TWI472386B - Mold and method for manufacturing metal case - Google Patents
Mold and method for manufacturing metal case Download PDFInfo
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Description
本發明係有關一種製造金屬殼件的模具及方法，特別是關於一種大量製造金屬殼件的模具及方法。The present invention relates to a mold and method for manufacturing a metal shell member, and more particularly to a mold and method for mass producing a metal shell member.
金屬殼件可說是近年消費電子產品的新寵，舉凡筆記型電腦、智慧型手機及新堀起的平板電腦等均紛紛採用散熱佳且耐衝擊的金屬機殼。一般而言，在傳統上電子產品金屬殼件的製造普遍採用預先單獨製造各部殼件，其可選擇利用沖壓、壓鑄或鍛造方式製造各部殼件，最後再將各部殼件組裝。但是上述方式必然產生各部殼件之間具有精度偏差的技術問題，其將可能影響產品的組裝品質及組裝效率。因此，傳統電子產品金屬殼件的各部殼件需要額外加工作業，以改善殼件精度偏差的技術問題。如此，傳統電子產品金屬殼件的各部殼件製造方法具有製程複雜、增加金屬廢料及生產速率慢等缺點。Metal shells can be said to be the new darling of consumer electronics in recent years. All notebook computers, smart phones and new tablet PCs have adopted heat-dissipating and impact-resistant metal casings. In general, in the manufacture of electronic metal casings, it has been conventionally practiced to separately manufacture the various shell members in advance, which may alternatively be used to manufacture the various shell members by stamping, die casting or forging, and finally to assemble the shell members. However, the above method inevitably creates a technical problem of precision deviation between the respective shell members, which may affect the assembly quality and assembly efficiency of the product. Therefore, the various shell parts of the metal shell of the conventional electronic product require additional processing work to improve the technical problem of the precision deviation of the shell. Thus, the manufacturing method of the various shell parts of the metal shell of the conventional electronic product has the disadvantages of complicated process, increased metal scrap and slow production rate.
另外，針對外形複雜或有特殊圖案的金屬殼件而言，習知的沖壓方式亦有成形速度慢、對圖案或外形的成形能力不佳及須額外精加工程序等缺點。In addition, for metal shells with complex shapes or special patterns, conventional stamping methods also have disadvantages such as slow forming speed, poor forming ability for patterns or shapes, and additional finishing procedures.
因3C產業的產品具有生命週期短、種類多、設計複雜、研發速度快等特性，故生產電子產品的速度及良率是影響製造商本身競爭力的關鍵。因此，此領域著實需要一種能快速生產高品質金屬殼件的方法。Because the products of 3C industry have the characteristics of short life cycle, various types, complicated design and fast development speed, the speed and yield of producing electronic products are the key factors affecting the competitiveness of manufacturers themselves. Therefore, there is a real need in the art for a method for rapidly producing high quality metal shell parts.
相對於習知製造金屬殼件的方法，本案所提出的模具及方法可以倍速提高的製程速度製成一體成形且兼具質感及特殊圖案的金屬殼件，以達到減少金屬廢料、提升金屬殼件品質及降低製造成本之功效，並滿足3C產業的產品種類多樣化的需求。Compared with the conventional method for manufacturing a metal shell member, the mold and method proposed in the present invention can be integrally formed and have a metal shell member with both texture and special pattern to reduce metal scrap and lift the metal shell member. Quality and reduced manufacturing costs, and meet the diverse needs of the 3C industry.
本案之目的之一為提供一種製造金屬殼件的方法，包括：將一下母模與一下模仁組裝成一下模；將一上母模與一上模仁組裝成一上模，其中該下模仁與該上模仁至少其中之一的一工作表面上包含複數圖紋單元；利用包含該下模及該上模的一模具將一金屬管件成形為包含對應該複數圖紋之複數對應圖紋的一成形金屬管件；以及將該成形金屬管件分割成分別具有該複數對應圖紋的複數殼件。One of the purposes of the present invention is to provide a method for manufacturing a metal shell member, comprising: assembling a lower master mold and a lower mold core into a lower mold; assembling an upper female mold and an upper mold core into an upper mold, wherein the lower mold core Forming a plurality of pattern units on a working surface of at least one of the upper mold cores; forming a metal tube member into a plurality of corresponding patterns corresponding to the plurality of patterns by using a mold including the lower mold and the upper mold a shaped metal tubular member; and the shaped metal tubular member is divided into a plurality of shell members each having the plurality of corresponding patterns.
本案之另一目的為一種製造金屬殼件的方法，該方法包括：組裝至少一下模仁至一下母模以組成一具有複數圖紋單元的下模，該複數圖紋單元是形成於該至少一下模仁的一工作表面；將一金屬管件置於該下模仁上，並與該複數圖紋單元相對；將一上模與該下模合模；進行管件液壓成形，形成具有該複數圖紋單元的一成形金屬管件；以及根據該複數圖紋單元的數量切割該成形金屬管件，以製成複數殼件。Another object of the present invention is a method for manufacturing a metal shell member, the method comprising: assembling at least a mold core to a lower mold to form a lower mold having a plurality of pattern units, wherein the plurality of pattern units are formed at least a working surface of the mold core; placing a metal pipe member on the lower mold core and opposite to the plurality of pattern elements; and clamping an upper mold and the lower mold; performing hydraulic forming of the pipe member to form the plurality of patterns a formed metal tubular member of the unit; and the shaped metal tubular member is cut according to the number of the plurality of patterned unit to form a plurality of shell members.
本案之另一目的為提供一種製造金屬殼件的模具，包括：一上母模，具有用於容置一上模仁的一上凹槽；以及一下母模，具有用於容置一下模仁的一下凹槽，其中該上凹槽與該下凹槽具有相同的深度。Another object of the present invention is to provide a mold for manufacturing a metal shell member, comprising: an upper mother mold having an upper groove for receiving an upper mold core; and a lower mother mold for accommodating the mold core a lower groove, wherein the upper groove has the same depth as the lower groove.
