Metal composite board

Abstract

The invention provides a metal composite board which is suitable for forming a machine shell through stamping and bending. The metal composite board comprises a metal layer, a bonding layer and an appearance decoration layer. The metal layer has a first surface, a second surface opposite to the first surface, and a groove recessed in the first surface. The bonding layer covers the second surface. The appearance decoration layer covers the bonding layer and is attached to the metal layer through the bonding layer. The machine shell formed by stamping and bending the metal composite board is provided with a bending lead angle, and the bending lead angle comprises a bending outer angle and a bending inner angle. A positive draft angle or a negative draft angle is formed at the bending outer angle, and the groove is located at the bending inner angle.

Description

Technical Field

[0001] This invention relates to a sheet material, and more particularly to a metal composite sheet material. Background Technology

[0002] Metal casings, commonly found in electronic products, are typically made by stamping and bending sheet metal. During the stamping and bending process, insufficient material ductility, improper bending radius or direction design, or excessive stamping speed may cause excessive stress on the bent parts, resulting in cracks. These cracks not only cause cosmetic defects to the casing but may also lead to delamination between the metal layer and the decorative layer, and even weaken the structural strength and durability of the casing. Summary of the Invention

[0003] This invention relates to a metal composite sheet material that helps improve the appearance quality, structural reliability, and structural strength of the manufactured casing.

[0004] According to an embodiment of the present invention, a metal composite sheet is suitable for forming a housing by stamping and bending. The metal composite sheet includes a metal layer, an adhesive layer, and an appearance decorative layer. The metal layer has a first surface, a second surface opposite to the first surface, and a groove recessed in the first surface. The adhesive layer covers the second surface. The appearance decorative layer covers the adhesive layer and is attached to the metal layer through the adhesive layer. The housing formed by stamping and bending the metal composite sheet has a bending guide angle, and the bending guide angle includes an outer bending angle and an inner bending angle. A positive draft angle is formed at the outer bending angle, and the groove falls at the inner bending angle. The radius of the outer bending angle is R1, and the angle of the positive draft angle is A1. The arc length of the outer bending angle is AL1, and AL1 = (90° - |A1|) × π × R1 ÷ 180°.

[0005] In one embodiment of the present invention, the width of the groove is W1, and W1 ≥ 0.9 × AL1.

[0006] In one embodiment of the present invention, the above-mentioned 0°≤A1≤30°.

[0007] In one embodiment of the present invention, the thickness of the metal layer is T1, and the depth of the groove is D1. The distance between the bottom of the groove and the second surface is T2, where T2 = (T1 - D1) and R1 ≥ T2.

[0008] In one embodiment of the present invention, the radius of the aforementioned inner bend angle is R2, and R2≥0.1×T2.

[0009] In one embodiment of the present invention, the above-mentioned decorative layer includes a color layer covering the adhesive layer and a texture layer covering the color layer, wherein the color layer is located between the texture layer and the adhesive layer.

[0010] In one embodiment of the present invention, after the aforementioned metal composite sheet is stamped and bent to form a housing, a reinforcing layer is formed on the first surface. The reinforcing layer covers the first surface and is embedded in a groove.

[0011] In one embodiment of the present invention, the aforementioned bend guide angle is a bend fillet.

[0012] According to another embodiment of the present invention, a metal composite sheet is suitable for forming a housing by stamping and bending. The metal composite sheet includes a metal layer, an adhesive layer, and an appearance decorative layer. The metal layer has a first surface, a second surface opposite to the first surface, and a groove recessed in the first surface. The adhesive layer covers the second surface. The appearance decorative layer covers the adhesive layer and is attached to the metal layer through the adhesive layer. The housing formed by stamping and bending the metal composite sheet has a bending guide angle, and the bending guide angle includes an outer bending angle and an inner bending angle. A negative draft angle is formed at the outer bending angle, and the groove falls at the inner bending angle. The radius of the outer bending angle is R11, and the angle of the negative draft angle is A11. The arc length of the outer bending angle is AL11, and AL11 = (90° + |A11|) × π × R11 ÷ 180°.

[0013] In another embodiment of the invention, the width of the groove is W1, and W1 ≥ 0.9 × AL11.

[0014] In another embodiment of the invention, -30°≤A11≤0° as described above.

[0015] In another embodiment of the invention, the thickness of the metal layer is T1, and the depth of the groove is D1. The distance between the bottom of the groove and the second surface is T2, where T2 = (T1 - D1) and R11 ≥ T2.

[0016] In another embodiment of the present invention, the radius of the aforementioned inner bend angle is R21, and R21≥0.1×T2.

