Abstract:
The present invention discloses a metal-to-nonmetal coupling structure that utilizes substantially symmetrically arranged coupling grooves in a metal substrate in conjunction with plastic molding technique to achieve secure structural coupling of components of different materials. A manufacturing method for the metal-nonmetal coupling interface structure is also disclosed to provide a simplified metal shell manufacturing process capable of achieving secure joining of various non-metal components onto a metal surface.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a metal-to-plastic coupling interface structure and a manufacturing method thereof, and more particularly to a metal-to-nonmetal coupling structure that utilizes substantially symmetrically arranged coupling grooves in a metal substrate in conjunction with plastic molding technique to achieve secure structural coupling of components of different materials, and a manufacturing method thereof. 
         [0003]    2. Description of Related Art 
         [0004]    With the development of science and technology, various electronic products and electronic equipments occur. Metal constructed components are widely applied in these electronic products and electronic equipments, including external shell assembly and internal mechanism arrangement. Especially, internal mechanisms always have many functional components mounted therein, and the functional components need to be securely disposed in metal shells by metal manufacturing. Taking notebook computers for example, hardware, such as motherboards, hard disks, power supplies and so on, are mounted and fixed in metal shells. 
         [0005]    As shown in  FIG. 1A  and  FIG. 1B , a conventional manufacturing method includes: cutting a low positioning hole  2   a  in a surface of a metal substrate  1   a,  positioning an assembling pole  3   a  according with the size of the positioning hole  2   a  in the positioning hole  2   a,  and fixedly welding the assembling pole  3   a  in the positioning hole  2   a  by welding. At this time, a welding block  5   a  is connected with a bottom of the assembling pole  3   a  and an outer edge of the positioning hole  2   a.  A functional component  7   a  desired to be mounted is assembled in an assembling hole  4   a  (as shown in  FIG. 2A  and  FIG. 2B ) formed in the assembling pole  3   a  by a screw  6   a,  thereby completing the assembly. 
         [0006]    However, the above-mentioned manufacturing method is very complicated: the size of the positioning hole  2   a  must be very accurately defined, and each positioning hole  2   a  needs to be cut separately and each assembling pole  3   a  needs to be positioned and welded separately. The same steps must be repeated on each position. So the more the components desired to be mounted are, the more the repeated steps are, which causes that the operation time is prolonged, the probability of failure is high, and the costs are quite high. 
       SUMMARY OF THE INVENTION 
       [0007]    One aspect of the present invention is to provide a metal-to-nonmetal coupling interface structure that utilizes substantially symmetrically arranged coupling grooves in a metal substrate in conjunction with plastic molding technique to achieve secure structural coupling of components of different materials. Another aspect of the instant disclosure provides a manufacturing method of the metal-to-nonmetal coupling interface structure having a simplified metal shell manufacturing process and capable of achieving secure joining of various non-metal components onto metal surfaces in a simple process, thereby reducing the costs and saving time. 
         [0008]    To achieve the above-mentioned object, a metal-nonmetal coupling interface structure in accordance with the present invention is provided. The metal-nonmetal coupling interface structure comprises: a metal substrate having a top surface; at least one fixing groove structure having a central axis disposed on the top surface of metal substrate, where the lateral cross-section of the fixing groove structure comprises a pair of opposingly arranged slanting grooves substantially symmetrical to each other about the central axis of the fixing groove structure, where the slanting groove and the top surface of the metal substrate form an oblique angle; at least one plastic layer disposed on the metal substrate and fastened in the fixing groove structure; and at least one assembling hole exposedly formed in the plastic layer and accessible from a top surface thereof. 