本案之再一目的為提供一種製造金屬殼件的模具，包括：一下母模；以及一下模仁，組裝於該下母模，該下模仁的一工作表面具有複數圖紋單元，該複數圖紋單元是用於在複數金屬殼件中的每一金屬殼件上形成一對應圖紋單元。A further object of the present invention is to provide a mold for manufacturing a metal shell member, comprising: a lower master mold; and a lower mold core assembled to the lower master mold, a working surface of the lower mold core having a plurality of pattern units, the plurality of patterns The embossing unit is for forming a corresponding pattern unit on each of the plurality of metal shell members.
本案之再一目的為提供一種製造金屬殼件的模具，該模具具有複數圖紋單元，並包括：至少一模仁，該複數圖紋單元是設置於該至少一模仁的一模穴表面，該至少一模仁是用以模製一具有與該複數圖紋單元相對應的複數圖紋單元的金屬管件。A further object of the present invention is to provide a mold for manufacturing a metal shell member, the mold having a plurality of pattern units, and comprising: at least one mold unit, the plurality of pattern units being disposed on a cavity surface of the at least one mold core, The at least one mold core is for molding a metal pipe member having a plurality of pattern elements corresponding to the plurality of pattern elements.
本案之再一目的為提供一種製造金屬殼件的模具，包括：一下母模；以及複數下模仁，組裝於該下母模，該複數下模仁的一工作表面具有複數圖紋單元，該複數圖紋單元是用於在複數金屬殼件中的每一金屬殼件上形成一對應圖紋單元。A further object of the present invention is to provide a mold for manufacturing a metal shell member, comprising: a lower master mold; and a plurality of lower mold cores assembled to the lower master mold, a working surface of the plurality of lower mold cores having a plurality of pattern units, The plurality of pattern elements are for forming a corresponding pattern unit on each of the plurality of metal shell members.
本案之再一目的為提供一種製造金屬殼件的方法。上述方法包括以下步驟：在一模仁的一工作表面上形成複數圖紋；利用該模仁將一金屬管件成形為包含對應該複數圖紋之複數對應圖紋的一成形金屬管件；以及分割該成形金屬管件以製成分別具有該複數對應圖紋的複數金屬殼件。A further object of the present invention is to provide a method of making a metal shell. The above method comprises the steps of: forming a plurality of patterns on a working surface of a mold core; forming a metal tube member into a shaped metal tube member corresponding to a plurality of corresponding patterns corresponding to the plurality of patterns; and dividing the The metal tubular members are formed to form a plurality of metal shell members each having the plurality of corresponding patterns.
本案得藉由下列詳細說明，俾得更深入之了解：The case can be further explained by the following detailed explanation:
本發明將藉由下述之較佳實施例及其配合之圖式，做進一步之詳細說明。The invention will be further described in detail by the following preferred embodiments and the accompanying drawings.
本案的目的之一在於提供適用於管件(特別是擠型管)液壓成形(Tube Hydroforming，THF)技術的模具，特別是用以大量製造具有多種圖紋之金屬殼件的模具。管件液壓成形技術係於管件內部加入高壓流體，藉由高壓流體將管料壓入到模具腔體內成形，非常適用於異厚異形之一體形3D中空結構管件生產。One of the objects of the present invention is to provide a mold suitable for pipe fitting (especially extruded pipe) hydroforming (THF) technology, in particular, a mold for mass producing a metal shell member having a plurality of patterns. Pipe fitting hydroforming technology is to add high-pressure fluid inside the pipe, and press the pipe material into the cavity of the mold by high-pressure fluid. It is very suitable for the production of 3D hollow structural pipe with different thickness and shape.
請參考第一圖(A)及(B)，其分別為本案所提模具的第一較佳實施例的上、下母模及沖頭的示意圖。本案所提供用以製造金屬殼件的模具包含上模、下模及沖頭10。該上模包括：上母模11，該上母模11中間包含上凹槽110，於上凹槽110周圍設有複數鎖固孔111(請參考第二圖(A))；及一或多個上模仁20(請參考第二圖(A))，該上模仁20可配合置於上母模11之上凹槽110中，並藉由複數鎖固孔111鎖固於上母模11，以本例而言，上模仁20之數量為四個，但不以此為限。該下模包括：下母模12，該下母模12中間包含下凹槽120，於下凹槽120周圍設有複數鎖固孔121；及下模仁，以本例而言，下模仁之數量為四個，下模仁21A~D(請參考第二圖(B))，但不以此為限，該些下模仁21A~D可配合置於下母模12之下凹槽120中，並藉由複數鎖固孔121鎖固於下母模12。請參考第一圖(B)，該沖頭10包含基座101及與基座101相連接的密封元件102，該密封元件102的形狀可依據管件橫截面的形狀和尺寸而設計。Please refer to the first figures (A) and (B), which are schematic diagrams of the upper and lower masters and punches of the first preferred embodiment of the mold proposed in the present invention. The mold provided in the present invention for manufacturing a metal shell member includes an upper mold, a lower mold, and a punch 10. The upper mold includes: an upper female mold 11 including an upper recess 110 in the middle thereof, and a plurality of locking holes 111 around the upper recess 110 (please refer to FIG. 2(A)); and one or more The upper mold core 20 (please refer to the second figure (A)), the upper mold core 20 can be fitted into the groove 110 above the upper mother mold 11, and locked to the upper mother mold by the plurality of locking holes 111. 11. In this example, the number of upper mold cores 20 is four, but not limited thereto. The lower die includes: a lower die 12, the lower die 12 includes a lower groove 120 in the middle, and a plurality of locking holes 121 are arranged around the lower groove 120; and a lower die, in this case, a lower die The number is four, the lower mold core 21A~D (please refer to the second figure (B)), but not limited thereto, the lower mold cores 21A~D can be matched to the recess 120 below the lower female mold 12. And locked to the lower master mold 12 by a plurality of locking holes 121. Referring to the first figure (B), the punch 10 includes a base 101 and a sealing member 102 connected to the base 101. The shape of the sealing member 102 can be designed according to the shape and size of the cross-section of the tubular member.
