the side walls 32 .
- the rounded edge 33 of the preformed cover 30 is pressed into the beveled edge 26 .
- the second forming die 300 includes an upper die 310 , a lower die 320 , a pressing member 330 , a punch 340 , a first resilient member 350 , and a second resilient member 360 .
- the principle of the second forming die 300 is similar to the first forming die 200 .
- the punch 340 is different from the punch 240 of the first forming die 200 .
- the punch 340 will now be described in detail as follows.
- the punch 340 includes a punching portion 3401 and a restricting portion 3402 connecting to the punching portion 3401 .
- the punching portion 3401 includes a first side surface 3404 , a second side surface 3405 , and a slanted working surface 3406 .
- the first side surface 3404 is parallel to the second side surface 3405
- first side surface 3404 and the second side surface 3405 are on opposite sides of the punching portion 3401 correspondingly.
- a distance d 2 between the first side surface 3404 and the second side surface 3405 equals to the thickness t of the sidewall of the metallic cover to be formed.
- An edge of the slanted working surface 3406 connects the first side surface 3404 and an opposite edge of the slanted working surface 3406 connects the second side surface 3405 .
- the opposite edge of the slanted working surface 3406 adjacent to the second side surface 3405 is configured to be higher than the edge of the slanted working surface 3406 adjacent to the first side surface 3404 .
- An angle ⁇ 2 defined by the slanted working surface 3406 relative to the first side surface 3404 should be in a range from about 45 degrees to about 70 degrees.
- the angle ⁇ 2 is preferably in a range from about 60 degrees to about 65 degrees.
- the restricting portion 3402 includes a positioning surface 3403 for restricting the motion range of the pressing member 330 .
- the punch 340 , the lower die 320 , and the pressing member 330 cooperatively define a molding groove 370 for receiving the side walls 32 of the preformed metallic cover 30 .
- a thickness of the molding groove 370 is greater than the thickness of the side walls 32 of the preformed metallic cover 30 .
- the pressing member 330 and the bottom base 31 of the preformed metallic cover 30 is pressed by the upper die 310 .
- the side walls 32 of the preformed metallic cover 30 received in the molding groove 370 presses/pushes against the slanted working surface 3406 of the punch 340 ; material of the side walls 32 displaces (molds) into the molding groove 370 .
- the extending portion 3303 of the pressing member 230 abuts the positioning surface 3403 of the restricting portion 3402 of the punch 340 , the lower die 320 and the pressing member 330 stop moving.
- each of the side walls 32 of the preformed metallic cover 30 is machined to a predetermined shape by a machining tool such as a milling machine, and thereby forming the metallic cover 20 .
- a machining tool such as a milling machine
- the first slanted pressing surface 321 and the second slanted pressing surface 322 of each of the side walls 32 are cut off and a flat surface is formed on the side walls 32 .
- a precision machining process is applied between the second cold forging process and the finish machining process.
- the sidewalls 32 of the preformed metallic cover 30 are processed by a precision forming die 400 .
- the precision forming die 400 includes an upper die 401 , a lower die 402 , and a pressing plate 403 .
- the preformed metallic cover 30 is fixed on the lower die 402 by the pressing plate 403 , and the side walls of the preformed metallic cover 30 extend out of the lower die 402 .
- the upper die 401 moves towards the lower die 402 , a part of the side walls 32 of the preformed metallic cover 30 is cut off, thus the surface appearance the side walls 32 is improved.
Abstract
A metallic cover includes a bottom base and four side walls perpendicularly extending from a periphery of the rectangular bottom base. The four side walls cooperatively define a cavity together with the rectangular bottom base. The bottom base and each of the side walls of the metallic cover are correspondingly connected at an edge. The side walls of the metallic cover are formed by cold forging, thus a thickness of each of the side walls of the metallic cover is greater than that of the bottom base.
Description
- The present application is a divisional application of U.S. patent application Ser. No. 12/012,298, filed on Feb. 1, 2008.
- 1. Field of the Invention
- The present invention generally relates to metallic covers, and more particularly to a metallic cover used for electronic devices and a method for making the metallic cover.
- 2. Discussion of the Related Art
- Generally, a metallic cover has a more appealing appearance and a better surface feel than a plastic cover, thus metallic covers are popularly used for electronic devices such as mobile phones.