[0017] Based on the above, the metal composite sheet of the present invention has grooves in the metal layer to improve the ductility of the bending part when the metal composite sheet is stamped and bent, and to effectively disperse the internal stress generated during the bending process, so as to avoid cracks in the bending part due to excessive stress, thereby achieving the purpose of improving the appearance quality, structural reliability and structural strength of the manufactured casing. Attached Figure Description

[0018] Figures 1A to 1C This is a cross-sectional schematic diagram of the process of forming a machine housing by stamping and bending a metal composite sheet according to an embodiment of the present invention;

[0019] Figure 1D yes Figure 1A A magnified cross-sectional view corresponding to the location of the groove;

[0020] Figure 2 yes Figure 1A A cross-sectional schematic diagram of another example of a housing formed by stamping and bending of a metal composite sheet.

[0021] Figure 3 yes Figure 1A A cross-sectional schematic diagram of a casing formed by stamping and bending of a metal composite sheet. Detailed Implementation

[0022] Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same element references are used in the drawings and description to denote the same or similar parts.

[0023] Figures 1A to 1C This is a cross-sectional schematic diagram of the process of forming a machine housing by stamping and bending a metal composite sheet according to an embodiment of the present invention. Figure 1D yes Figure 1A This is a magnified cross-sectional view of the area corresponding to the groove. Please refer to the diagram. Figure 1A In this embodiment, the metal composite sheet 100 includes a metal layer 110, an adhesive layer 120, and an appearance decorative layer 130. The metal layer 110 may be a thin metal sheet made of aluminum alloy, magnesium alloy, titanium alloy, stainless steel, or galvanized steel sheet, and has a first surface 111, a second surface 112 opposite to the first surface 111, and a groove 113 recessed in the first surface 111.

[0024] The adhesive layer 120 covers the second surface 112 of the metal layer 110 and can be formed by coating the second surface 112 of the metal layer 110 with an adhesive material such as acrylic resin, polyurethane resin, epoxy resin or polyisocyanate. On the other hand, the appearance decorative layer 130 covers the adhesive layer 120 and is attached to the metal layer 110 through the adhesive layer 120, for example, by tightly adhering it to the metal layer 110 through a hot pressing process.

[0025] In detail, the decorative layer 130 includes a color layer 131 covering the adhesive layer 120 and a texture layer 132 covering the color layer 131, with the color layer 131 located between the texture layer 132 and the adhesive layer 120. For example, the color layer 131 may be composed of acrylic resin, polyurethane resin, polyamide resin, or combinations thereof, while the texture layer 132 may be composed of unsaturated polyester, epoxy acrylate, polyurethane acrylate, polyester acrylate, or combinations thereof.

[0026] Please refer to Figure 1A and Figure 1DThe second surface 112 of the metal layer 110 can be a smooth plane or a surface with a textured surface, for example, by forming geometric patterns or hairline textures on the second surface 112 through laser processing, mechanical polishing, or chemical etching. On the other hand, the appearance surface 132a of the texture layer 132 relative to the color layer 131 can be a smooth plane or a surface with a textured surface, for example, by forming geometric patterns or hairline textures on the appearance surface 132a through transfer printing, rolling, laser processing, or chemical etching.

[0027] Furthermore, the textured surface 112 formed on the second surface 112 of the metal layer 110 not only presents a visually appealing effect with texture and light and shadow variations, but also enhances the adhesion of the bonding layer 120 to prevent interlayer delamination. The textured surface 132a formed on the color layer 131 not only presents a visually appealing effect with texture and light and shadow variations, but also provides the user with a smooth and delicate tactile experience. On the other hand, through the combination of the textured layer 132, the color layer 131, and the metal layer 110, a metallic luster with depth and layered variations can be achieved.

[0028] For example, the thickness of the metal layer 110 can be between 0.4 and 1.2 millimeters, and the thickness of the bonding layer 120 can be between 1 and 20 micrometers. In addition, the thickness of the color layer 131 can be between 1 and 10 micrometers, and the thickness of the texture layer 132 can be between 1 and 30 micrometers.

[0029] Please refer to Figure 1A and Figure 1B The metal composite sheet 100 is stamped and bent, specifically the portion of the metal layer 110 containing the groove 113. Specifically, the groove 113 is designed to improve the ductility of the bent portion and effectively disperse the internal stress generated during bending, preventing cracks from forming due to excessive stress. This achieves the goal of improving the appearance quality, structural reliability, and structural strength of the manufactured housing 200.

[0030] like Figure 1B As shown, the housing 200 formed by stamping and bending the metal composite sheet 100 has a bending guide angle 201, wherein the bending guide angle 201 can be a bending rounded corner, and the bending guide angle 201 includes an outer bending angle 201a and an inner bending angle 201b. A positive draft angle is formed at the outer bending angle 201a, and the groove 113 falls at the inner bending angle 201b.

