Combination injection molding and hydroforming

Patent metadata

Field	Value
Publication number	US-2016368189-A1
Application number	US-201615140177-A
Country	US
Kind code	A1
Filing date	Apr 27, 2016
Priority date	Jun 22, 2015
Publication date	Dec 22, 2016
Grant date	—

Abstract

Manufacturing methods that combine molding processes and shaping processes are described. The systems and methods described can be used to form composite parts using a single manufacturing process. In some embodiments, the methods involve positioning a workpiece within a mold cavity, then injecting a moldable material within the cavity at pressures sufficient to deform the workpiece such that features, such as protrusions or cavities, are formed within the workpiece. The resultant composite part includes the workpiece molded to a molded material. In some embodiments, the workpiece is a layer of metal material and the molded material is a structurally rigid plastic material, such that the composite part is a structurally rigid plastic with a metal coating. In some embodiments, multiple workpieces are molded within a composite part.

First claim

What is claimed is:

1 . A method of forming a composite part, the method comprising:
positioning a workpiece within a mold cavity of a mold; and injecting a moldable material within the mold cavity such that an applied pressure exerted on the workpiece by the moldable material deforms the workpiece to take on a predetermined shape, wherein the moldable material bonds with the workpiece to form the composite part.

2 . The method of claim 1 , further comprising:
prior to the injecting, preconditioning the workpiece such that the workpiece is more deformable.

3 . The method of claim 2 , wherein the preconditioning includes heating the workpiece or chemically treating the workpiece.

4 . The method of claim 1 , wherein the workpiece is includes at least one of metal, a polymer material, glass, ceramic or a composite material.

5 . The method of claim 1 , wherein the moldable material is includes of one or more of metal, a polymer material, glass, ceramic or a composite material.

6 . The method of claim 1 , wherein the workpiece includes the same material as the moldable material.

7 . The method of claim 1 , wherein the workpiece includes a different material than the moldable material.

8 . The method of claim 1 , wherein the mold cavity includes a feature in accordance with the predetermined shape.

9 . The method of claim 1 , further comprising:
after the injecting, removing at least a portion of the moldable material from the composite part.

10 . The method of claim 1 , wherein the workpiece is one of a plurality of workpieces positioned within a mold cavity, wherein the injecting deforms the plurality of workpieces to take on the predetermined shape.

11 . A method of forming a composite part, the method comprising:
injecting a polymer material into a mold cavity of a mold such that a flow of polymer material is directed toward a surface of a workpiece positioned within the mold cavity, wherein an applied pressure associated with the flow deforms the workpiece to create a protruding feature on the workpiece corresponding to a recessed feature of the mold.

12 . The method of claim 11 , wherein the polymer material bonds with the workpiece.

13 . The method of claim 11 , wherein the workpiece includes at least one of metal, a polymer material, glass, ceramic or a composite material.

14 . The method of claim 11 , further comprising:
removing the composite part from the mold; positioning the composite part within a second mold cavity of a second mold, wherein the polymer material is a first polymer material; and injecting a second polymer material into the second mold cavity such that the second polymer material bonds with the polymer material.

15 . The method of claim 11 , further comprising:
removing the composite part from the mold; and performing a machining operation or a surface finishing operation on the composite part.

16 . The method of claim 11 , wherein the composite part is an enclosure for an electronic device, wherein the workpiece corresponds to a cosmetic exterior coating of the enclosure.

17 . An enclosure for an electronic device, the enclosure comprising:
an exterior layer having a recessed feature; and a polymer base bonded to the exterior layer, the polymer base having a protruding feature, wherein the recessed feature surrounds the protruding feature of the polymer base.

18 . The enclosure of claim 17 , wherein the exterior layer includes at least one of metal, a polymer material, glass, ceramic or a composite material.

19 . The enclosure of claim 17 , wherein the exterior layer includes multiple layers, each layer including at least one of metal, polymer material, glass, ceramic or composite material.

20 . The enclosure of claim 19 , wherein the exterior layer includes a first layer and a second layer, the first layer including a different material than the second layer.

Assignees

• Apple Inc

Inventors

• Meschke Andrew J
• Bustle Benjamin Shane
• Krass Derek C
• Johannessen Thomas

Classifications

• B21D26/02

  by applying fluid pressure · CPC title

• B29C2791/007

  Using fluid under pressure · CPC title

• B29L2031/34

  Electrical apparatus, e.g. sparking plugs or parts thereof · CPC title

• Y10T29/49805

  Shaping by direct application of fluent pressure · CPC title

• B29C45/1418 Primary

  the inserts being deformed or preformed, e.g. by the injection pressure · CPC title