請參考第二圖(B)，其為本案第一較佳實施例中下母模及下模仁的示意圖。本實施例之下模具有複數圖紋單元，詳言之，該複數圖紋單元是形成於下模仁21A~D的模穴表面處(即工作表面)，以製成具有對應圖紋的金屬殼件。第二圖所揭示的下模仁21A、21C、21D是分別於模穴表面處形成複數圖紋單元，惟每一下模仁的圖紋單元不以複數為限，亦可僅有一圖紋單元，或未形成圖紋單元(如下模仁21B)。當模穴上的圖紋為凹紋時，可在金屬殼件上產生相對應的凸紋，反之亦然。所謂「圖紋單元」意指單一產品(即本案方法最終製成的複數金屬殼件中的單一金屬殼件)上所有圖紋的集合，以下模仁21A為例，其模穴中即設置有4個圖紋單元。所述複數圖紋單元可以是重複的單一圖紋單元(例如下模仁21A)、重複的兩種以上圖紋單元(例如下模仁21C)或相異的多種圖紋單元(例如下模仁21D)。下模仁21A~21D具有可替換性，依據客戶對金屬殼件圖紋種類、形狀及數量的需求，可在下母模12的下凹槽120中容置一或複數個下模仁21A~D，其中具有圖紋單元的下模仁21A、21C及21D可搭配不具有圖紋單元的下模仁21B使用。以第二圖(B)為例，若將下模仁21A-D置於下凹槽120中，經管件液壓成形及管件切割後，可同時產出16個殼件，其中4個殼件不具有圖紋，其他12個殼件各具有一圖紋單元。因此，針對不同圖紋、形狀及數量的殼件需求，廠商僅須要重製並替換模仁，無須重製整個模具，對於廠商來說無疑提高了便利性並降低了生產成本。Please refer to the second figure (B), which is a schematic diagram of the lower master mold and the lower mold core in the first preferred embodiment of the present invention. In the embodiment, the mold has a plurality of pattern elements. In detail, the plurality of pattern elements are formed on the surface of the cavity of the lower mold cores 21A to D (ie, the working surface) to form a metal having a corresponding pattern. Shell piece. The lower mold cores 21A, 21C, and 21D disclosed in the second figure respectively form a plurality of pattern elements at the surface of the cavity, but the pattern unit of each lower mold core is not limited to a plurality of patterns, and only one pattern unit may be used. Or the pattern unit is not formed (the following mold 21B). When the pattern on the cavity is concave, a corresponding relief can be produced on the metal shell, and vice versa. The so-called "pattern unit" means a collection of all patterns on a single product (ie, a single metal shell member in a plurality of metal shell members finally produced by the method of the present invention). The following mold core 21A is taken as an example, and the mold cavity is provided with 4 pattern units. The plurality of pattern units may be repeated single pattern units (eg, lower mold core 21A), repeated two or more pattern units (eg, lower mold core 21C), or different plurality of pattern units (eg, lower mold core) 21D). The lower mold cores 21A~21D are replaceable. According to the customer's requirements for the type, shape and quantity of the metal shell parts, one or more lower mold cores 21A~D can be accommodated in the lower recess 120 of the lower mother mold 12. The lower mold cores 21A, 21C, and 21D having the pattern unit can be used with the lower mold core 21B having no pattern unit. Taking the second figure (B) as an example, if the lower mold cores 21A-D are placed in the lower recess 120, after the hydraulic forming of the pipe fittings and the pipe cutting, 16 shell pieces can be simultaneously produced, of which 4 shell parts are not With a pattern, the other 12 shells each have a pattern unit. Therefore, for different shell patterns, shapes and quantities of shell parts, the manufacturer only needs to remanufacture and replace the mold core, without having to reproduce the entire mold, which undoubtedly improves the convenience and reduces the production cost for the manufacturer.
請參考第三圖，其為使用本案所提模具的第一較佳實施例來製造金屬殼件的方法的示意圖。上述方法包含如下步驟：將下母模12與一個或複數個下模仁21A組裝為具有複數圖紋單元的下模，該複數圖紋單元是形成於該(些)下模仁21A的模穴表面(即工作表面)處，以本例而言，下模仁21A的數量為二，每一下模仁21A具有四個圖紋單元；依同樣方式組裝上模(圖中未示)；將金屬管件(例如擠型管等)30置於下模仁21A上，並與該複數圖紋單元相對，金屬管件30的材料可選自鐵、銅、鈦、鎂、鋁、金、銀、鉑及其合金等；將上、下模合模；金屬管件30的兩端分別以沖頭10(參考第一圖(B))密封，並由沖頭10灌入工作流體(例如油、水等)以進行管件液壓成形(THF)(圖中未示)；開模取出成形金屬管件31(即具有與該複數圖紋單元相對應的複數圖紋單元的金屬管件)；根據複數圖紋單元的數量(以圖中為例為8個)，以刀具、水刀或雷射光束等切割技術切割成形金屬管件31，以製成複數殼件32(以圖中為例為8個)，其可視產品設計及需求，進一步加工製成電子產品的金屬殼件，例如手機、PDA、筆記型電腦、數位電視機、遊戲機等，或其他電器產品等之殼件。因本案是透過管件作為原料，藉由對管腔內施加液體壓力，使其透過管壁與下模仁21A之模穴表面貼合來得到具有所需圖紋的成形金屬管件31，故本案的上述方法可以依照產品的圖紋需求大量製造各種具有所需圖紋的金屬殼件。由上述方法所製成的金屬殼件及其表面之圖紋為一體成形，且該圖紋能呈現各種浮凸或凹陷的立體圖案，故此方法可有效地增加殼體在外觀造型及形狀規格方面的變化效能。Please refer to the third drawing, which is a schematic view of a method of manufacturing a metal shell member using the first preferred embodiment of the mold of the present invention. The above method comprises the steps of assembling the lower master mold 12 and one or more lower mold cores 21A into a lower mold having a plurality of pattern elements, which are formed in the mold cavity of the lower mold core 21A. At the surface (ie, the working surface), in this example, the number of the lower mold cores 21A is two, and each of the lower mold cores 21A has four pattern units; the upper molds are assembled in the same manner (not shown); A pipe member (for example, an extruded pipe or the like) 30 is placed on the lower mold core 21A, and opposite to the plurality of pattern units, the material of the metal pipe member 30 may be selected from the group consisting of iron, copper, titanium, magnesium, aluminum, gold, silver, platinum, and The alloy or the like; the upper and lower molds are closed; the two ends of the metal pipe member 30 are respectively sealed by the punch 10 (refer to the first figure (B)), and the punch 10 is filled with the working fluid (for example, oil, water, etc.). For pipe fitting hydroforming (THF) (not shown); opening the mold to take out the formed metal pipe member 31 (ie, the metal pipe member having the plurality of pattern elements corresponding to the plurality of pattern elements); according to the number of complex pattern elements (8 in the figure), the metal pipe fitting 31 is cut by a cutting technique such as a cutter, a water jet or a laser beam to make the metal pipe member 31. The plurality of shell members 32 (eight in the figure) are further processed into metal shell parts of electronic products, such as mobile phones, PDAs, notebook computers, digital televisions, game consoles, etc., depending on product design and requirements. Or shell parts such as other electrical products. In the present case, the tubular metal pipe member 31 having the desired pattern is obtained by applying a liquid pressure to the lumen through the tube wall and applying the liquid pressure to the cavity of the lower mold core 21A. The above method can mass-produce various metal shell members having desired patterns according to the pattern requirements of the product. The metal shell member made by the above method and the pattern of the surface thereof are integrally formed, and the pattern can exhibit various embossed or concave three-dimensional patterns, so the method can effectively increase the appearance and shape specifications of the shell. The performance of change.
