201102280 六、發明說明： 【發明所屬之技術領域】 [0001] 本發明涉及一種金屬殼體及其製造方法。 ’ 【先前技搞ί】 ❹ [0002] 現在市場上出售的可檇式電子裝置，比如筆記型電腦、 行動電話等，其外殼大多係由塑膠製成。相對於塑膠外 殼而言，金屬合金外殼具有更高的強度以及更好的散熱 效果，同時，金屬的質感可以使電子裝置的外殼更顯高 檔、美觀。然而，現階段的金屬合金外殼（如鎂合金外 殼等）因其加工工藝僅限於壓鑄成型等，其成型週期廠 ，生產效率低，不易實現高速連續化生產，導致加工製 造成本較高，目前僅用於少數高端產品，推廣度有限。 【發明内容】 [0003] 有鑒於此，有必要提供一種美觀的、可以實現高速連續 化生產的金屬殼體及其製造方法。 〇 [0004] 一種金屬殼體，其兩侧面均具有利用衝壓加工工藝形成 的立體花紋，兩側面的立體花紋相互對應。 [0005] 種金屬殼體的製造方法，包括以下步驟 [0006] 將金屬板材放入一衝壓模具内； [0007] 採用半剪衝壓的加工工藝對金屬板材進行衝壓壓花，使 金屬板材的兩侧面均形成立體花紋。 [0008] 相較習知技術，上述金屬殼體經過該製造方法的加工， 使得兩侧面均形成立體花紋，使產品美觀，而且容易實 現高速連續化生產。 098123311 表單編號Α0101 第3頁/共17頁 0982039709-0 201102280 【實施方式】 [0009] 請參閱圖1，本發明較佳實施方式提供一種金屬殼體1〇〇 ，該金屬殼體100應用在筆記型電腦上。 [0010] 請一併參閱圖2，該金屬殼體1 00為矩形，其包括外側面 1 〇 1及内侧面1 〇 2 ’其外側面1 01及内側面1 〇 2均形成有大 面積及局松度的立體花紋1 1 〇。該兩側面的立體花紋1 1 〇 係利用模具衝壓工藝一體衝壓加工形成並且相互對應， 即如果内側面102為凹陷的陰花紋，則外側面1〇1於對應 位置形成圖案相同的凸起的陽花紋，且陰花紋的凹陷深 度與陽花紋的凸起高度相同。該金屬般體100的四周邊緣 向内側面102—侧延伸形成a緣12。該等凸緣丨2於該金屬 殼體100的四角分別形成一圓弧。該金屬殼體於其中 一侧邊緣開設一缺口 1 4，使該金屬殼體1 .〇 〇平面呈“凹” 字形。凸緣12係利用模具衝壓工藝拉深形成。 [0011] 該金屬殼體1〇〇的材料可採用銅、鐵、鋁、不銹鋼和鈦的 任一種或其合金，本發明優選實碜方式的金屬殼體1〇〇材 料為鋁合金。根據產品的實傺需要及掛壓工藝的許可， 本發明衝壓工藝適用於一般的具有一定成形加工性能的 鋁合金材質，比如AL1100、AL5052等，優選地，本發明 選用AL5052加工成的鋁合金薄板。該鋁合金薄板的厚度 範圍為0.2毫米至1.5毫米之間，優選地，本實施方式中 鋁合金薄板的厚度約為0.8毫米。 剛4參閱圖5 ’該具有立體花紋的金屬殼體1〇〇的製造流程 及製造方法具體包括以下步驟： [〇_步驟902，對金屬板材進行壓花，其過程係將金屬板材放 098123311 表單編號删1 第4頁/共17頁 〇982〇397〇9-〇 201102280 [0014] ❹ [0015] [0016] ❹ 入一衝壓模具内進行半勢衝壓。 如果需要在金屬板材的其中一侧面形成凹陷的陰花紋， 則需要在該衝壓模具的公模上形成相應的凸起的陽花紋 ，同時在母模上相應的位置形成凹陷的陰花紋。衝壓加 工時，將金屬板材需要形成凹陷的陰花紋的一侧面朝向 公模中形成有凸起的陽花紋的一侧放入衝壓模具内進行 衝壓加工，衝壓成形過程中，公模上的凸起的陽花紋將 金屬板材上需要形成凹陷的陰花紋的位置的材料擠向對 應位置的母模上的凹陷的陰花紋，從而形成半剪的效果 。同理，可以在金屬板材的任意一侧面形成需要的立體 花紋，只需要對模具的公、母模進行相應的加工即可。 公母模需要形成花紋的部分一般採用陽極加工處理或者 餘刻加工處理。 為了達到花紋清晰的目的，凹陷的陰花紋的深度t (如圖 4所示）至少在0.02毫米以上。同時，在立體花紋較密集 的產品上，如果花紋深度過深，將會影響金屬殼體100的 機械強度以及後續的加工工序。假設進行壓花成形的金 屬板材的厚度為T，經多次試驗後得知花紋深度t不應超 過金屬板材料厚的20%。優選地，壓花深度t範圍在0. 02 毫米-10%T之間。另外，花紋的疏密也會影響到金屬殼體 100的機械強度以及後續加工工序，花紋較密時，則應當 使花紋深度t不應超過金屬板材料厚的10%，以避免影響 金屬殼體100的機械強度以及後續加工工序，花紋較疏時 ，花紋深度t可以適當加大。優選地，本實施方式中花紋 的深度為0. 03毫米。 098123311 表單編號A0101 第5頁/共17頁 0982039709-0 201102280 [0017] 進行衝壓壓花加工之後，該金屬板材的厚度由加工之前 的T增加為T + t，為金屬板材的厚度與花紋凸出板材表面 高度之和。經過檢驗得知，衝壓壓花後金屬殼體100的機 械強度明顯增強。 [0018] 本發明中金屬衝壓壓花的花紋具有大面積及高密度的特 點，每平方米内的花紋周長最高可達到650米。花紋過密 會使外觀效果變差並且模具加工成本顯著增加。優選地 ，本實施方式中的花紋密度為每平方米内的花紋周長540 米，可達到花紋美觀同時兼顧合理的加工成本。 [0019] 對金屬板材進行半剪衝壓壓花加工時，其衝裁間隙為 0-1 0%T。經過試驗得知，進行衝壓壓花時的也可以選用 負衝裁間隙，即公模上形成的凸起的陽花紋的尺寸比母 模上的凹陷的陰花紋的尺寸要大。優選地，本實施方式 中衝裁間隙為零，可以獲得更好的外觀效果。 [0020] 經過多次試驗得知，金屬衝壓壓花的花紋平面視角上的 所有位置的曲率半徑rl (如圖3所示）應滿足rl20.05 毫米的條件以獲得較好的外觀效果並且可以控制模具的 加工成本。 [0021] 經過多次試驗得知，金屬衝壓壓花的凹陷花紋的侧壁與 底壁之間的圓角曲率半徑r2 (如圖4所示）應滿足的條件 為：r2 20.005毫米。優選地，金屬衝壓壓花的花紋在深 度上的曲率半徑r2為0. 005毫米Sr2 S0. 01毫米以獲得 較好的外觀效果並且可以控制模具的加工成本。 [0022] 經過多次試驗得知，對於較大尺寸的金屬殼體100，比如 098123311 表單編號A0101 第6頁/共17頁 0982039709-0 201102280 450*400毫米以上 ,θ ^ W尺寸’應當進行分段衝壓壓花，以獲 得較好的壓花欵、， 又 亚且可以減少衝壓條件要求以降低 衝壓成本。對於私 小尺寸的金屬殼體100，比如450*400 毫米及以下的尺寸，π τ 可以進行一次性衝壓壓花。 [0023] 本發月中金屬衝壓壓花的花紋側壁與底壁平面之間的角 度α (如圖4所不）可達到9〇_11〇度其輪廓明顯，立體感很強。優選地’本實·式巾餘㈣減壁平面之 間的角度α為90度。 Ο 陶] [0025] [0026]Ο [0027] 步驟9〇4 ϋ切下料’卿進行壓花處理後的金属板材周緣 進行裁切，根據金屬殼體刚的尺寸大小計算所需金屬板 材的尺寸，並且預留下金屬板材邊緣拉深彎折後需要整 形裁邊的餘量。 ’ 步驟906，對金屬板材進行拉深處理，使其四周邊緣向内 侧面凸伸形成一圈凸緣12，進而形成一金屬殼體丨〇〇。 經過試驗得知’對金屬板材進行拉深形成的凸緣1 2的高 度Η—般在20毫米以内^ 拉深之後形成的該金屬殼體100四角分別形成一圓角，經 過試驗得知’該圓角的半徑R需滿足rg 1/5Η的條件，或 者需滿足R2 3T的條件’其中Η為凸緣12的高度，Τ為金屬 板材的料厚。 [0028] [0029] 步驟908 ’對該成形後的金屬殼體1〇〇的凸緣12進行側切 處理，使凸緣12的高度平整’外表光滑，尺寸精確。 步驟910，對該金屬殼體1〇〇進行陽極處理，使該金屬殼 098123311 表單编號Α0101 第7頁/共17頁 0982039709-0 201102280 體100表面覆蓋一陽極氧化膜層。