[0031] The radius of the outer bending angle 201a is R1, and the positive draft angle is A1. Furthermore, the arc length of the outer bending angle 201a is AL1, and it meets the following condition: AL1=(90°-∣A1∣)×π×R1÷180°, to avoid excessive stress on the bending area due to improper bending radius design, which could lead to cracks. For example, the positive draft angle A1 meets the following numerical range: 0°≤A1≤30°.

[0032] like Figure 1A and Figure 1B As shown, the width of the groove 113 is W1, and it conforms to the following relationship: W1≥0.9×AL1.

[0033] On the other hand, the thickness of the metal layer 110 is T1, and the depth of the groove 113 is D1. The distance between the bottom of the groove 113 and the second surface 112 is T2, and the radius of the inner bend angle 201b is R2. Furthermore, the distance between the bottom of the groove 113 and the second surface 112 is essentially equal to the difference between the thickness of the metal layer 110 and the depth of the groove 113, thus satisfying the following condition: T2 = (T1 - D1).

[0034] Since the bending center 201c of the bend guide angle 201 falls on the side where the inner bend angle 201b is located, the radius of the outer bend angle 201a, the distance between the bottom of the groove 113 and the second surface 112, and the radius of the inner bend angle 201b meet the following relationship: R1≥T2, and R2≥0.1×T2, so as to avoid cracks caused by excessive stress on the bending part due to improper bending radius design.

[0035] Please refer to Figure 1B and Figure 1C After the metal composite sheet 100 is stamped and bent to form the housing 200, a reinforcing layer 140 can be formed on the first surface 111 of the metal layer 110 by means of hot pressing or injection molding. Specifically, the reinforcing layer 140 covers the first surface 111 of the metal layer 110 and is embedded in grooves 113 to reinforce the structural strength of the metal layer 110. For example, the material of the reinforcing layer 140 may include polycarbonate, acrylonitrile-butadiene-styrene copolymer, polypropylene, magnesium alloy, or other plastic or metal materials.

[0036] According to actual design requirements, the draft angle formed by the bending guide angle 201 of the four sides of the housing 200 at the outer bending angle 201a can be set in the following ways: at least two sides are positive draft angles, one side is a positive draft angle and three sides are negative draft angles, or one side is a positive draft angle and three sides are 0-degree draft angles.

[0037] Figure 2 yes Figure 1AA cross-sectional view of another example of a casing formed by stamping and bending of metal composite sheets. Please refer to... Figure 1A and Figure 2 The metal composite sheet 100 can be stamped and bent to form a housing 200a, wherein the housing 200a has a bending guide angle 202, and the bending guide angle 202 can be a bending rounded corner. In addition, the bending guide angle 202 includes a bending outer angle 202a and a bending inner angle 202b, wherein a negative draft angle is formed at the bending outer angle 202a, and the groove 113 falls at the bending inner angle 202b.

[0038] The radius of the outer bending angle 202a is R11, and the negative draft angle is A11. Furthermore, the arc length of the outer bending angle 202a is AL11, and it meets the following condition: AL11=(90°+∣A11∣)×π×R11÷180°, to avoid excessive stress on the bending area due to improper bending radius design, which could lead to cracks. For example, the negative draft angle A11 meets the following numerical range: -30°≤A11≤0°.

[0039] like Figure 1A and Figure 1B As shown, the width of the groove 113 is W1, and it conforms to the following relationship: W1≥0.9×AL11.

[0040] On the other hand, the thickness of the metal layer 110 is T1, and the depth of the groove 113 is D1. The distance between the bottom of the groove 113 and the second surface 112 is T2, and the radius of the inner bend angle 202b is R21. Furthermore, the distance between the bottom of the groove 113 and the second surface 112 is essentially equal to the difference between the thickness of the metal layer 110 and the depth of the groove 113, thus satisfying the following condition: T2 = (T1 - D1).

[0041] Since the bending center 202c of the bend guide angle 202 falls on the side where the inner bend angle 202b is located, the radius of the outer bend angle 202a, the distance between the bottom of the groove 113 and the second surface 112, and the radius of the inner bend angle 202b meet the following relationship: R11≥T2, and R21≥0.1×T2, so as to avoid cracks caused by excessive stress on the bending part due to improper bending radius design.

[0042] According to actual design requirements, the draft angle formed by the bending guide angle 202 of the four sides of the housing 200a at the outer corner 202a of the bend can be set in the following ways: at least two sides are negative draft angles, one side is negative draft angle and three sides are positive draft angles, or one side is negative draft angle and three sides are 0-degree draft angles.