於本案第一較佳實施例中，複數圖紋單元是形成於下模仁21A~D的模穴表面上，然而，本領域技術人員可以領會的是，其亦可形成於上模仁20的模穴表面上。以具有兩個主要表面的扁平金屬管件為例，當本案方法利用扁平金屬管件產生的殼件32是用於手機等產品之殼件時，因該殼件32的其中一表面通常須被部分或完全切除以適於組裝內部組件並安裝顯示面板，故通常不會於該表面上形成圖紋；但是若該殼件32是用於製成飾品或文具等方面，亦可利用上、下模穴上的圖紋單元使該殼件32的兩個主要表面上都產生相應圖紋。In the first preferred embodiment of the present invention, the plurality of pattern elements are formed on the surface of the cavity of the lower mold cores 21A to D. However, those skilled in the art can appreciate that they can also be formed on the upper mold core 20. On the surface of the cavity. Taking a flat metal pipe member having two main surfaces as an example, when the case member 32 produced by the method of the present invention utilizes a flat metal pipe member is a case member for a product such as a mobile phone, since one surface of the case member 32 usually has to be partially or Completely cut off to fit the internal components and install the display panel, so the pattern is usually not formed on the surface; but if the shell member 32 is used for making jewelry or stationery, the upper and lower mold holes can also be utilized. The upper pattern unit produces a corresponding pattern on both major surfaces of the shell member 32.
於本案第三圖所示用以製造金屬殼件的方法中，其金屬管件30的種類並不受限，例如圓管或異型管(包括橫斷面輪廓非圓形的、等壁厚的、變壁厚的、沿長度方向變直徑和變壁厚的、斷面對稱和不對稱的異型管)。當所使用的金屬管件30為擠型異型管時，本案特別提供一轉接設計於擠型管的兩端並提供與該轉接設計相配的沖頭(即第一圖(B)所示之沖頭10)。請參考第四圖，其為本案第一較佳實施例中金屬管件端點處轉接設計的示意圖。如圖所示，當本案第三圖方法中的金屬管件30是擠型管時，其擠型管截面301(圖中僅示出左端)的兩側下緣各具有一極小圓角(於本案中，圓角及R角等名詞得交替使用)。如採用具有極小圓角之擠型管截面301作為密封截面，會因圓角過小而不易密封持壓，且會因應力易於集中而造成管件或沖頭損壞。一般為配合標準圓形沖頭的形狀，習知方式是透過模穴的設計使具有圓形截面的擠型管於合模時在兩端之間的區域壓製成扁平形截面，也就是由兩端圓形截面向內漸變成扁平形截面，並以圓形截面進行密封，但是此方式會使漸變處過長，屆時需要切除管件過長之漸變處而導致材料浪費。是故，本案透過模穴和沖頭的設計，藉由沖頭密封擠型管兩端的過程，使擠型管的兩端漸變為扁平管302，其可便於密封具有極小圓角之有縫或無縫擠型異型管，以利液壓成形的進行。擠型管兩端的扁平管302的設計使得原來具有極小圓角之擠型管截面301逐漸變為較大圓角之扁形密封截面303，此可增加沖頭10的密封元件102與擠型管間之密封效果及沖頭10的使用壽命，且亦無習知方式漸變處過長的問題。也就是說，針對擠型管，只要密封截面303的圓角略大於原來的擠型管截面301的圓角，即可改善習用技術的問題。這樣的設計概念亦可適用於其他非圓形的異型管。此外，本發明亦提供與上述轉接設計相配的沖頭10(如第一圖(B)所示)。為了使擠型管由原來的擠型管截面301漸變為扁平管302的扁形密封截面303，沖頭10的密封元件102包含一前錐部1021和一密封部1022，前錐部1021之橫截面形狀大致與擠型管截面301的形狀相同，其橫截面面積由鄰近密封部1022的一端(粗端)往遠離密封部1022的另一端(細端)漸縮，且遠離密封部1022的另一端(細端)的面積是小於擠型管截面301的面積(參考第四圖)，以利沖頭10置入。密封部1022是呈一扁形，其兩側各自形成圓角，該些圓角略大於原來的擠型管截面301的圓角。將二沖頭10密封金屬管件30兩端時，密封元件102前錐部1021的細端先伸入金屬管件30內，由於前錐部1021的橫截面面積由細端往粗端漸擴，沖頭10前進的過程中將使金屬管件30兩端由原先之擠型管截面301變形為扁形密封截面303，並使金屬管件30兩端形成扁平管302，進而使沖頭10之密封元件102(密封部1022)密封扁平管302。密封部1022具有8-100mm的一寬度，較佳是具有12-75 mm的一寬度。具有上述寬度的密封元件102(密封部1022)皆可達到液壓成形過程中所需的良好密封效果。In the method for manufacturing a metal shell member shown in the third figure of the present invention, the type of the metal pipe member 30 is not limited, such as a circular pipe or a profiled pipe (including a cross-sectional profile non-circular, equal wall thickness, Variable-walled, symmetrical and asymmetrical shaped tubes that vary in length and become wall thickness. When the metal pipe member 30 used is an extruded profile pipe, the present invention particularly provides a transfer design at both ends of the extruded pipe and provides a punch matched with the transfer design (ie, as shown in the first figure (B). Punch 10). Please refer to the fourth figure, which is a schematic diagram of the transfer design of the end of the metal pipe in the first preferred embodiment of the present invention. As shown in the figure, when the metal pipe member 30 in the method of the third embodiment of the present invention is an extruded pipe, the two sides of the extruded pipe section 301 (only the left end is shown) have a small rounded corner (in this case). In the middle, rounded corners and R angles are used interchangeably. If the extruded section 301 with a very small rounded corner is used as the sealing section, the rounded corner is too small to be easily sealed and held, and the pipe or the punch may be damaged due to the easy concentration of the stress. Generally, in order to match the shape of a standard circular punch, the conventional method is to make the extruded tube having a circular cross section pressed into a flat cross section at the region between the two ends when the mold is closed by the design of the cavity, that is, by two The circular section of the end is tapered inwardly into a flat section and sealed with a circular section, but this way the gradient is too long, and it is necessary to cut off the long gradient of the tube and cause material waste. Therefore, in this case, through the design of the cavity and the punch, the process of sealing the two ends of the extruded tube by the punch causes the two ends of the extruded tube to be tapered into a flat tube 302, which can facilitate the sealing with a small rounded seam or Seamlessly extruded profiled tube for hydraulic forming. The flat tubes 302 at both ends of the extruded tube are designed such that the extruded tube section 301 having a very small rounded corner gradually becomes a relatively rounded flat sealing section 303, which increases the gap between the sealing member 102 and the extruded tube of the punch 10. The sealing effect and the service life of