         [0009]    To achieve the above-mentioned object, a metal shell manufacturing method executed by a metal shell manufacturing cutter device for producing the same in accordance with the present invention is provided. The metal shell manufacturing method executed by the cutter includes the steps of: 
         [0010]    (1). providing a metal substrate; 
         [0011]    (2) providing a metal shell manufacturing cutter device with a knife module in a hollow cylindrical shape, having a main body, at least two blade bodies, at least two extension ends, at least two blade heads at least two spaces formed between the blade bodies in lateral direction, wherein the knife module is rotatable upon an axis, and the blade heads stretches out from the blade bodies in an angle, the blade heads together form at least one pair of partial cyclic hook structure opposite to each other, the partial cyclic hook structure forms a variable diameter, which is further controlled by a pressing tool contacted to the extension ends,; 
         [0012]    (3). Abutting the knife module against the metal substrate with slightly pressing on the metal substrate so that the blade heads of the partial cyclic hook structure make a primary cut in an oblique angle and form at least one shallow groove in the metal substrate; 
         [0013]    (4) subsequently pressing the pressing tool to further compress the extension ands so that the blade heads keep moving laterally in substance more and the diameter of partial cyclic hook structure alters to make a secondary cut to form at least one fixing groove in the metal substrate, the secondary cut resulting in a wider fixing groove groove; 
         [0014]    (5) the fixing groove further extending into the metal substrate in a deeper oblique angle from the shallow groove while the diameter of the partial circle hook structure alters; 
         [0015]    (6) relaxing the pressing tool to decrease the pressing of the extension end so that the blade head deviated from the fixing groove laterally in substance, completing the fixing groove; and 
         [0016]    (7) disposing at least one plastic layer on the metal substrate, the plastic layer fastened in the fixing groove and fixed on the metal substrate; and forming at least one assembling hole in the plastic layer, the assembling hole extending into the plastic layer from a surface of the plastic layer. 
         [0017]    In the metal-nonmetal coupling interface structure and method of the present invention, the formed plastic layers are fastened in the fixing groove structure directly and the plastic layers and the assembling holes can be formed in one piece via a mold, so there is no need for cutting a hole separately and welding the assembling poles like prior arts, thereby simplifying the manufacturing process, reducing the costs, saving time and maximizing the efficiency for manufacturing metal shells. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1A  is a first top view of a prior art; 
           [0019]      FIG. 1B  is a first cross-sectional view of the prior art; 
           [0020]      FIG. 2A  is a second top view of the prior art; 
           [0021]      FIG. 2B  is a second cross-sectional view of the prior art; 
           [0022]      FIG. 3A  is a cross-sectional side view of a knife module assembled in a metal shell manufacturing cutter device of the present invention; 
           [0023]      FIG. 3B  is in a cross-sectional bird&#39;s eye view of the knife module; 
           [0024]      FIG. 3C  is a cross-sectional side view of the knife module; 
           [0025]      FIG. 4  is a cross-sectional side view of the knife module when executing a primary cut on a metal substrate; 
           [0026]      FIG. 5A  is a cross-sectional side view of a metal substrate with a shallow groove produced by a primary cut; 
           [0027]      FIG. 5B  is a cross-sectional side view of a metal substrate with a fixing groove produced by a secondary cut; 
           [0028]      FIG. 5C  is a bird&#39;s eye view of a metal substrate with a fixing groove produced in a cutting way; 
           [0029]      FIG. 5D  is a bird&#39;s eye view of a metal substrate with a fixing groove produced in a pressing way; 
           [0030]      FIG. 6A  is a knife module with a lock protruding from the coat into the blade body in a cross-sectional bird&#39;s eye view; 
           [0031]      FIG. 6B  is a cross-sectional side view of the knife module according to  FIG. 6A ; 
           [0032]      FIG. 7A  is an outwards-stretching blade of the knife module with a lock protruding from the blade body into the coat in a cross-sectional bird&#39;s eye view; 
           [0033]      FIG. 7B  is an outwards-stretching blade of the knife module with a lock protruding from the blade body into the coat in a cross-sectional side view according to  FIG. 7A ; 
           [0034]      FIG. 8A  is an outwards-stretching blade of the knife module with a lock protruding from the coat into the blade body in a cross-sectional bird&#39;s eye view; 
           [0035]      FIG. 8B  is an outwards-stretching blade of the knife module with a lock protruding from the coat into the blade body in a cross-sectional side view according to  FIG. 8A ; 
           [0036]      FIG. 9A  is an cross-sectional side view of a metal substrate with a shallow groove produced by an primary cut of outwards-stretching blade of the knife module; 