- Referring to
FIG. 14 , a typicalmetallic cover 10 is shown. Themetallic cover 10 includes arectangular bottom base 11, afirst side wall 12, asecond side wall 13, athird side wall 14, and afourth side wall 15. Theside walls rectangular bottom base 11. Each of theside walls side walls - Each of the
side walls bottom base 11 are connected at an edge (not labeled). The edge is generally a rounded edge so that themetallic cover 10 can easily be made by metal drawing method. - However, in order to obtain a different appearance, an edge of another typical cover for connecting the side walls and the bottom base may be a beveled edge instead of the rounded edge. Generally, it is practically impossible to produce the beveled edge using the metal drawing method. A typical method for making a metallic cover with a beveled edge includes two following steps: drawing a metal sheet into a preformed cover; pressing the preformed cover into a metallic cover with a beveled edge by a forming die. However, the edges of the metallic cover are prone to cracks, when using the above method, thus decreasing quality of the metallic covers.
- In addition, in order to reduce the volume, size or weight of these electronic devices such as mobile phones, the described metallic covers are generally made by thin metal sheet. However, a thickness of the side walls of the metallic covers is the same as that of the bottom base of the metallic covers. As a result, the strength of the side walls of the metallic covers is relatively low. To enhance the strength of the side walls of a metallic cover, a thickness of each side wall of the metallic cover should be greater than that of the bottom base of the metallic cover. It is also practically impossible to produce an unequal-thickness metallic cover using the metal drawing method. The unequal-thickness metallic cover is generally made by a die-casting method. However, the appearance of the unequal-thickness metallic cover made by the die-casting method is not good, thus the unequal-thickness metallic cover needs to be polished to improve the quality of the appearance of the unequal-thickness metallic cover.
- At present, unequal-thickness metallic covers can also be manufactured by computerized numerical control (CNC) milling machines. A first typical method for making an unequal-thickness metallic cover will now be described. A relatively thick raw metallic block is provided. The raw metallic block has to go through several milling processes so as to get a preformed body. The preformed body is made into a metallic cover by a process of finish machining. The above method for making unequal-thickness metallic covers takes a great deal of time, for example, it needs more than ten hours for a process to make one unequal-thickness metallic cover of a mobile phone. Because the unequal-thickness metallic cover goes through several milling processes, the efficiency of the described method is low, thereby increasing the cost of the unequal-thickness metallic covers.
- Referring to
FIG. 15 , a metallic cover made of aluminum alloy, e.g., an aluminum alloy of grade AL5052 using the above milling method shows a metallographic photograph of a portion of the side walls of the metallic cover under 23±5 Celsius degrees (° C.) and 40-80% relative humidity (RH) conditions. The internal structure of the metallic cover is magnified by 200×. The metallographic structure of the metallic cover is relatively incompact. A Vickers hardness of the metallic cover under 23±5° C., 40-80% RH and 0.5 kilograms (kgs) is in a range from 68 to 70. - Therefore, a new metallic cover is desired in order to overcome the above described shortcomings. A new method having high efficiency for making such metallic cover is also needed.
- In one aspect, a metallic cover includes a bottom base and a side wall extending from the bottom base. The side wall is formed by cold forging so that a thickness of the side wall is greater than that of the bottom base.
- In another aspect, a method for making the metallic cover described above, includes: drawing a metallic sheet into a preformed cover having a bottom base and a plurality of side walls, and the bottom base and each of the sidewalls connected at a rounded edge; forging the preformed cover by a first forming die to thicken the side walls, and a first slanted pressing surface formed on an end of each of the side walls; forging the preformed cover by a second forming die to further thicken the side walls, and a second slanted pressing surface intersecting with the first slanted pressing surface formed on the end of each of the side walls, and the rounded edge of the preformed cover pressed into a beveled edge; and machining the end of each of the side walls of the preformed metallic cover so that the preformed metallic cover is made into the metallic cover.
- Other novel features and advantages will become more apparent from the following detailed description, when taken in conjunction with the accompanying drawings.
- The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating principles of the present metallic cover and method for making the same. Moreover, in the drawings, like reference numerals designate corresponding parts throughout several views, and all the views are schematic.