the punch 10, and there is no problem that the gradation is too long in the conventional manner. That is, for the extruded tube, as long as the rounded corner of the sealing section 303 is slightly larger than the rounded corner of the original extruded tube section 301, the problem of the conventional technique can be improved. This design concept can also be applied to other non-circular shaped tubes. In addition, the present invention also provides a punch 10 (as shown in the first figure (B)) that is matched to the above described transfer design. In order to gradualize the extruded tube from the original extruded tube section 301 to the flat sealing section 303 of the flat tube 302, the sealing element 102 of the punch 10 includes a front tapered portion 1021 and a sealing portion 1022, and a cross section of the front tapered portion 1021. The shape is substantially the same as the shape of the extruded tube section 301, and the cross-sectional area thereof is tapered from the one end (thick end) adjacent to the sealing portion 1022 toward the other end (thin end) away from the sealing portion 1022, and away from the other end of the sealing portion 1022. The area of the (thin end) is smaller than the area of the extruded tube section 301 (refer to the fourth figure) to facilitate the insertion of the punch 10. The sealing portion 1022 has a flat shape with rounded corners on both sides, and the rounded corners are slightly larger than the rounded corners of the original extruded tube section 301. When the two punches 10 seal the two ends of the metal pipe member 30, the thin end of the front taper portion 1021 of the sealing member 102 first protrudes into the metal pipe member 30, since the cross-sectional area of the front taper portion 1021 is gradually expanded from the thin end to the thick end, During the advancement of the head 10, the ends of the metal pipe member 30 are deformed from the original extruded pipe section 301 into a flat sealing section 303, and the flat ends of the metal pipe member 30 are formed into a flat tube 302, thereby making the sealing member 102 of the punch 10 ( The sealing portion 1022) seals the flat tube 302. The sealing portion 1022 has a width of 8 to 100 mm, preferably a width of 12 to 75 mm. The sealing member 102 (seal portion 1022) having the above width can achieve a good sealing effect required in the hydroforming process.
請參考第五圖，其為本案所提模具的第二較佳實施例的示意圖。於本實施例中，下模仁及上模仁(圖中未示)分別具有並列且上下相對應的複數模穴，在此實施例中為上、下模仁各具有三個模穴。當有三個模穴時，可在三個模穴上放置三個金屬管件，而各個模穴上圖紋的設計可參考第一較佳實施例進行。上、下模合模後欲進行密封時，本發明於模具兩端(圖中僅示出模具的左端)各提供一個複數獨立沖頭組50，以便從左右兩端密封三個金屬管件。以本實施例而言，該複數獨立沖頭組50包含三個沖頭501(沖頭的數量是依模穴的數量而定)，其是獨立地鎖固於一墊塊502上。考慮精度及組裝問題，三個獨立鎖固的沖頭501可個別微調其鎖固位置。另外，複數獨立沖頭組50另包含一高壓液體分接單元503，工作流體可經由高壓液體分接單元503直接給複數個沖頭501增壓，無須流經沖頭座，以減少密封不良的問題。根據本案第二較佳實施例的設計，若此實施例使用的金屬管件長度與本案第三圖中第一較佳實施例所使用的金屬管件長度一致，則使用第二較佳實施例於一次生產流程中所能產生金屬殼件的數量將是第一較佳實施例的三倍。因此，本案第二實施例的設計將可使產品的生產速率以倍速增加。Please refer to the fifth figure, which is a schematic view of a second preferred embodiment of the mold proposed in the present invention. In the present embodiment, the lower mold core and the upper mold core (not shown) respectively have a plurality of mold cavities juxtaposed and correspondingly upper and lower, and in this embodiment, the upper and lower mold cores each have three mold cavities. When there are three cavities, three metal tubes can be placed on the three cavities, and the design of the patterns on the respective cavities can be made with reference to the first preferred embodiment. When the upper and lower molds are to be sealed after clamping, the present invention provides a plurality of independent punch sets 50 at both ends of the mold (only the left end of the mold is shown) to seal the three metal tubes from the left and right ends. In the present embodiment, the plurality of independent punch sets 50 include three punches 501 (the number of punches is determined by the number of die holes), which are independently locked to a spacer 502. Considering the accuracy and assembly issues, the three independently locked punches 501 can individually fine tune their locking position. In addition, the plurality of independent punch groups 50 further comprise a high pressure liquid tapping unit 503, and the working fluid can directly pressurize the plurality of punches 501 via the high pressure liquid tapping unit 503 without flowing through the punch holder to reduce the poor sealing. problem. According to the design of the second preferred embodiment of the present invention, if the length of the metal pipe used in this embodiment is the same as the length of the metal pipe used in the first preferred embodiment of the third embodiment of the present invention, the second preferred embodiment is used once. The number of metal shell members that can be produced in the production process will be three times that of the first preferred embodiment. Therefore, the design of the second embodiment of the present invention will increase the production rate of the product at a multiple speed.
