Patent Publication Number: US-2020290248-A1

Title: Formed member having metal sheet and method for manufacturing same

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION 
     This non-provisional application claims priority to and the benefit of, pursuant to 35 U.S.C. § 119(a), patent application Serial No. CN 201910180318.5 filed in China on Mar. 11, 2019. The disclosures of the above applications are incorporated herein in their entireties by reference. 
     Some references, which may include patents, patent applications and various publications, are cited and discussed in the description of this disclosure. The citation and/or discussion of such references is provided merely to clarify the description of the present disclosure and is not an admission that any such reference is “prior art” to the disclosure described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference were individually incorporated by reference. 
    
    
     FIELD 
     The present invention relates to a formed member and a method for manufacturing the same, and particularly to a formed member having a metal sheet and a method for manufacturing the same. 
     BACKGROUND 
     The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure. 
     An existing formed member includes a metal sheet and a plastic member injection-molded together with the metal sheet. 
     With development of the formed member being miniaturized and thinned, the plastic member is usually slender, resulting in a mold cavity correspondingly forming the plastic member to be also slender. Currently, the liquid plastic is usually filled by vertical point plastic feeding, and the space above the slender mold cavity for provide plastic feeding runner channels is insufficient, resulting in a small quantity of the plastic feeding runner channels. In this case, an excessively small flow rate of the liquid plastic does not flow uniformly in the slender mold cavity, resulting in a short shot phenomenon to the plastic member in the injection molding process. 
     Therefore, a heretofore unaddressed need to design an improved manufacturing method exists in the art to address the aforementioned deficiencies and inadequacies. 
     SUMMARY 
     The present invention is directed to a formed member capable of implementing complete filling the mold by injection molding and a method for manufacturing the same. 
     To achieve the foregoing objective, the present invention adopts the following technical solutions. 
     A method for manufacturing a formed member having a metal sheet includes: step S 1 : providing the metal sheet; step S 2 : providing a mold, comprising a mold cavity, at least one first upper runner channel and a plurality of side runner channels, wherein an upper end of the mold cavity is in communication with the at least one first upper runner channel, each of a left side and a right side of the mold cavity is in communication with at least one of the side runner channels respectively, the metal sheet is placed in the mold, a liquid insulating material is injected into the mold, the liquid insulating material flows into the mold cavity from the at least one first upper runner channel and the side runner channels respectively, and after the liquid insulating material is solidified, a body is formed in the mold cavity and fixed to the metal sheet, a first upper connecting portion is formed in each of the at least one first upper runner channel, and a side connecting portion is formed in each of the side runner channels; and step S 3 : obtaining the formed member by disconnecting a joint of each of the first upper connecting portion and the body and a joint of each of the side connecting portion and the body. 
     In certain embodiments, in the step S 1 , at least one protruding portion is formed by stamping at each of a left side and a right side of the metal sheet; and in the step S 2 , each of the at least one side runner channel is in communication to a lower surface of a corresponding one of the at least one protruding portion, and the liquid insulating material flows into the mold cavity from the side runner channel along the lower surface of the corresponding one of the at least one protruding portion. 
     In certain embodiments, in the step S 3 , the side connecting portion is pulled downward to be disconnected from the body and form a side broken surface on the body. 
     In certain embodiments, in the step S 1 , the metal sheet is stamped to form a plurality of through holes, and the through holes are arranged on a straight line in a front-rear direction; and in the step S 2 , the upper end of the mold cavity is in communication with a plurality of first upper runner channels, each of the first upper runner channels is in communication with one of the through holes, and at least one of the through holes is provided between two adjacent ones of the first upper runner channels. 
     In certain embodiments, in the step S 1 , the metal sheet is stamped to form a plurality of through slots, each of the through holes is located between two corresponding ones of the through slots in a left-right direction, and each of the through holes and the two corresponding ones of the through slots are arranged on a straight line in the left-right direction; and in the step S 2 , the liquid insulating material flows into the through slots through the mold cavity, and after the liquid insulating material is solidified, the body is fixed to the through slots. 