-
FIG. 1 is an isometric view of a metallic cover in accordance with a preferred embodiment of the present invention. -
FIG. 2 is a partial, cross-sectional view of an edge of the metallic cover ofFIG. 1 . -
FIG. 3 is a metallographic photograph of part of the edge of the metallic cover magnified by 200×. -
FIG. 4 is an isometric view of a preformed metallic cover formed in a method for making the metallic cover ofFIG. 1 . -
FIG. 5 is a cross-sectional view of a first forming die used for pressing the preformed metallic cover ofFIG. 4 . -
FIG. 6 is an enlarged, side cross-sectional view of a punch of the first forming die ofFIG. 5 . -
FIG. 7 is a partial, cross-sectional view of the first forming die which is pressing the preformed metallic cover ofFIG. 4 . -
FIG. 8 is a partial, cross-sectional view of the preformed metallic cover after being pressed by the first forming die ofFIG. 5 . -
FIG. 9 is a cross-sectional view of a second forming die used for further pressing the preformed metallic cover which has been pressed by the first forming die ofFIG. 5 . -
FIG. 10 is an enlarged, side cross-sectional view of a punch of the second forming die ofFIG. 9 . -
FIG. 11 is a partial, cross-sectional view of the second forming die which is pressing the preformed metallic cover which has been pressed by the first forming die. -
FIG. 12 is a partial, cross-sectional view of the preformed metallic cover after being pressed by the second forming die ofFIG. 9 . -
FIG. 13 is a partial, cross-sectional view of a third finish machining die for making the preformed metallic cover which pressed by the second forming die ofFIG. 9 into the metallic cover ofFIG. 1 . -
FIG. 14 is an isometric view of a conventional metallic cover. -
FIG. 15 is a metallographic photograph of part of the conventional metallic cover magnified by 200×. - Reference will now be made to the drawings to describe preferred embodiments of the present metallic cover and method in detail.
- Referring to
FIGS. 1 and 2 , ametallic cover 20 according to a preferred embodiment is shown. In the illustrated embodiment, themetallic cover 20 is used as a cover for a mobile phone. Themetallic cover 20 includes arectangular bottom base 21, afirst side wall 22, asecond side wall 23, athird side wall 24, and afourth side wall 25. Theside walls rectangular bottom base 21. Theside walls bottom base 21 and each of theside walls edge 26. Theside walls metallic cover 20 are formed by cold forging, thus a thickness of each of theside walls metallic cover 20 is greater than that of thebottom base 21 of themetallic cover 20. - In the described embodiment, b represents a thickness of the
bottom base 21, t represents a thickness of each of theside walls side walls metallic cover 20 is preferably made of aluminum alloy. Theedge 26 is a beveled edge formed by cold forging. The angle formed between an outer surface of thebottom base 21 and an outer surface of each of thesidewalls edge 26 is in a range from about 90 degrees to about 135 degrees. - It should be pointed out that, the
bottom base 21 can also be other shapes such as triangular, pentagonal, and hexagonal. Theedge 26 is not limited to a beveled edge, the edge can also be other shapes, that is, not beveled, formed by cold forging. - Referring to
FIG. 3 , themetallic cover 20 made of aluminum alloy, e.g., an aluminum alloy of grade 5052-0 using cold forging method shows a metallographic photograph of a portion of the metallic cover under 23±5° C. and 40-80% relative humidity (RH) conditions. The metallographic photograph of the metallic cover is magnified by 200×. The metallographic structure of the metallic cover is relatively compact. A Vickers hardness of themetallic cover 20 under 23±5° C., 40-80% RH and 0.5 kilograms (kgs) is in a range from 71 to 75. Therefore, the Vickers hardness of themetallic cover 20 formed by cold forging is greater than the Vickers hardness of a metallic cover which is formed by milling method. - Referring to
FIGS. 4 through 13 , an exemplary method for making themetallic cover 20 will now be described. The method for making the metallic cover includes the following main steps: a drawing process; a first cold forging process; a second cold forging process; and a finish machining process. - In the drawing process, a metallic sheet is drawn into a preformed
metallic cover 30. In the illustrated embodiment, the metallic sheet used for making the preformedmetallic cover 30 is preferably made of aluminum alloys such as 5052-O aluminum alloy. The preformedcover 30 includes abottom base 31 and a plurality ofside walls 32. Theside walls 32 cooperatively define a cavity (not labeled) for receiving electronic components (not shown). Thebottom base 31 and each of thesidewalls 32 are connected at arounded edge 33. - In the first cold forging process, the preformed
cover 30 is forged by a first formingdie 200 to flatten theside walls 32, thereby thickening (widening) theside walls 32, and to form a first slanted pressed surface 321 (seeFIG. 8 ) on an end of each of theside walls 32. - Referring to