[0043] Figure 3 yes Figure 1AA cross-sectional schematic diagram of another example of a casing formed by stamping and bending of metal composite sheets. Please refer to... Figure 1A and Figure 3 The metal composite sheet 100 can be formed into a housing 200b by stamping and bending, and at least two of the four sides of the housing 200b include a bending guide angle 201 with a positive draft angle at the outer bending angle 201a and a bending guide angle 202 with a negative draft angle at the outer bending angle 202a.

[0044] In summary, the stamping and bending process of the metal composite sheet of this invention essentially involves bending the portion of the metal layer containing the groove, ensuring that the groove falls at the inner angle of the bend. Furthermore, the groove design helps improve the ductility of the bent portion and effectively disperses the internal stress generated during bending, preventing cracks from forming due to excessive stress. This achieves the goal of improving the appearance quality, structural reliability, and structural strength of the manufactured casing.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A metal composite sheet, suitable for forming a machine housing by stamping and bending, characterized in that, The metal composite plate includes: A metal layer having a first surface, a second surface opposite to the first surface, and a groove recessed in the first surface; Next, a layer is applied to cover the second surface; and A decorative layer covers the adhesive layer and is attached to the metal layer via the adhesive layer. The housing formed by stamping and bending the metal composite sheet has bending guide angles, including an outer bending angle and an inner bending angle. A positive draft angle is formed at the outer bending angle, and the groove falls at the inner bending angle. The radius of the outer bending angle is R1, the angle of the positive draft angle is A1, and the arc length of the outer bending angle is AL1. Wherein, AL1=(90°-∣A1∣)×π×R1÷180°.

2. The metal composite sheet according to claim 1, characterized in that, The width of the groove is W1, and W1 ≥ 0.9 × AL1.

3. The metal composite sheet according to claim 1, characterized in that, 0°≤A1≤30°。 4. The metal composite sheet according to claim 1, characterized in that, The thickness of the metal layer is T1, the depth of the groove is D1, and the distance between the bottom of the groove and the second surface is T2, where T2 = (T1 - D1) and R1 ≥ T2.

5. The metal composite sheet according to claim 4, characterized in that, The radius of the inner angle of the bend is R2, and R2≥0.1×T2.

6. The metal composite sheet according to claim 1, characterized in that, The decorative layer includes a color layer covering the adhesive layer and a texture layer covering the color layer, with the color layer located between the texture layer and the adhesive layer.

7. The metal composite sheet according to claim 1, characterized in that, After the metal composite sheet is stamped and bent to form the housing, a reinforcing layer is formed on the first surface. The reinforcing layer covers the first surface and is embedded in the groove.

8. The metal composite sheet according to claim 1, characterized in that, The bending chamfer is a rounded bend.

9. A metal composite sheet, suitable for forming a machine housing by stamping and bending, characterized in that, The metal composite plate includes: A metal layer having a first surface, a second surface opposite to the first surface, and a groove recessed in the first surface; Next, a layer is applied to cover the second surface; and A decorative layer covers the adhesive layer and is attached to the metal layer via the adhesive layer. The housing formed by stamping and bending the metal composite sheet has bending guide angles, including an outer bending angle and an inner bending angle. A negative draft angle is formed at the outer bending angle, and the groove falls at the inner bending angle. The radius of the outer bending angle is R11, the angle of the negative draft angle is A11, and the arc length of the outer bending angle is AL11. Where, AL11=(90°+∣A11∣)×π×R11÷180°.

10. The metal composite sheet according to claim 9, characterized in that, The width of the groove is W1, and W1 ≥ 0.9 × AL11.

11. The metal composite sheet according to claim 9, characterized in that, -30°≤A11≤0°。 12. The metal composite sheet according to claim 9, characterized in that, The thickness of the metal layer is T1, the depth of the groove is D1, and the distance between the bottom of the groove and the second surface is T2, where T2 = (T1 - D1) and R11 ≥ T2.

13. The metal composite sheet according to claim 12, characterized in that, The radius of the inner angle of the bend is R21, and R21≥0.1×T2.

14. The metal composite sheet according to claim 9, characterized in that, The decorative layer includes a color layer covering the adhesive layer and a texture layer covering the color layer, with the color layer located between the texture layer and the adhesive layer.

15. The metal composite sheet according to claim 9, characterized in that, After the metal composite sheet is stamped and bent to form the housing, a reinforcing layer is formed on the first surface. The reinforcing layer covers the first surface and is embedded in the groove.

16. The metal composite sheet according to claim 9, characterized in that, The bending chamfer is a rounded bend.

Images