Metal Mobile Device Case Molding via Multi-Stage Slide Block Die
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Solution Overview
Problem
Current manufacturing methods for mobile device cases, particularly metal cases, are costly and inefficient due to the use of CNC processing, which is time-consuming, environmentally polluting, and difficult to operate, and existing molding techniques cannot produce metal cases with good heat dissipation and quality at a lower cost.
Innovation Solution
A mold system comprising multiple main bodies and slide blocks that form a male and female mold section, allowing for the molding of metal device cases using a metal thin sheet, which can be shaped and demolded efficiently, reducing manufacturing costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CNC processing apparatus is used to cut and process metal blocks, then metal cases with good heat dissipation can be manufactured, but manufacturing time is prolonged and cost increases
Solution Approach 1:
The patent replaces the mechanical CNC cutting and milling system with a molding system that uses dies and pressing mechanisms. Instead of removing material through cutting blades, the invention forms metal cases by molding metal sheets or blocks between dies, significantly reducing manufacturing time while maintaining heat dissipation performance through proper metal material selection and case design
Solution Approach 2:
The invention changes the manufacturing parameter from subtractive processing (CNC cutting) to formative processing (molding/pressing). By altering the fundamental manufacturing approach from removing material to shaping material, the process achieves both speed improvement and heat dissipation requirements through controlled forming parameters such as pressing force, temperature, and mold design
2Shape
If multiaxial CNC processing apparatus is used, then complex metal cases can be manufactured, but device complexity and maintenance cost increase
Solution Approach 1:
The patent divides the complex molding process into separate, simpler stages using multiple independent dies and molding steps. Instead of using a single complex multiaxial CNC machine, the invention employs sequential molding operations with simpler pressing mechanisms, where each die handles a specific portion of the case formation, reducing overall system complexity while achieving complex case geometries
Solution Approach 2:
The invention uses physical mold dies that are precise copies or replicas of the desired case geometry. These dies directly imprint the complex shape onto the metal material without requiring complex real-time control systems or programming, simplifying the manufacturing apparatus while maintaining the ability to produce complex case designs
3Ease of manufacture
If punching method is used for manufacturing, then manufacturing cost can be reduced, but material cannot be de-molded for complicated structures
Solution Approach 1:
The patent employs dynamic mold designs where the dies can move relative to each other during the molding process. For complex structures, the mold includes movable or flexible components that allow the mold cavity to expand or adjust during ejection, enabling successful removal of molded parts with complex geometries while maintaining cost-effective manufacturing processes
Solution Approach 2:
The invention introduces additional degrees of freedom in the molding process by using multi-directional pressing and ejection mechanisms. Instead of simple single-axis punching, the mold system applies force and enables removal in multiple dimensions, allowing complex three-dimensional case structures to be formed and successfully de-molded without increasing manufacturing cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the cost-effective and efficient production of metal mobile device cases with improved heat dissipation, overcoming the limitations of conventional techniques by allowing metal cases to be molded at lower costs and reducing material waste and environmental pollution.
Implementation Method 1
forcedly mating the female mold section with the male mold section to shape the metal thin sheet into a configuration identical to that of the mold cavity
Data Source
AI summary
A mold for molding a case of a mobile device includes a first, second, third, fourth and fifth main body, connection slide blocks, and first and second abutment slide blocks. The connection slide blocks and the second abutment slide blocks are inlaid in first and second slide channels of the first and second main bodies. The first abutment slide blocks are inlaid in channels of the connection slide blocks. The third, fourth and fifth main bodies are horizontally movable relative to the first and second main bodies. The first and second main bodies, the connection slide blocks and the first and second abutment slide blocks together define a male mold section and the third, fourth and fifth main bodies together define a female mold section. A metal thin sheet is placed on the male mold section and pressurized and molded by the female mold section to form the case.