FIGS. 5 through 8 , the first formingdie 200 includes anupper die 210, alower die 220, a pressingmember 230, apunch 240, a firstresilient member 250, and a secondresilient member 260. Thelower die 220 and thepressing member 230 are disposed adjacent to and on opposite sides of thepunch 240 correspondingly. Thepunch 240, thelower die 220, and thepressing member 230 cooperatively define amolding groove 270 for receiving theside walls 32 of the preformedmetallic cover 30. A thickness of themolding groove 270 is greater than that of each of theside walls 32 of the preformedmetallic cover 30. Theupper die 210 is disposed above thelower die 220, the pressingmember 230, and thepunch 240. The firstresilient member 250 and the secondresilient member 260 are both springs. The firstresilient member 250 is disposed below thelower die 220. The secondresilient member 260 is disposed below the pressingmember 230. Theupper die 210 includes a workingsurface 2101 formed on a bottom surface for pressing thebottom base 31 of the preformedmetallic cover 30. Thelower die 220 includes a mountingsurface 2201 formed on a top surface for mounting the preformedmetallic cover 30. The pressingmember 230 includes aside surface 2301 and anupper surface 2302 perpendicular to each other. An extendingportion 2303 is formed on theside surface 2301 adjacent to theupper surface 2302. The extendingportion 2303 includes apressing surface 2304 for pushing against theside walls 32 of the preformedcover 30. Thepressing surface 2304 is perpendicular to the working surface of theupper die 220, and is parallel to theside surface 2301. - The
punch 240 includes apunching portion 2401 and a restrictingportion 2402 that connects to thepunching portion 2401. The punchingportion 2401 includes afirst side surface 2404, asecond side surface 2405, and aslanted working surface 2406. Thefirst side surface 2404 is parallel to thesecond side surface 2405, and thefirst side surface 2404 and thesecond side surface 2405 are on opposite sides of the punchingportion 2401 correspondingly. d1 represents a distance between thefirst side surface 2404 and thesecond side surface 2405, and t represents the final thickness of the sidewall of the metallic cover. The distance d1 should be in a range from 0.7 t to 0.9 t. The distance d1 is preferably in a range from 0.8 t to 0.85 t. An edge of the slanted workingsurface 2406 connects thefirst side surface 2404 and an opposite edge of the slanted workingsurface 2406 connects thesecond side surface 2405. The edge of the slanted workingsurface 2406 adjacent to thefirst side surface 2404 is configured to be higher than the opposite edge of the slanted workingsurface 2406 adjacent to thesecond side surface 2405. In other words, the slanted workingsurface 2406 slants towards thefirst side surface 2404. An angle β1 defined by the slanted workingsurface 2406 relative to thefirst side surface 2404 should be in a range from about 45 degrees to about 70 degrees. The angle β1 is preferably in a range from about 60 degrees to about 65 degrees. The restrictingportion 2402 includes apositioning surface 2403 for restricting the motion range of thepressing member 230. - Before the first cold forging process, a distance between the
upper surface 2302 of thepressing member 230 and the mountingsurface 2201 of thelower die 220 is greater than the thickness of thebottom base 31 of the preformedmetallic cover 30. Thepressing surface 2304 of the extendingportion 2303 of thepressing member 230 abuts thesecond side surface 2405 of the punchingportion 2401 of thepunch 240. Theside surface 2301 of thepressing member 230 abuts the restrictingportion 2402 of thepunch 240. A lower end of the extendingportion 2303 of thepressing member 230 is set a predetermined distance away from thepositioning surface 2403 of the restrictingportion 2402 of thepunch 240. The preformedmetallic cover 30 is placed on thelower die 220 and theside walls 32 of the preformed metallic cover are received in themolding groove 270. - During the first cold forging process, the
upper surface 2302 of thepressing member 230 and thebottom base 31 of the preformedmetallic cover 30 are pressed by theupper die 210. When thelower die 220 and thepressing member 230 are pressed, the firstresilient member 250 and the secondresilient member 260 becomes compressed. When thelower die 220 and thepressing member 230 are pressed, theside walls 32 of the preformedmetallic cover 30 received in themolding groove 270 presses/pushes against the slanted workingsurface 2406 of thepunch 240; material of theside walls 32 displaces (molds) into themolding groove 270. When thepressing member 230 is pressed until the extendingportion 2303 of thepressing member 230 abuts thepositioning surface 2403 of the restrictingportion 2402 of thepunch 240, thelower die 220 and thepressing member 230 stop moving. In the first cold forging process, material of theside walls 32 of the preformedmetallic cover 30 flattens out into themolding groove 270, thus theside walls 32 of the preformedmetallic cover 30 become thicker (wider) than thebottom base 31. Therounded edge 33 of the preformedcover 30 is pressed into a substantially beveled edge. - In the second cold forging process, the preformed