           [0037]      FIG. 9B  is an cross-sectional side view of a metal substrate with a fixing groove produced by an secondary cut of outwards-stretching blade heads of the knife module; 
           [0038]      FIG. 10A  is a first top view of a metal-nonmetal coupling interface structure of the present invention; 
           [0039]      FIG. 10B  is a partially enlarged top view of part A in  FIG. 10A ; 
           [0040]      FIG. 10C  is a partially enlarged cross-sectional side view of part A in  FIG. 10A ; 
           [0041]      FIG. 11A  is a second top view of the metal-nonmetal coupling interface structure of the present invention; 
           [0042]      FIG. 11B  is a partially enlarged top view of part B in  FIG. 11A ; 
           [0043]      FIG. 11C  is a partially enlarged cross-sectional side view of part B in  FIG. 11A ; 
           [0044]      FIG. 12A  is a third top view of the metal-nonmetal coupling interface structure of the present invention; 
           [0045]      FIG. 12B  is a partially enlarged top view of part C in  FIG. 12A ; 
           [0046]      FIG. 12C  is a partially enlarged cross-sectional side view of part C in  FIG. 12A ; 
           [0047]      FIG. 13A  is a fourth top view of the metal-nonmetal coupling interface structure of the present invention; 
           [0048]      FIG. 13B  is a partially enlarged top view of part D in  FIG. 13A ; 
           [0049]      FIG. 13C  is a partially enlarged cross-sectional side view of part D in  FIG. 13A ; and 
           [0050]      FIG. 14  is a flow chart of a metal shell manufacturing method of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0051]    Please refer to  FIG. 3A-3C , illustrating a metal shell manufacturing cutter device suitable for manufacturing the metal-to-plastic coupling interface structure in accordance with the instant disclosure. The present invention utilizes a metal shell manufacturing cutter which includes a knife module I and a pressing tool  2 . The knife module  1  is in a hollow cylindrical shape, having a main body  11 , at least two blade bodies  12 , at least two extension ends  13  at least two blade heads  14 , at least two spaces  15  formed between the blade bodies  12 . In this embodiment, as shown in  FIG. 3B and 3C , the knife module  1  concludes a main body  11 , four blade bodies  12 , four extension ends  13 , four blade heads  14  and four spaces  15  formed between the blade bodies  12 . The four spaces  15  between each blade bodies  12  result in capable of elastic and substantially-lateral moving of the four blade bodies  12  as well as the blade heads  14 . The four extension ends  13 , in this embodiment, extend downward and outward from the blade bodies  12  to form a surrounding angle. From a cross-sectional bird&#39;s eye view and a cross-sectional view, the blade heads  14  represent an inner partial cyclic hook structure. In addition, the inner partial cyclic hook structure of the blade heads  14  can move in an elastically and substantially lateral way. The four blade heads  14  extend from bottom end of each blade bodies  12  and the blade heads  14  together with the blade bodies  2  constitute an inwards angle. The knife module  1  is capped with the pressing tool  2  and the bottom end of the pressing tool  2  contacts against the extension ends  13 . 
         [0052]    All elements of the knife module  1  are integrally joined. In particular, the blade bodies  12  are further connected to the pressing tool  2  by protruding a lock  31  from the blade body  12  into the pressing tool  2 , and on the lock  31  is a lifting space  32 . The at least two blades  14  are now four blades  14  in this preferred embodiment. The four spaces  15  between each blade bodies  12  as well as the blade heads  14 , make it allowable, when pressing the pressing tool  2  to the extension ends  13 , a substantially lateral and elastic movement of the blade bodies  12  as well as the blade heads  14 . 
         [0053]    The knife module  1  is set on a machining equipment  4  which includes a first table  41 , second table  42 , third table  43 , at least two first sliding posts  44 , at least two second sliding posts  45  and a driving device  46 . The first table  41  is located between the second table  42  and the third table  43 , the three tables are parallel to each other. The first table  41  has at least two first holes  411  penetrating thereon, mounted with at least two first sliding posts  44 , so that the first table  41  is able to move up and down along the first sliding post  44 . Each of the sliding posts  44  has a position limit  441  for limiting the lowest position of the first table  41 , which is referred as primary cutting site, to carry out primary cut. The second sliding post  45  is set through the second sliding hole  412  penetrating on the first table  41  and the second sliding post  45  is fixed to the second table  42  and third table  43  so that the second and third table  42 ,  43  move up and down together relative to the first table. Each second sliding post  45  possesses a spring thereon between the first table  41  and the third table  43 (in this embodiment) or the first table  41  and the second table  42 , providing an elastic force of buffer and a restoring position. 
