USB Metal Casing Manufacturing via Integrated Mold Forming
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Solution Overview
Problem
The existing manufacturing methods for USB interface metal casings with integrated structures are complex, result in uneven material shrinkage, and require additional processes like burring to meet size requirements, making it impossible to achieve the desired dimensions in a single production step.
Innovation Solution
A manufacturing method involving three sequential mold closures: pipe-expansion forming, necking and chamfering, and final modification using a lower mold and three upper molds, with specific elements like elastic elements, guiding posts, and restricting plates to ensure uniform shrinkage and precise dimensioning without additional processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamping forming and punching processes are used to create the USB interface metal casing, then the port can be formed, but the processes become complicated and additional burring processes are needed
Solution Approach 1:
The patent combines multiple manufacturing operations (punching, burring, and fillet formation) into a single integrated die set. The die includes a punching component for creating the port opening, a burring component for removing burrs, and a fillet formation component for creating rounded corners, all of which operate simultaneously during one stamping cycle. This eliminates the need for separate sequential processes and reduces overall manufacturing complexity.
Solution Approach 2:
The die is designed as a multi-functional tool that performs multiple operations on the metal casing blank in a single step. It simultaneously punches the port opening, forms the fillet at the port corner, and burrs the edge, making the die itself a universal manufacturing device that replaces multiple specialized tools and processes.
2Productivity
If multiple separate processes are used for punching and burring, then each feature can be formed, but the production time increases
Solution Approach 1:
The patent merges punching, burring, and fillet formation operations into a single simultaneous process using an integrated die set. All three operations occur during one stamping cycle, eliminating the sequential nature of traditional manufacturing and significantly reducing total production time.
Solution Approach 2:
The die is designed so that the burring component and fillet formation component are already in position and configured before the stamping operation begins. The punching component creates the port opening while simultaneously, the burring component removes burrs and the fillet formation component creates rounded corners. This preliminary positioning and simultaneous execution eliminates setup time between operations and accelerates production.
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
This method simplifies the process, achieves uniform material shrinkage, and allows for the production of USB interface metal casings that meet size requirements in a single step, eliminating the need for additional processes like burring.
Implementation Method 1
a pipe-expanding element connected to the first upper mold base via an elastic element; the elastic element penetrates through the pipe-pressing element; wherein during the closing process of the first upper mold and the lower mold, the pipe-expanding element firstly contacts with the stripper, and the first upper mold gradually closes to the lower mold; the elastic element is compressed, and the pipe-pressing element presses downwardly onto the top of the pipe blank
Data Source
AI summary
The present disclosure provides a manufacturing method and a manufacturing apparatus for an USB interface metal casing. The manufacturing method for an USB interface metal casing includes: feeding a flat-shaped pipe blank to a lower mold (S100); closing a first upper mold and the lower mold, and performing pipe-expansion forming to a bottom of the pipe blank (S110); closing a second upper mold and the lower mold, and performing necking and chamfering to a top port of the pipe blank (S120); and closing a third upper mold and the lower mold, and modifying the pipe blank to obtain a final finished product of the USB interface metal casing (S130).