也可以對該金屬殼體 100表面進行喷塗，使該金屬殼體100表面覆蓋一喷塗層 〇 [0030] 其中拉深有關步驟視乎產品需求而設置，若產品形狀無 需拉深，則該等步驟應省略。 [0031] 此外，該金屬殼體100也可為其他形狀，如圓形外殼等， 均可使用本加工工藝進行加工製造。該立體花紋110的圖 案不止於附圖中所示，其可以係所需要的任何其他圖案 〇 [0032] 本發明金屬殼體100係採用金屬薄板一體衝壓形成，相較 於其他成形方式而言，其可以達到更輕、更薄、更美觀 的要求。因該金屬殼體100具有雙面花紋，可有效增強機 械強度。使用衝壓加工的方式進行壓花，加工週期短， 生產製造速度快，可有效降低加工製造成本。 [0033] 綜上所述，本發明符合發明專利要件，爰依法提出專利 申請。惟，以上所述者僅為本發明之較佳實施方式，舉 凡熟悉本案技藝之人士，在爰依本發明精神所作之等效 修飾或變化，皆應涵蓋於以下之申請專利範圍内。 【圖式簡單說明】 [0034] 圖1為本發明金屬殼體較佳實施方式的立體圖。 [0035] 圖2為圖1所示金屬殼體的剖視圖。 [0036] 圖3表示金屬殼體上立體花紋的局部放大示意圖。 [0037] 圖4表示金屬殼體的局部截面放大圖。 098123311 表單編號A0101 第8頁/共17頁 0982039709-0 201102280 [0038] 圖5為本發明金屬殼體的製造方法的流程圖。 【主要元件符!^說明】 金屬殼體 100 外側面 101 内侧面 102 凸緣 12 缺口 14 立體花紋 110 〇 098123311 表單編號A0101 第9頁/共17頁 0982039709-0201102280 VI. Description of the Invention: [Technical Field of the Invention] [0001] The present invention relates to a metal casing and a method of manufacturing the same. 〔 [Previous technology] ❹ [0002] The electronic devices that are currently on the market, such as notebook computers, mobile phones, etc., are mostly made of plastic. Compared with the plastic case, the metal alloy case has higher strength and better heat dissipation effect, and the metal texture can make the outer casing of the electronic device more high-grade and beautiful. However, at present, metal alloy casings (such as magnesium alloy casings) are limited to die-casting and the like because of their processing technology. The molding cycle plant has low production efficiency and is not easy to achieve high-speed continuous production, resulting in high processing and manufacturing costs. For a few high-end products, the promotion is limited. SUMMARY OF THE INVENTION [0003] In view of the above, it is necessary to provide an aesthetically pleasing metal casing that can realize high-speed continuous production and a method of manufacturing the same. 0004 [0004] A metal casing having a three-dimensional pattern formed by a press working process on both sides thereof, and the three-dimensional patterns on both sides correspond to each other. [0005] A method of manufacturing a metal casing, comprising the steps of: [0006] placing a metal sheet into a stamping die; [0007] stamping and embossing a metal sheet by a half-shear stamping process to make two metal sheets The sides are all formed with a three-dimensional pattern. Compared with the prior art, the above-mentioned metal casing is processed by the manufacturing method, so that the three sides form a three-dimensional pattern, which makes the product beautiful and easy to realize high-speed continuous production. 098123311 Form No. 1010101 Page 3/17 Page 0992039709-0 201102280 [Embodiment] [0009] Referring to FIG. 1, a preferred embodiment of the present invention provides a metal casing 1〇〇, which is applied to a note. On the computer. [0010] Please refer to FIG. 2 together, the metal casing 100 is rectangular, and includes an outer side surface 1 〇1 and an inner side surface 1 〇 2 ′, the outer side surface 101 and the inner side surface 1 〇 2 are formed with a large area and The looseness of the three-dimensional pattern 1 1 〇. The two-side three-dimensional pattern 1 1 is formed by integral stamping process and corresponding to each other, that is, if the inner side surface 102 is a concave female pattern, the outer side surface 1〇1 forms a convex shape with the same convexity at the