     In certain embodiments, the mold comprises an upper mold and a lower mold pressed with each other, and the step S 3  is divided into steps S 3 - 1 , S 3 - 2  and S 3 - 3  sequentially performed, comprising: step S 3 - 1 : moving the upper mold upward to drive the first upper connecting portion to move upward, and disconnecting the first upper connecting portion from the body and form an upper broken surface on the body; step S 3 - 2 : moving the metal sheet, the side connecting portion and the body upward to be completely separated from the lower mold; and step S 3 - 3 : obtaining the formed member formed by the metal sheet and the body by pulling the side connecting portion downward to be disconnected from the body and removing the side connecting portion. 
     In certain embodiments, the mold comprises a plurality of first upper runner channels and a plurality of second upper runner channels, the first upper runner channels and the second upper runner channels are all provided to extend vertically, and each of the second upper runner channels is in communication with one of the side runner channels; and in the step S 2 , the liquid insulating material flows into the corresponding side runner channels from the second upper runner channels, and a second upper connecting portion is formed in each of the second upper runner channels to be connected to the corresponding side connecting portion. 
     In certain embodiments, the mold comprises an upper mold and a lower mold pressed with each other; and in the step S 3 , the upper mold is moved upward to drive the first upper connecting portion and the second upper connecting portions to move upward, the first upper connecting portion is disconnected from the body, and each of the second upper connecting portions is disconnected from the corresponding side connecting portion. 
     In certain embodiments, the second upper connecting portions are arranged in two rows in a left-right direction, the first upper connecting portions are arranged in a row in a front-rear direction, the first upper connecting portions in the row are located between the second upper connecting portions in the two rows in the left-right direction, and each of the first upper connecting portions and each of the second upper connecting portions in the two rows adjacent thereto are provided staggeredly in the front-rear direction. 
     A method for manufacturing a formed member having a metal sheet includes: step S 1 : providing the metal sheet; step S 2 : providing a mold, comprising a left mold cavity, a middle mold cavity and a right mold cavity separated from one another, wherein a left side of the left mold cavity is in communication with at least one left side runner channel, an upper end of the middle mold cavity is in communication with at least one first upper runner channel, a right side of the right mold cavity is in communication with at least one right side runner channel, the metal sheet is placed in the mold, a liquid insulating material is injected into the mold, the liquid insulating material flows into the left mold cavity, the middle mold cavity and the right mold cavity correspondingly from the left side runner channel, the first upper runner channel and the right side runner channel respectively, after the liquid insulating material is solidified, a left body is formed in the left mold cavity, a middle body is formed in the middle mold cavity, a right body is formed in the right mold cavity, the left body, the middle body and the right body are separated from one another and fixed to the metal sheet respectively, a left side connecting portion is formed in each of the at least one left side runner channel, a first upper connecting portion is formed in each of the at least one first upper runner channel, and a right side connecting portion is formed in each of the at least one right side runner channel; and step S 3 : obtaining the formed member by disconnecting a joint of each of the left side connecting portion and the left body, a joint of each of the first upper connecting portion and the middle body, and a joint of each of the right side connecting portion and the right body. 
     In certain embodiments, in the step S 1 , at least one protruding portion is formed by stamping at each of a left side and a right side of the metal sheet; and in the step S 2 , each of the at least one left side runner channel is in communication to a lower surface of a corresponding one of the at least one protruding portion located at the left side of the metal sheet, the liquid insulating material flows into the left mold cavity from the left side runner channel along the lower surface of the corresponding one of the at least one protruding portion located at the left side of the metal sheet, each of the at least one right side runner channel is in communication to a lower surface of a corresponding one of the at least one protruding portion located at the right side of the metal sheet, and the liquid insulating material flows into the right mold cavity from the right side runner channel along the lower surface of the corresponding one of the at least one protruding portion located at the right side of the metal sheet. 
     In certain embodiments, in the step S 3 , the left side connecting portion is pulled downward to be disconnected from the left body and form a left side broken surface on the left body, and the right side connecting portion is pulled downward to be disconnected from the right body and form a right side broken surface on the right body. 