         [0054]    A knife-module bearing  413  capable of rotating is set on the first table  41  so that the knife module  1  is able to rotate upon its axis as the driving device  46  acts. The second table  42  has a pressing-tool bearing  423  penetrating thereon under the knife-module bearing  413  and the upper end of the pressing tool  2  is connected to the pressing-tool bearing  423 , contributing the rotating of the pressing tool  2  upon the axis. 
         [0055]    The driving device  46  is responsible for the simultaneous rotating of the knife-module bearing  413  and the pressing-tool bearing  423  as well as the simultaneous rotating of the knife module  1  and the pressing tool  2 . In another way, the driving device  46  can be responsible for the independent rotating of the knife-module bearing  413  only, or can be responsible for the independent rotating of the pressing-tool bearing  423  only and then subsequent can be responsible for linking-up of the simultaneous rotating of the knife module  1  combined with the pressing tool  2  by means of the lock  31  and the lifting space  32 . The driving device  46  is also responsible for the rise and drop of the first  41 , second  42  and third  43  tables. 
         [0056]    The knife module  1  is connected to a driving device  46  on top, providing power to drive the pressing tool  2 . The pressing tool  2  is connected to a first table  41  and a second table  42  with an outer knife-module bearing  413  and an outer pressing-tool bearing  423  respectively so that the pressing tool  2  is able to rotate upon the axis ( FIG. 4 ) and further to drive the whole knife module  1 , the blade heads  14 , as well as the main bodies  11 , to rotate. While rotating, the second table  42  is able to rise and drop independently to the first table  41 , and the rise or drop of the second table  42  is controlled by the third table  43 . 
         [0057]    Please refer to  FIG. 3A ,  4 ,  5 A- 5 D. By pressing down the first table  41 , the knife module  1  is abutted against the metal substrate slightly to make a primary cut and form at least one shallow groove in the metal substrate as well as causing an oblique angle in the metal substrate  5 . By pressing down the second  42  or the third  43  table continuingly, the pressing tool  2  is pressed to subsequently compress the extension ends  13  so that the blade heads  14  are compressed to move laterally in substance, causing a variable diameter of the partial cyclic hook structure, and to make a secondary cut. In this embodiment, however, the variable diameter means a reduced diameter, causing an inner cut to complete the primary and secondary cut. And the secondary cut is of non-fullness cut. Thereafter at least one fixing groove  52  is formed. Furthermore, the knife module  1  is allowed to rotate for treating the metal substrate  5  in a cutting method or to be kept steady for treating the metal substrate  5  in a pressing mehtod when exposing to the metal substrate  5 . If the cutting method is used, a fixing groove structure  52  of continuous enclosed circle (viewed from a bird&#39;s eye) can be formed ( FIG. 5C ). If the pressing method is used, a discontinuous circle, or a half-moon shaped fixing groove structure  52  (viewing from an overhead view) may be formed ( FIG. 5D ). When the fixing groove  52  is completed, the blade heads  14  can be departed form the fixing groove  52  laterally in substance by decreasing the pressing of the second  42  or the third  43  table and then the first table  41  for preventing the blade heads  14  from destroying the fixing groove  52 . 
         [0058]    Please refer to  FIG. 6A and 6B , illustrating another embodiment of lock  31  which is protruded from the pressing tool  2  into the blade bodies  12 . 