corresponding position. The pattern, and the concave depth of the female pattern is the same as the convex height of the male pattern. The peripheral edge of the metal body 100 extends to the side of the inner side surface 102 to form an edge 12. The flanges 2 respectively form an arc at the four corners of the metal casing 100. The metal casing has a notch 14 at one side edge thereof, so that the plane of the metal casing 1 is "concave". The flange 12 is formed by drawing deep using a die stamping process. [0011] The material of the metal casing 1〇〇 may be any one of copper, iron, aluminum, stainless steel and titanium or an alloy thereof, and the metal casing 1 material of the preferred embodiment of the invention is an aluminum alloy. According to the actual needs of the product and the permission of the hanging process, the stamping process of the present invention is applicable to general aluminum alloy materials having certain forming processing properties, such as AL1100, AL5052, etc. Preferably, the aluminum alloy sheet processed by AL5052 is selected in the present invention. . The thickness of the aluminum alloy sheet ranges from 0.2 mm to 1.5 mm, and preferably, the thickness of the aluminum alloy sheet in the present embodiment is about 0.8 mm. Referring to FIG. 5, the manufacturing process and manufacturing method of the metal casing 1 having the three-dimensional pattern specifically include the following steps: [〇_Step 902, embossing the metal sheet, the process of placing the metal sheet into the 098123311 form No. Delete 1 Page 4 of 17 〇 982 〇 〇 〇 〇 102 102 102 102 102 102 102 102 102 102 102 [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ [ If it is desired to form a concave negative pattern on one of the sides of the metal sheet, it is necessary to form a corresponding convex pattern on the male mold of the stamping die, while forming a concave negative pattern on the corresponding position on the master. In the stamping process, one side of the negative plate pattern on which the metal sheet needs to be formed is placed in a stamping die toward the side of the male mold in which the convex pattern is formed, and the punch on the male mold is formed during the press forming process. The positive pattern pushes the material on the metal sheet where the concave pattern is formed to the concave pattern on the female mold at the corresponding position, thereby forming a half-cut effect. In the same way, the required three-dimensional pattern can be formed on any side of the metal sheet, and only the male and female molds of the mold need to be processed correspondingly. The part of the male and female molds that need to be patterned is generally processed by anodizing or engraving. In order to achieve a clear pattern, the depth t of the concave pattern (as shown in Fig. 4) is at least 0.02 mm or more. At the same time, if the pattern depth is too deep on a product with a dense three-dimensional pattern, the mechanical strength of the metal casing 100 and the subsequent processing steps will be affected. It is assumed that the thickness of the metal sheet subjected to embossing is T, and after a plurality of tests, it is found that the pattern depth t should not exceed 20% of the thickness of the sheet metal material. Preferably, the embossing depth t ranges from 0.02 mm to 10% T. In addition, the density of the pattern will also affect the mechanical strength of the metal shell 100 and the subsequent processing steps. When the pattern is dense, the pattern depth t should not exceed 10% of the thickness of the sheet metal material to avoid affecting the metal shell. The mechanical strength of 100 and the subsequent processing steps, when the pattern is sparse, the pattern depth t can be appropriately increased. 