     In certain embodiments, in the step S 1 , the metal sheet is stamped to form a plurality of through holes, and the through holes are arranged on a straight line in a front-rear direction; and in the step S 2 , the upper end of the middle mold cavity is in communication with a plurality of first upper runner channels, each of the first upper runner channels is in communication with one of the through holes, and at least one of the through holes is provided between two adjacent ones of the first upper runner channels. 
     In certain embodiments, the mold comprises a plurality of first upper runner channels and a plurality of second upper runner channels, the first upper runner channels and the second upper runner channels are all provided to extend vertically, and each of the second upper runner channels is in communication with one of the at least one left side runner channel or one of the at least one right side runner channel; and in the step S 2 , the liquid insulating material flows into the corresponding left side runner channel and the corresponding right side runner channel from the second upper runner channels, and a second upper connecting portion is formed in each of the second upper runner channels to be connected to the corresponding left side connecting portion or the corresponding right side connecting portion. 
     In certain embodiments, the mold comprises an upper mold and a lower mold pressed with each other; and in the step S 3 , the upper mold is moved upward to drive the first upper connecting portions and the second upper connecting portions to move upward, the first upper connecting portions are disconnected from the body, and the second upper connecting portions are disconnected from the corresponding left side connecting portion and the corresponding right side connecting portion. 
     In certain embodiments, the second upper connecting portions are arranged in two rows in a left-right direction, the first upper connecting portions are arranged in a row in a front-rear direction, the first upper connecting portions in the row are located between the second upper connecting portions in the two rows in the left-right direction, and each of the first upper connecting portions and each of the second upper connecting portions in the two rows adjacent thereto are provided staggeredly in the front-rear direction. 
     In certain embodiments, the left body and the middle body are structurally different, and the left body and the right body are provided symmetrically relative to the middle body. 
     A formed member includes: a metal sheet; and a body, injection-molded together with the metal sheet, wherein a left side of the body has at least one left side broken surface, an upper end of the body has at least one upper broken surface, and a right side of the body has at least one right side broken surface. 
     In certain embodiments, the body comprises a left body, a middle body and a right body separated from one another, a left side of the left body has the at least one left side broken surface, an upper end of the middle body has the at least one upper broken surface, and a right side of the right body has the at least one right side broken surface. 
     In certain embodiments, the left body and the middle body are structurally different, and the left body and the right body are provided symmetrically relative to the middle body. 
     In certain embodiments, at least one protruding portion is protrudingly provided at each of a left side and a right side of the metal sheet, each of the at least one left side broken surface is provided corresponding to one of the protruding portion located at the left side of the metal sheet in a left-right direction, and each of the at least one right side broken surface is provided corresponding to one of the protruding portion located at the right side of the metal sheet in the left-right direction. 
     In certain embodiments, the sheet metal is provided with a plurality of through slots, each of the through slots is provided corresponding to one of the protruding portion in the left-right direction, the body is located below the metal sheet, the body is provided with a plurality of clamping blocks protruding toward the through slots correspondingly, and each of the clamping blocks is fixed to a corresponding one of the through slots and protrudes upward out of the corresponding one of the through slots. 
     In certain embodiments, the sheet metal is provided with a plurality of through holes, the through holes are arranged on a straight line in a front-rear direction, the body is located below the metal sheet, the body is provided with a plurality of protruding blocks protruding toward the through holes correspondingly, each of the protruding blocks is fixed to a corresponding one of the through holes and protrudes upward out of the corresponding one of the through holes, at least two of the protruding blocks are respectively provided with upper broken surfaces at upper ends thereof, and at least one of the through holes is provided between two adjacent ones of the protruding blocks provided with the upper broken surfaces. 
     Compared with the related art, certain embodiments of the present invention has the following beneficial effects. 
     In certain embodiments of the present invention, the liquid insulating material flows into the mold cavity from the first upper runner channels and the side runner channels. That is, a manner of feeding the liquid insulating material from the side runner channels is additionally adopted. With the premise that the quantity of the first upper runner channels is unchanged, the side runner channels are additionally provided by fully utilizing the space of the mold cavity, thereby increasing a flow rate of the liquid insulating material flowing into the mold cavity, and further implementing uniform plastic feeding and completely filling the formed member by to injection molding. 