         [0059]    Please refer to  FIG. 7A-7B  and  FIG. 9A-9B  illustrating another embodiment of the knife module  1  and the fixing groove  52  caused by the knife module  1 . The blade heads  14  are turned outwards in an angle to the blade bodies  12  to form an outer partial cyclic hook structure with the spaces  5  between the blade bodies  12 , and the pressing tool  2  is set inside the knife module  1 . The extension ends  13  protrude inwards from the back of the blade heads  14  and contact to the pressing tool  2 , therefore, when pressing the pressing tool  2 , the compression to the extension ends  13  initiated by the pressing tool  2  causes the blade heads  14  to move laterally in substance. In this embodiment, the blade heads  14  form an outer partial cyclic hook structure with the spaces  15  between the blade bodies  12 . At the mean time, the spaces  15 , of course, provides space for the lateral moving of the blade heads  14 r as blade heads  14  keep moving outwards in a bigger lateral range. Similar to the  FIG. 5C and 5D , the blade heads  14  can also be used in a cutting way or a pressing way to produce a continuous-enclosed circle of fixing groove  52  or a discontinuous circle of fixing groove  52  from a bird&#39;s eye. And it&#39;s also in a similar way, shown as  FIG. 7A-7B  and  FIG. 8A-8B , the lock  31  can be protruded from the blade bodies  12  or from the pressing tool  2  respectively. 
         [0060]    Please refer to  FIGS. 10A-10C ,  FIGS. 11A-11C ,  FIGS. 12A-12C  and  FIGS. 13A-13C , illustrating a metal-nonmetal coupling interface structure according to the present invention. The metal-nonmetal coupling interface structure includes a metal substrate  5  having a top surface; at least one fixing groove structure  52  having a central axis disposed on the top surface of metal substrate, where the lateral cross-section of the fixing groove structure comprises a pair of opposingly arranged slanting grooves substantially symmetrical to each other about the central axis of the fixing groove structure, and where the slanting groove and the top surface of the metal substrate form an oblique angle; at least one plastic layer  6  molded into the slanting groove Of the fixing groove structure, thereby retained atop the top surface of the metal substrate  5 ; and at least one assembling hole  7  exposedly formed in the plastic layer and accessible from a top surface thereof. The fixing groove structure  52  is formed in the metal substrate  5 , the plastic layer  6  is disposed on the metal substrate  5  and fastened in the fixing groove structure  52 , and the assembling hole  7  is formed in the plastic layers  6 . 
         [0061]    As shown in  FIGS. 10A-10C , the metal substrate  5  originally has a smooth top surface. The fixing groove structure  52  are formed at a desirable location on the the metal substrate  5 , by a drilling machine, a lathing machine, a punching machine, a milling machine or other machining equipments. The fixing groove structure  52  extends slantingly into the metal substrate  5  from the top surface of the metal substrate  5  at an oblique angle. Specifically, in the cross-sectional view, the fixing groove structure  52  and the surface of the metal substrate  5  form an oblique angle therebetween so that the plastic layers  6  can be molded into and fastened in the fixing groove structure  52 . As shown in  FIGS. 11A-11C , according to desired appearances of products, the metal substrate  1  may include a bottom board  53  and at least one side board  54  which are formed by punching. The side board  54  is located on the periphery of the bottom board  53  and the bottom board  53  is perpendicular to the side board  54 . The bottom board  53  and the side board  54  both have the fixing groove structure  52 . Further, as shown in  FIGS. 12A-12C , in a mold-forming way, the plastic layers  6  are formed on the metal substrate  5  and the assembling holes  7  are formed in the plastic layers  6  and extend into the plastic layer  6  from a surface of the plastic layer  6 . The plastic layers  6  and the assembling holes  7  may have an integrated structure formed by mold-forming, 
         [0062]    The desired mold has a shape and structure according with the manufacturing demands. By injection molding or other forming ways, the molten plastic material is coated on the metal substrate  5  and filled in the fixing groove structure  52 . After the plastic material is solidified, the mold is removed and the plastic layers  6  are formed on the metal substrate  5 . Based on the plastic material filled in the fixing groove structure  52 , each formed plastic layer  6  has at least one fastening portion  61 , and the plastic layer  6  may be fastened in the fixing groove structure  52  of the bottom board  53  or the fixing groove structure  52  of the side board  54  via the fastening portion  61  and fixed on the metal substrate  5 . Because the plastic layers  6  and all the assembling holes  7  may be formed in one piece directly via the mold, so there is no need for cutting a hole separately. 