0毫米。 The depth of the pattern is 0. 03 mm. 098123311 Form No. A0101 Page 5 of 17 0992039709-0 201102280 [0017] After stamping and embossing, the thickness of the sheet metal is increased from T before processing to T + t, which is the thickness and pattern of the sheet metal. The sum of the heights of the surface of the sheet. It has been found that the mechanical strength of the metal casing 100 after punching and embossing is remarkably enhanced. [0018] In the present invention, the pattern of the metal stamping embossing has a large area and a high density, and the pattern circumference per square meter can be up to 650 meters. Excessive patterning will result in poor appearance and a significant increase in mold processing costs. Preferably, the pattern density in the embodiment is 540 meters per square meter, which can achieve a beautiful pattern while taking into consideration reasonable processing costs. [0019] When the metal sheet is subjected to half-shear stamping and embossing, the punching gap is 0-1 0%T. It has been experimentally found that a negative blanking gap can also be selected for stamping and embossing, that is, the size of the raised male pattern formed on the male mold is larger than the size of the concave female pattern on the female mold. Preferably, in the present embodiment, the blanking gap is zero, and a better appearance effect can be obtained. [0020] After many experiments, it is known that the curvature radius rl (shown in FIG. 3) of all positions on the plane view angle of the metal stamping embossing should satisfy the condition of rl20.05 mm to obtain a better appearance effect and can Control the processing cost of the mold. [0021] After many experiments, it is known that the radius of curvature r2 (shown in FIG. 4) between the side wall and the bottom wall of the recessed pattern of the metal stamping embossing should satisfy the condition: r2 20.005 mm. Preferably, the metal stamping embossing pattern has a radius of curvature r2 of 0.005 mm Sr2 S0. 01 mm for better appearance and control of the processing cost of the mold. [0022] After many experiments, it is known that for a larger size metal casing 100, such as 098123311 Form No. A0101 Page 6 / 17 pages 0992039709-0 201102280 450 * 400 mm or more, θ ^ W size 'should be divided Segment stamping and embossing to obtain better embossing, and also reduce the stamping conditions to reduce the cost of stamping. For the small-sized metal casing 100, such as 450*400 mm and below, π τ can be stamped and embossed at one time. [0023] In the present month, the angle α between the side wall of the metal stamping embossing and the plane of the bottom wall (as shown in FIG. 4) can reach 9〇_11〇, the outline is obvious, and the three-dimensional feeling is strong. Preferably, the angle α between the remaining (four) reduced wall planes of the present embodiment is 90 degrees. Ο 陶] [0025] [0026] Ο [0027] Step 