     These and other aspects of the present invention will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications therein may be effected without departing from the spirit and scope of the novel concepts of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings illustrate one or more embodiments of the disclosure and together with the written description, serve to explain the principles of the disclosure. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein: 
         FIG. 1  is a perspective assembled view of a flexible circuit board according to certain embodiments of the present invention. 
         FIG. 2  is a perspective exploded view of the flexible circuit board in  FIG. 1  after removing an insulating layer therefrom. 
         FIG. 3  is a sectional view of  FIG. 1 . 
         FIG. 4  is a partial enlarged view of  FIG. 3 . 
         FIG. 5  is a perspective view of an upper metal sheet according to certain embodiments of the present invention. 
         FIG. 6  is a perspective view of an upper formed member according to certain embodiments of the present invention. 
         FIG. 7  is a partial enlarged view of  FIG. 6 . 
         FIG. 8  is a perspective view of the upper formed member of  FIG. 6  being 180° inversed. 
         FIG. 9  is a partial enlarged view of  FIG. 8 . 
         FIG. 10  is a perspective view of the upper formed member of  FIG. 6  connected with connecting portions. 
         FIG. 11  is a top view of  FIG. 10 . 
         FIG. 12  is a sectional view of the upper formed member in a forming process along an A-A direction in  FIG. 11  according to certain embodiments of the present invention. 
         FIG. 13  is a sectional view of the upper formed member in the forming process along a B-B direction in  FIG. 11  according to certain embodiments of the present invention. 
         FIG. 14  is a schematic view of upward separation of an upper mold from a lower mold in  FIG. 13 . 
         FIG. 15  is a schematic view of separation of an upper connecting portion from the upper mold in  FIG. 14 . 
         FIG. 16  is a schematic view of separation of an upper metal sheet, an upper body and side connecting portions from the lower mold in  FIG. 14 . 
         FIG. 17  is a schematic view of downward pulling the side connecting portions in  FIG. 16 . 
         FIG. 18  is a schematic view of an upper formed member obtained after removing the side connecting portions in  FIG. 17 . 
     
    
    
     DETAILED DESCRIPTION 
     The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Various embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. Moreover, titles or subtitles may be used in the specification for the convenience of a reader, which shall have no influence on the scope of the present invention. 
     It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element&#39;s relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower”, can therefore, encompasses both an orientation of “lower” and “upper,” depending of the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below. 
     As used herein, “around”, “about” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around”, “about” or “approximately” can be inferred if not expressly stated. 
     As used herein, the terms “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. 
     The description will be made as to the embodiments of the present invention in conjunction with the accompanying drawings in  FIGS. 1-18 . In accordance with the purposes of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a formed member having a metal sheet and a method for manufacturing the same. 
     Certain embodiments of the present invention define that an X axis is a front-rear direction, a Y axis is a left-right direction and a Z axis is a vertical direction (i.e., an up-down direction). 
       FIG. 1  to  FIG. 3  show a flexible circuit board  100  according to certain embodiments of the present invention, which includes multiple electric conductors  1 , a formed member  2  fixing the electric conductors  1 , and an insulating layer  3  wrapping a periphery of the formed member  2 . 
     As shown in  FIG. 1  to  FIG. 3 , twelve electric conductors  1  are provided and are arranged in a single row in the Y-axis direction, including, sequentially rightward from left thereof, a ground body  11 , two signal bodies  12 , a power body  13 , four signal bodies  12 , a power body  13 , two signal bodies  12  and a ground body  11 . The two signal bodies  12  located between their adjacent power body  13  and ground body  11  form a differential pair to transmit differential signals. 