本案利用的是管件液壓成形技術，該技術製成的金屬殼體相較於沖壓或板液壓技術製成的殼體強度更高。再者，相較於傳統沖壓方式，本案製程較乾淨、速度快及產量大，且製出的成品表面較平滑且尺寸精度較高，於殼體上的圖案亦可較複雜及細緻。此外，本案模具的設計方式可減少廢料約30%、增加沖頭和模具間的密封能力和使用壽命以及加快產率，如此可有效地降低殼件廠商的製造成本。而本發明製造金屬殼件的方法可同時產生多種不同樣式的殼件，此倍速量產的製程將可帶來龐大的經濟效益。In this case, the hydraulic forming technology of the pipe fitting is utilized, and the metal casing made by the technology is stronger than the casing made by the stamping or plate hydraulic technology. Moreover, compared with the conventional stamping method, the process of the present invention is relatively clean, fast, and the output is large, and the finished product has a smooth surface and high dimensional accuracy, and the pattern on the casing can be complicated and detailed. In addition, the design of the mold in this case can reduce the waste capacity by about 30%, increase the sealing ability and service life between the punch and the mold, and accelerate the yield, which can effectively reduce the manufacturing cost of the shell manufacturer. However, the method for manufacturing a metal shell member of the present invention can simultaneously produce a plurality of shell members of different styles, and the multi-speed production process can bring huge economic benefits.
1.一種製造金屬殼件的方法，包括：將一下母模與一下模仁組裝成一下模；將一上母模與一上模仁組裝成一上模，其中該下模仁與該上模仁至少其中之一的一工作表面上包含複數圖紋；利用包含該下模及該上模的一模具將一金屬管件成形為包含對應該複數圖紋之複數對應圖紋的一成形金屬管件；以及將該成形金屬管件分割成分別具有該複數對應圖紋的複數殼件。A method of manufacturing a metal shell member, comprising: assembling a lower master mold and a lower mold core into a lower mold; assembling an upper female mold and an upper mold core into an upper mold, wherein the lower mold core and the upper mold core Forming a plurality of patterns on at least one of the working surfaces; forming a metal tube member into a formed metal tube member including a plurality of corresponding patterns corresponding to the plurality of patterns by using a mold including the lower mold and the upper mold; The shaped metal tubular member is divided into a plurality of shell members each having the plurality of corresponding patterns.
2.一種製造金屬殼件的方法，包括：在一模仁的一工作表面上形成複數圖紋；利用該模仁將一金屬管件成形為包含對應該複數圖紋之複數對應圖紋的一成形金屬管件；以及分割該成形金屬管件以製成分別具有該複數對應圖紋的複數金屬殼件。2. A method of manufacturing a metal shell member, comprising: forming a plurality of patterns on a working surface of a mold core; forming a metal tube member into a shape including a plurality of corresponding patterns corresponding to the plurality of patterns by the mold core a metal tubular member; and the shaped metal tubular member is divided to form a plurality of metal shell members each having the plurality of corresponding patterns.
3.如上述實施例任一項所述之方法，其中該上母模具有用以容置該上模仁的一上凹槽，且該下母模具有用以容置該下模仁的一下凹槽，該上凹槽與該下凹槽具有一相同深度。3. The method of any of the above embodiments, wherein the upper master mold is adapted to receive an upper recess of the upper mold core, and the lower female mold is adapted to receive a lower recess of the lower mold core The upper groove has the same depth as the lower groove.
4.如上述實施例任一項所述之方法，其中該下模仁及該上模仁各具有並列且上下相對應的複數模穴。4. The method of any of the preceding embodiments, wherein the lower mold core and the upper mold core each have a plurality of mold cavities juxtaposed and correspondingly upper and lower.
5.如上述實施例任一項所述之方法，其中該模具還包含相對應該複數模穴的複數沖頭。5. The method of any of the preceding embodiments, wherein the mold further comprises a plurality of punches corresponding to the plurality of mold cavities.
6.如上述實施例任一項所述之方法，其中該複數沖頭是共同耦接至一液體分接單元。6. The method of any of the preceding embodiments, wherein the plurality of punches are commonly coupled to a liquid tap unit.
7.如上述實施例任一項所述之方法，其中該複數沖頭中的每一個沖頭包含一密封元件。The method of any of the preceding embodiments, wherein each of the plurality of punches comprises a sealing element.
8.如上述實施例任一項所述之方法，其中成形該成形金屬管件包括：將該複數沖頭獨立地鎖固於一墊塊上。The method of any of the preceding embodiments, wherein forming the shaped metal tubular member comprises independently locking the plurality of punches to a spacer.
9.如上述實施例任一項所述之方法，其中該模具還包含一沖頭，該沖頭包含一基座及一密封元件。9. The method of any of the preceding embodiments, wherein the mold further comprises a punch, the punch comprising a base and a sealing element.
10. 如上述實施例任一項所述之方法，其中該密封元件呈一扁形，且具有8-100mm的一寬度。10. The method of any of the preceding embodiments, wherein the sealing element has a flat shape and has a width of from 8 to 100 mm.
11. 如上述實施例任一項所述之方法，其中該密封元件呈一扁形，且具有12-75mm的一寬度。11. The method of any of the preceding embodiments, wherein the sealing element has a flat shape and has a width of 12-75 mm.