cover 30 is forged by a second forming die 300 to flatten theside walls 32, thereby further thickening (widening) theside walls 32, and to form a second slanted pressingsurface 322 intersecting with the first slantedpressing surface 321 on the end of each of theside walls 32. Therounded edge 33 of the preformedcover 30 is pressed into thebeveled edge 26. - Referring to
FIGS. 9 through 12 , the second forming die 300 includes anupper die 310, alower die 320, a pressingmember 330, apunch 340, a firstresilient member 350, and a secondresilient member 360. The principle of the second forming die 300 is similar to the first formingdie 200. However, thepunch 340 is different from thepunch 240 of the first formingdie 200. Thepunch 340 will now be described in detail as follows. - The
punch 340 includes apunching portion 3401 and a restrictingportion 3402 connecting to thepunching portion 3401. The punchingportion 3401 includes afirst side surface 3404, asecond side surface 3405, and aslanted working surface 3406. Thefirst side surface 3404 is parallel to thesecond side surface 3405,first side surface 3404 and thesecond side surface 3405 are on opposite sides of the punchingportion 3401 correspondingly. A distance d2 between thefirst side surface 3404 and thesecond side surface 3405 equals to the thickness t of the sidewall of the metallic cover to be formed. An edge of the slanted workingsurface 3406 connects thefirst side surface 3404 and an opposite edge of the slanted workingsurface 3406 connects thesecond side surface 3405. The opposite edge of the slanted workingsurface 3406 adjacent to thesecond side surface 3405 is configured to be higher than the edge of the slanted workingsurface 3406 adjacent to thefirst side surface 3404. An angle β2 defined by the slanted workingsurface 3406 relative to thefirst side surface 3404 should be in a range from about 45 degrees to about 70 degrees. The angle β2 is preferably in a range from about 60 degrees to about 65 degrees. The restrictingportion 3402 includes apositioning surface 3403 for restricting the motion range of thepressing member 330. Thepunch 340, thelower die 320, and thepressing member 330 cooperatively define amolding groove 370 for receiving theside walls 32 of the preformedmetallic cover 30. A thickness of themolding groove 370 is greater than the thickness of theside walls 32 of the preformedmetallic cover 30. - In the second cold forging process, the pressing
member 330 and thebottom base 31 of the preformedmetallic cover 30 is pressed by theupper die 310. When thelower die 320 and thepressing member 330 are pressed, theside walls 32 of the preformedmetallic cover 30 received in themolding groove 370 presses/pushes against the slanted workingsurface 3406 of thepunch 340; material of theside walls 32 displaces (molds) into themolding groove 370. When the extending portion 3303 of thepressing member 230 abuts thepositioning surface 3403 of the restrictingportion 3402 of thepunch 340, thelower die 320 and thepressing member 330 stop moving. In the second cold forging process, material of theside walls 32 of the preformedmetallic cover 30 flattens out into themolding groove 370, thus theside walls 32 of the preformedmetallic cover 30 become thicker than thebottom base 31 and therounded edge 33 of the preformedcover 30 is pressed into beveled edge. - In the finish machining process, each of the
side walls 32 of the preformedmetallic cover 30 is machined to a predetermined shape by a machining tool such as a milling machine, and thereby forming themetallic cover 20. In the described embodiment, the first slantedpressing surface 321 and the second slanted pressingsurface 322 of each of theside walls 32 are cut off and a flat surface is formed on theside walls 32. - In an alternative embodiment, referring to
FIG. 13 , in order to further improving the surface appearance of the preformedmetallic cover 30, a precision machining process is applied between the second cold forging process and the finish machining process. In the precision machining process, thesidewalls 32 of the preformedmetallic cover 30 are processed by aprecision forming die 400. Theprecision forming die 400 includes anupper die 401, alower die 402, and apressing plate 403. In use, the preformedmetallic cover 30 is fixed on thelower die 402 by thepressing plate 403, and the side walls of the preformedmetallic cover 30 extend out of thelower die 402. When theupper die 401 moves towards thelower die 402, a part of theside walls 32 of the preformedmetallic cover 30 is cut off, thus the surface appearance theside walls 32 is improved. - It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention.