     As shown in  FIG. 3  and  FIG. 4 , the power bodies  13  are cylindrical shaped, and a periphery of each power body  13  is sequentially wrapped with an insulator  14  and a shielding body  15 . Both of the signal bodies  12  and the ground bodies  11  are flat shaped. A diameter D 1  of each power body  13  is equal to a width D 2  of each signal body  12  in the Y-axis direction and smaller than a width D 3  of each ground body  11  in the Y-axis direction. A distance between each power body  13  and its adjacent signal body  12  is d 1 . A distance between the two signal bodies  12  forming the differential pair is d 2 . A distance between each ground body  11  and its adjacent signal body  12  is d 3 . The distance d 1 , the distance d 2  and the distance d 3  are all equal. Each ground body  11  extends beyond the formed member  2  in the Y-axis direction. 
     As shown in  FIG. 2  to  FIG. 4 , the formed member  2  includes an upper formed member  2 A and a lower formed member  2 B pressed with each other. The upper formed member  2 A and the lower formed member  2 B are pressed with each other vertically to fix the electric conductors  1 . 
     As shown in  FIG. 2  and  FIG. 3 , the upper formed member  2 A includes an upper metal sheet  21  and an upper body  22  injection-molded together with the upper metal sheet  21 . 
     As shown in  FIG. 5 , the upper metal sheet  21  is provided with multiple through holes  211  and multiple through slots  212 . Multiple protruding portions  213  are provided at each of left and right sides of the upper metal sheet  21  and protruding outward. The through holes  211  and the through slots  212  have different structures. Each through hole  211  is located between two adjacent through slots  212  in the Y-axis direction. Each through slot  212  is provided corresponding to one of the protruding portions  213  in the Y-axis direction, and two adjacent through slots  212  are located between two adjacent protruding portions in the Y-axis direction. In the present embodiment, the two adjacent protruding portions  213 , the two adjacent through slots  212  and one of the through holes  211  are arranged on a straight line in the Y-axis direction. In other embodiments, there may also be only one through hole  211  and only one through slot  212 , and there may also be only two protruding portions  213  respectively provided at the left and right sides of the upper metal sheet  21 . 
     As shown in  FIG. 1  to  FIG. 3 , the protruding portion  213  at the left side of the upper metal sheet  21  bends toward a corresponding ground body  11  and abuts the corresponding ground body  11 . The protruding portion  213  at the right side of the upper metal sheet  21  bends toward the other corresponding ground body  11  and abuts the other corresponding ground body  11 . 
     As shown in  FIG. 3 ,  FIG. 6  and  FIG. 7 , the upper body  22  is located below the upper metal sheet  21 . The upper body  22  includes a left body  221 , a middle body  222  and a right body  223  separated from one another. The left body  221  and the middle body  222  are structurally different, and the left body  221  and the right body  223  are provided symmetrically relative to the middle body  222 . The left body  221 , the middle body  222  and the right body  223  are fixed on the upper metal sheet  21  respectively. One power body  13  is provided between the left body  221  and the middle body  222 , and the other power body  13  is provided between the middle body  222  and the right body  223 . In other embodiments, the left body  221 , the middle body  222  and the right body  223  may also be connected to form an integral structure. 
     As shown in  FIG. 3 ,  FIG. 5  and  FIG. 6 , each of the left body  221  and the right body  223  is provided with a plurality of clamping blocks  224  protruding toward the through slots  212  correspondingly. Each clamping block  224  is fixed with the corresponding through slot  212  and protrudes upward from the corresponding through slot  212 . The middle body  222  is provided with a plurality of protruding blocks  225  protruding toward the through holes  211  correspondingly. Each protruding block  225  is fixed with the corresponding through hole  211  and protrudes upward from the corresponding through hole  211 . 
     As shown in  FIG. 6  to  FIG. 9 , a left side of the left body  221  has multiple left side broken surfaces  2211  (referring to  FIG. 17  and  FIG. 18 ), an upper end of the middle body  222  has multiple upper broken surfaces  2221 , and a right side of the right body  223  has multiple right side broken surfaces  2231 . The structures and quantities of the left side broken surfaces  2211  and the right side broken surfaces  2231  are the same. Each left side broken surface  2211  is provided corresponding to one protruding portion  213  at the left side of the upper metal sheet  21  in the Y-axis direction (referring to  FIG. 17  and  FIG. 18 ). Each right side broken surface  2231  is provided corresponding to one protruding portion  213  at the right side of the upper metal sheet  21  in the Y-axis direction. In other embodiments, there may be only one left side broken surface  2211 , only one upper broken surface  2221  and only one right side broken surface  2231 . 