12. 如上述實施例任一項所述之方法，其中該成形金屬管件的兩端是設計為由該密封元件密封。12. The method of any of the preceding embodiments, wherein the ends of the shaped metal tubular member are designed to be sealed by the sealing member.
13. 如上述實施例任一項所述之方法，其中該金屬管件是一異型管。13. The method of any of the preceding embodiments, wherein the metal tubular member is a shaped tube.
14. 如上述實施例任一項所述之方法，其中該金屬管件是一扁平異型管，其具有一第一截面，該成形金屬管件的一端具有一第二截面，其中該第一截面的圓角小於該第二截面的圓角。14. The method of any of the above embodiments, wherein the metal tubular member is a flat shaped tube having a first cross section, the formed metal tubular member having a second cross section at one end, wherein the first cross section of the circle The corner is smaller than the rounded corner of the second section.
15. 如上述實施例任一項所述之方法，其中利用一刀具、一水刀及一雷射光束的其中之一來分割該成形金屬管件。The method of any of the preceding embodiments, wherein the shaped metal tubular member is divided by one of a cutter, a water jet, and a laser beam.
16. 如上述實施例任一項所述之方法，其中是利用一管件液壓成形法將該金屬管件成形為該成形金屬管件。16. The method of any of the preceding embodiments, wherein the metal tubular member is formed into the formed metal tubular member by a tube hydroforming process.
17. 如上述實施例任一項所述之方法，其中該金屬管件是由一材料製成，該材料是選自鐵、銅、鈦、鎂、鋁、金、銀、鉑及其合金所組成的群組。17. The method according to any of the preceding embodiments, wherein the metal pipe member is made of a material selected from the group consisting of iron, copper, titanium, magnesium, aluminum, gold, silver, platinum, and alloys thereof. Group.
18. 一種製造金屬殼件的方法，包括：組裝至少一下模仁至一下母模以組成一具有複數圖紋單元的下模，該複數圖紋單元是形成於該至少一下模仁的一工作表面；將一金屬管件置於該下模仁上，並與該複數圖紋單元相對；將一上模與該下模合模；進行管件液壓成形，形成具有該複數圖紋單元的一成形金屬管件；以及根據該複數圖紋單元的數量切割該成形金屬管件，以製成複數殼件。18. A method of manufacturing a metal shell member, comprising: assembling at least a mold core to a lower mold to form a lower mold having a plurality of pattern elements, the plurality of pattern units being formed on a working surface of the at least one lower mold core Place a metal pipe member on the lower mold core and opposite to the plurality of pattern elements; mold an upper mold and the lower mold; perform hydroforming of the pipe member to form a formed metal pipe member having the plurality of pattern elements And cutting the formed metal pipe member according to the number of the plurality of pattern units to form a plurality of shell members.
19. 如上述實施例任一項所述之方法，於該合模步驟前還包括將一上母模與至少一上模仁組裝成該上模。19. The method of any of the preceding embodiments, further comprising assembling an upper master and at least one upper mold into the upper mold prior to the clamping step.
20. 如上述實施例任一項所述之方法，該至少一上模仁的工作表面具有複數圖紋單元。20. The method of any of the preceding embodiments, wherein the working surface of the at least one upper mold has a plurality of pattern elements.
21. 如上述實施例任一項所述之方法，於該管件液壓成形步驟前還包括將一沖頭密封該金屬管件的一端，該金屬管件的該端具有一第一截面，該沖頭密封該金屬管件的過程中使該金屬管件的該端由該第一截面變形為一第二截面，其中該第一截面的圓角小於該第二截面的圓角。21. The method of any of the preceding embodiments, further comprising sealing a punch to one end of the metal tubular member prior to the step of hydroforming the tubular member, the end of the metal tubular member having a first cross section, the punch sealing The metal tubular member deforms the end of the metal tubular member from the first cross section into a second cross section, wherein the first cross section has a rounded corner smaller than the rounded corner of the second cross section.
22. 一種製造金屬殼件的模具，包括：一上母模，具有用於容置一上模仁的一上凹槽；以及一下母模，具有用於容置一下模仁的一下凹槽，其中該上凹槽與該下凹槽具有相同的深度。22. A mold for manufacturing a metal shell member, comprising: an upper master mold having an upper recess for receiving an upper mold core; and a lower master mold having a lower recess for receiving the mold core, Wherein the upper groove has the same depth as the lower groove.
23. 一種製造金屬殼件的模具，包括：一下母模；以及一下模仁，組裝於該下母模，該下模仁的一工作表面具有複數圖紋單元，該複數圖紋單元是用於在複數金屬殼件中的每一金屬殼件上形成一對應圖紋單元。23. A mold for manufacturing a metal shell member, comprising: a lower master mold; and a lower mold core assembled to the lower master mold, a working surface of the lower mold core having a plurality of pattern units, the plurality of pattern units being used for A corresponding pattern unit is formed on each of the plurality of metal shell members.
24. 如上述實施例任一項所述之模具，其中該模具還包括一沖頭，該沖頭包含一密封元件以密封該金屬管件，該密封元件包含一前錐部和一密封部，該前錐部之橫截面面積由鄰近該密封部的一端往遠離該密封部的另一端漸縮，且該前錐部遠離該密封部的另一端的橫截面面積是小於該金屬管件的橫截面面積，該密封部是呈一扁形，其兩側各自形成圓角。24. The mold of any of the above embodiments, wherein the mold further comprises a punch, the punch comprising a sealing member to seal the metal tubular member, the sealing member comprising a front tapered portion and a sealing portion, The cross-sectional area of the front tapered portion is tapered from an end adjacent to the sealing portion toward the other end away from the sealing portion, and a cross-sectional area of the front tapered portion away from the other end of the sealing portion is smaller than a cross-sectional area of the metal tubular member The sealing portion has a flat shape, and both sides are rounded.
25. 如上述實施例任一項所述之模具，其中該下模仁具有並列的複數模穴，該模具還包括相對應該複數模穴的複數沖頭，且該複數沖頭是獨立地鎖固於一墊塊上，並共同耦接至一液體分接單元。The mold of any of the above embodiments, wherein the lower mold core has a plurality of parallel mold cavities, the mold further comprising a plurality of punches corresponding to the plurality of mold cavities, and the plurality of punches are independently locked And on a pad, and coupled to a liquid tapping unit.