9 〇 4 ϋ 下 ' ' 卿 卿 卿 卿 卿 卿 压 压 压 压 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属 金属Dimensions, and the margin of the trimmed edge is required after the edge of the sheet metal is stretched and bent. Step 906, the metal sheet is subjected to a drawing process so that the peripheral edge of the peripheral edge protrudes to form a ring of flanges 12, thereby forming a metal casing. It has been experimentally found that the height of the flange 12 formed by drawing the metal sheet is generally rounded at a corner of the metal shell 100 formed within 20 mm. After the drawing, a circle is formed. The radius R of the corner needs to satisfy the condition of rg 1/5Η, or the condition of R2 3T needs to be satisfied, where Η is the height of the flange 12, and Τ is the thickness of the metal sheet. [0029] Step 908' The side-cutting process of the flange 12 of the formed metal casing 1〇〇 is such that the height of the flange 12 is smooth and the dimensions are accurate. Step 910, the metal casing 1 is anodized to make the metal shell 098123311 Form No. 1010101 Page 7 of 17 0982039709-0 201102280 The surface of the body 100 is covered with an anodized film layer. The surface of the metal casing 100 may also be sprayed so that the surface of the metal casing 100 is covered with a spray coating layer [0030] wherein the step of drawing is set according to product requirements, and if the shape of the product does not need to be deepened, Steps should be omitted. [0031] In addition, the metal casing 100 may also have other shapes, such as a circular outer casing, etc., which can be processed and manufactured using the present process. The pattern of the three-dimensional pattern 110 is not limited to that shown in the drawings, and it may be any other pattern required. [0032] The metal casing 100 of the present invention is integrally formed by stamping a thin metal sheet, compared to other forming methods. It can meet the requirements of lighter, thinner and more beautiful. Since the metal casing 100 has a double-sided pattern, the mechanical strength can be effectively enhanced. The embossing is performed by means of stamping, the processing cycle is short, the manufacturing speed is fast, and the processing and manufacturing cost can be effectively reduced. [0033] In summary, the present invention complies with the requirements of the invention patent, and submits a patent application according to law. The above description is only the preferred embodiment of the present invention, and equivalent modifications or variations made by those skilled in the art will be included in the following claims. BRIEF DESCRIPTION OF THE DRAWINGS [0034] FIG. 1 is a perspective view of a preferred embodiment of a metal casing of the present invention. 2 is a cross-sectional view of the metal casing shown in FIG. 1. [0036] FIG. 3 is a partially enlarged schematic view showing a three-dimensional pattern on a metal casing. 4 is a partial cross-sectional enlarged view of a metal casing. 098123311 Form No. A0101 Page 8 of 17 0982039709-0 201102280 [0038] FIG. 5 is a flow chart of a method of manufacturing a metal casing of the present invention. [Main component symbol!^Description] Metal case 100 Outer side 101 Inner side 102 Flange 12 Notch 14 Three-dimensional pattern 110 098 098123311 Form No. A0101 Page 9 of 17 0982039709-0