Claims (13)
1. A metallic cover, comprising:
a bottom base; and
at least one side wall extending from the bottom base;
wherein the at least one side wall is formed by cold forging so that a thickness of the at least one side wall is greater than that of the bottom base.
2. The metallic cover as claimed in claim 1 , wherein the bottom base and the at least one side wall are connected at an edge, and the edge is a beveled edge.
3. The metallic cover as claimed in claim 2 , wherein an angle defined by an outer surface of the bottom base relative to the at least one sidewall at the edge is in a range from 90 degrees to 135 degrees.
4. The metallic cover as claimed in claim 2 , wherein the metallic cover is made of aluminum alloy.
5. The metallic cover as claimed in claim 1 , wherein a ratio of a thickness of the at least one side wall with respect to a thickness of the bottom base is in a range from 1 to 3, and a ratio of a height of the at least one side wall with respect to the thickness of the bottom base is in a range from 1 to 2.5.
6. The metallic cover as claimed in claim 1 , wherein the bottom base is rectangular, the metallic cover comprises four side walls, and the side walls perpendicularly extend from a periphery of the rectangular bottom base.
7. The metallic cover as claimed in claim 6 , wherein the bottom base and each of the side walls are connected at an edge, and the edge is a beveled edge.
8. The metallic cover as claimed in claim 7 , wherein the metallic cover is made of aluminum alloy, and an angle defined by an outer surface of the bottom base relative to the sidewalls at the edge is in a range from 90 degrees to 135 degrees.
9. The metallic cover as claimed in claim 8 , wherein a ratio of a thickness of the side walls with respect to a thickness of the bottom base is in a range from 1 to 3, and a ratio of a height of the side walls with respect to the thickness of the bottom base is in a range from 1 to 2.5.
10. A metallic cover, comprising:
a rectangular bottom base; and
four side walls perpendicularly extending from a periphery of the rectangular bottom base, and cooperatively defining a cavity together with the rectangular bottom base;
wherein the bottom base and each of the side walls of the metallic cover are correspondingly connected at an edge, and the side walls of the metallic cover are formed by cold forging, thus a thickness of each of the side walls of the metallic cover is greater than that of the bottom base.
11. The metallic cover as claimed in claim 1 , wherein a ratio of a thickness of each of the side walls with respect to a thickness of the bottom base is in a range from 1 to 3, and a ratio of a height of each of the side walls with respect to the thickness of the bottom base is in a range from 1 to 2.5.
12. The metallic cover as claimed in claim 12 , wherein the metallic cover is made of aluminum alloy, and the edge is a beveled edge formed by cold forging.
13. The metallic cover as claimed in claim 13 , wherein an angle defined by an outer surface of the bottom base relative to the sidewalls at the edge is in a range from 90 degrees to 135 degrees.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/215,360 US20110303686A1 (en) | 2007-11-16 | 2011-08-23 | Metallic cover |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN200710202573A CN101437373B (en) | 2007-11-16 | 2007-11-16 | Metal casing and molding method thereof |
CN200710202573.2 | 2007-11-16 | ||
US12/012,298 US8015852B2 (en) | 2007-11-16 | 2008-02-01 | Metallic cover and method for making the same |
US13/215,360 US20110303686A1 (en) | 2007-11-16 | 2011-08-23 | Metallic cover |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/012,298 Division US8015852B2 (en) | 2007-11-16 | 2008-02-01 | Metallic cover and method for making the same |
Publications (1)
Publication Number | Publication Date |
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US20110303686A1 true US20110303686A1 (en) | 2011-12-15 |
Family
ID=40640548
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/012,298 Expired - Fee Related US8015852B2 (en) | 2007-11-16 | 2008-02-01 | Metallic cover and method for making the same |
US13/215,360 Abandoned US20110303686A1 (en) | 2007-11-16 | 2011-08-23 | Metallic cover |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US12/012,298 Expired - Fee Related US8015852B2 (en) | 2007-11-16 | 2008-02-01 | Metallic cover and method for making the same |
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US (2) | US8015852B2 (en) |
CN (1) | CN101437373B (en) |
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CN105979025A (en) * | 2015-03-06 | 2016-09-28 | 爱斯特技术开发有限公司 | Metal case for portable phone formed through press process and method of manufacturing the same |
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Also Published As
Publication number | Publication date |
---|---|
CN101437373A (en) | 2009-05-20 |
CN101437373B (en) | 2012-09-26 |
US8015852B2 (en) | 2011-09-13 |
US20090126450A1 (en) | 2009-05-21 |
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