26. 一種製造金屬殼件的模具，該模具具有複數圖紋單元，並包括：至少一模仁，該複數圖紋單元是設置於該至少一模仁的一模穴表面，該至少一模仁是用以模製一具有與該複數圖紋單元相對應的複數圖紋單元的金屬管件。26. A mold for manufacturing a metal shell member, the mold having a plurality of pattern units, and comprising: at least one mold unit, the plurality of pattern units being disposed on a cavity surface of the at least one mold core, the at least one mold core It is used to mold a metal pipe member having a plurality of pattern elements corresponding to the plurality of pattern elements.
27. 一種製造金屬殼件的模具，包括：一模仁，具有一工作表面，該工作表面設置複數圖紋單元。27. A mold for making a metal shell member, comprising: a mold core having a work surface, the work surface being provided with a plurality of pattern elements.
28. 如上述實施例任一項所述之模具，其中該模仁是用以模製一金屬管件之模仁。28. The mold of any of the preceding embodiments, wherein the mold core is a mold core for molding a metal pipe.
29. 如上述實施例任一項所述之模具，其中該複數圖紋單元是用於在複數金屬殼件中的每一金屬殼件上形成一對應圖紋單元。29. The mold of any of the preceding embodiments, wherein the plurality of pattern elements are for forming a corresponding pattern unit on each of the plurality of metal shell members.
30. 如上述實施例任一項所述之模具，其中該複數圖紋單元包含重複的至少一圖紋單元。30. The mold of any of the preceding embodiments, wherein the plurality of pattern elements comprise repeating at least one pattern unit.
31. 如上述實施例任一項所述之模具，其中該複數圖紋單元包含相異的複數圖紋單元。31. The mold of any of the preceding embodiments, wherein the plurality of pattern elements comprise distinct plurality of pattern elements.
惟以上所述僅為本發明之較佳實施例，非據此即拘限本發明之專利範圍，故舉凡運用本發明說明書及圖式內容所為之等效結構變化者，均同理包含於本發明之範圍內，合予陳明。However, the above description is only the preferred embodiment of the present invention, and the scope of the present invention is not limited thereto. Therefore, the equivalent structural changes of the present specification and the contents of the drawings are equally included in the present invention. Within the scope of the invention, it is given to Chen Ming.
10、501．．．沖頭10, 501. . . shower
101．．．基座101. . . Pedestal
102．．．密封元件102. . . Sealing element
1021．．．前錐部1021. . . Front cone
1022．．．密封部1022. . . Sealing part
11．．．上母模11. . . Upper master
110．．．上凹槽110. . . Upper groove
12．．．下母模12. . . Lower master
120．．．下凹槽120. . . Lower groove
111、121．．．鎖固孔111, 121. . . Locking hole
20．．．上模仁20. . . Upper mold
21A~D．．．下模仁21A~D. . . Lower mold
30．．．金屬管件30. . . Metal pipe fittings
301．．．擠型管截面301. . . Extruded pipe section
302．．．扁平管302. . . Flat tube
303．．．扁形密封截面303. . . Flat seal section
31．．．成形金屬管件31. . . Formed metal pipe fittings
32．．．殼件32. . . Shell
50．．．複數獨立沖頭組50. . . Complex independent punch group
502．．．墊塊502. . . Pad
503．．．高壓液體分接單元503. . . High pressure liquid tapping unit
第一圖(A)：本案所提模具的第一較佳實施例的上、下母模的示意圖；First drawing (A): schematic view of the upper and lower female molds of the first preferred embodiment of the mold proposed in the present invention;
第一圖(B)：本案所提模具的第一較佳實施例的沖頭的示意圖；First Figure (B) is a schematic view of a punch of a first preferred embodiment of the mold of the present invention;
第二圖(A)：本案第一較佳實施例中上母模及上模仁的示意圖；Figure 2 (A) is a schematic view showing the upper mother mold and the upper mold core in the first preferred embodiment of the present invention;
第二圖(B)：本案第一較佳實施例中下母模及下模仁的示意圖；Figure 2 (B) is a schematic view showing the lower master mold and the lower mold core in the first preferred embodiment of the present invention;
第三圖：使用本案所提模具的第一較佳實施例來製造金屬殼件的方法的示意圖；Third drawing: a schematic view of a method of manufacturing a metal shell member using a first preferred embodiment of the mold of the present invention;
第四圖：本案第一較佳實施例中成形金屬管件端點處轉接設計的示意圖；以及Figure 4 is a schematic view showing the transfer design of the end of the formed metal pipe in the first preferred embodiment of the present invention;
第五圖：本案所提模具的第二較佳實施例的示意圖。Figure 5 is a schematic view of a second preferred embodiment of the mold of the present invention.
21A~D．．．下模仁21A~D. . . Lower mold
12．．．下母模12. . . Lower master
120．．．下凹槽120. . . Lower groove
121．．．鎖固孔121. . . Locking hole
Claims (6)
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
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| TW101108956A TWI472386B (en) | 2012-03-15 | 2012-03-15 | Mold and method for manufacturing metal case |
| CN2012102673492A CN103302164A (en) | 2012-03-15 | 2012-07-31 | Mould and method for manufacturing tubular shell |
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| TW101108956A TWI472386B (en) | 2012-03-15 | 2012-03-15 | Mold and method for manufacturing metal case |
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| TWI472386B true TWI472386B (en) | 2015-02-11 |
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| TWI663004B (en) * | 2017-01-19 | 2019-06-21 | 鼎藝科技股份有限公司 | System and method for producing metal forming tube |
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| FR3020289B1 (en) * | 2014-04-25 | 2017-02-10 | Faurecia Sieges D'automobile | METHOD FOR ASSEMBLING AN ASSEMBLY COMPRISING A TUBE AND A PLATE AND ASSEMBLY THEREFOR |
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| CN103302164A (en) | 2013-09-18 |
| TW201336597A (en) | 2013-09-16 |
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