         [0063]    Any component may be disposed on the metal-nonmetal coupling interface structure easily, for example, motherboards, hard disks, power supplies, etc. As shown in  FIGS. 13A-13C , at least one functional component F is assembled in the assembling holes  7  via at least one assembling device  8  so as to mount the functional component F on the metal-nonmetal coupling interface structure. The assembling holes  7  may be mold-formed to be screw holes, fastening holes or other kinds of assembling holes. The assembling devices  8  may be screws, tenons or other kinds of assembling devices. 
         [0064]    In the metal-nonmetal coupling interface structure, the number, shapes and positions of the fixing groove structure  52 , the plastic layers  6  and the assembling holes  7  may be defined according to the configuration and arrangement of the functional components F. The larger the number of fixing groove structure  52  is, the more stably the plastic layer  6  is fixed on the metal substrate  5 . Based on shapes of cutting tools and manufacturing modes of manufacturing devices, besides the circular shape in the embodiment, the plane shape of the fixing groove structure may be other shapes, not limited herein. Additionally, the assembling holes  7  may also be formed by drilling, not limited in mold-forming. 
         [0065]    Accordingly, please refer to  FIG. 14  simultaneously, the present invention provides a metal shell manufacturing method by using a metal manufacturing cutter device which includes the steps of: 
         [0066]    (1). providing a metal substrate  5 ; 
         [0067]    (2). as shown in FIGS.  4  and  5 A- 5 D,  FIG. 7B ,  FIG. 8B  or  FIG. 9A-9B , forming at least one fixing groove  52  in the position desired to be manufactured of the metal substrate  5  after executing a primary cut and a secondary cut subsequently by the metal shell manufacturing cutters device, wherein the fixing groove  52  extends into the metal substrate  5  from the surface of the metal substrate  5 , and the fixing groove  52  and the surface of the metal substrate  5  form an oblique angle therebetween to enhance the fastening and fixing effect for the plastic layer molded thereon; 
         [0068]    (3). as shown in  FIGS. 11A-11C , punching the metal substrate  5  according to the desired shape of a product to form a bottom board  53  and at least one side board  54  on the metal substrate  5 , wherein the side board  54  is located on the periphery of the bottom board  53  and the bottom board  53  is perpendicular to the side board  54 , the bottom board  53  and the side board  54  both have the fixing groove structure  52 ; 
         [0069]    (4). as shown in  FIGS. 12A-12C , disposing at least one plastic layer  6  on the metal substrate  5  in a mold-forming way and forming at least one assembling hole  7  in the metal substrate  5 , wherein the assembling hole  7  extends into the plastic layer  6  from the surface of the plastic layer  6 , the plastic layer  6  and the assembling hole  7  have an integrated structure formed by mold-forming, the plastic layer  6  is fastened in the fixing groove  52  and fixed on the metal substrate  5 , the plastic layer  6  and all the assembling holes  7  may be formed in one piece via a mold, without a hole being cut separately. The assembling hole  7  may be mold-formed to be screw holes, fastening holes or other kinds of assembling holes. 
         [0070]    Furthermore, in the step (4), the assembling holes  7  may also be formed by drilling, not limited in mold-forming. 
         [0071]    After the metal shell manufacturing method, as shown in  FIGS. 13A-13C , at least one functional component F is assembled in the assembling holes  7  via at least one assembling device  8 . The assembling devices  8  may be screws, tenons or other kinds of assembling devices. 
         [0072]    Based on the above mentioned metal-nonmetal coupling interface structure and method of the present invention, the formed plastic layers  6  are fastened in the fixing groove structure.  52  directly and don&#39;t need to be fixed separately by welding, and the plastic layers  6  and all the assembling holes  7  may be formed in one piece via a mold, without a hole being cut separately. Accordingly, the manufacturing process is simplified, the costs are reduced, time is saved and the efficiency for manufacturing metal shells is maximized. 
         [0073]    What are disclosed above are only the specification and the drawings of the preferred embodiments of the present invention and it is therefore not intended that the present invention be limited to the particular embodiments disclosed. It will be understood by those skilled in the art that various equivalent variations may be made depending on the specification and the drawings of the present invention without departing from the scope of the present invention.