     As shown in  FIG. 5  and  FIG. 6 , the upper broken surfaces  2221  are correspondingly provided at upper ends of some of the protruding blocks  225  respectively, and one of the through holes  211  is provided between two adjacent protruding blocks  225  being provided with the upper broken surfaces  2221 . In other embodiments, multiple through holes  211  may also be provided between the two adjacent protruding blocks  225  being provided with the upper broken surfaces  2221 . 
     As shown in  FIG. 12  to  FIG. 18 , the upper formed member  2 A is formed in a mold  4 . The mold  4  includes an upper mold  40  and a lower mold  41  pressed with each other. The lower mold  41  includes a mold cavity  42 . The mold cavity  42  includes a left mold cavity  43 , a middle mold cavity  44  and a right mold cavity  45  separated from one another. The lower mold  41  further includes multiple side runner channels  46 . The side runner channels  46  include multiple left side runner channels  461  and multiple right side runner channels  462 . The left side runner channels  461  and the right side runner channels  462  are all provided to extend in the left-right direction. A left side of the left mold cavity  43  is in communication with the left side runner channels  461 , and a right side of the right mold cavity  45  is in communication with the right side runner channels  462 . In other embodiments, there may be only one left side runner channel  461  and only one right side runner channel  462 . The upper mold  40  includes multiple first upper runner channels  47  and multiple second upper runner channels  48 , and the second upper runner channels  48  and the first upper runner channels  47  are all provided to extend vertically. In other embodiments, there may be only one first upper runner channel  47  and only one second upper runner channel  48 . 
     As shown in  FIG. 12  to  FIG. 18 , when the upper metal sheet  21  is provided in the mold  4 , and the upper mold  40  and the lower mold  41  are pressed with each other, an upper end of the middle mold cavity  44  is in communication with the first upper runner channels  47 , each first upper runner channel  47  is in communication with one of the through holes  21 , and a through hole  21  is formed between two adjacent first upper runner channels  47 . Each second upper runner channel  48  is in communication with one side runner channel  46 . That is, each second upper runner channel  48  is in communication with one left side runner channel  461  or one right side runner channel  462 . In other embodiments, multiple through holes  211  may be provided between two adjacent first upper runner channels  47 . 
       FIG. 12  to  FIG. 18  show a method for manufacturing the upper formed member  2 A, which includes the following steps. 
     S 1 : the upper metal sheet  21  is provided. Multiple through holes  211  and multiple through slots  212  are formed in the upper metal sheet  21  by stamping, and multiple protruding portions  213  are formed at each of the left and right sides of the upper metal sheet  21  by stamping (referring to  FIG. 5 ). 
     S 2 : as shown in  FIG. 12  and  FIG. 13 , the mold  4  is provided. The upper metal sheet  21  is placed in the mold  4 , and the upper mold  40  and the lower mold  41  are pressed with each other. A liquid insulating material  5  is injected into the mold  4 , and the liquid insulating material  5  flows into the corresponding middle mold cavity  44  from the first upper runner channels  47  through the corresponding through holes  211  and then flows into the other through holes  211  not in communication with the first upper runner channels  47  through the middle mold cavity  44 . Meanwhile, the liquid insulating material  5  flows into the corresponding left side runner channels  461  and the corresponding right side runner channels  462  from the second upper runner channels  48 . The liquid insulating material  5  flows into the left mold cavity from the left side runner channels  461  along the lower surfaces of the corresponding protruding portions  213 , and then flows into the corresponding through slots  212  through the left mold cavity  43 . The liquid insulating material  5  flows into the right mold cavity  45  from the right side runner channels  462  along the lower surfaces of the corresponding protruding portions  213 , and then flows into the corresponding through slots  212  through the right mold cavity  45 . Then, after the liquid insulating material  5  is solidified, the left body  221  is formed in the left mold cavity  43 , the middle body  222  is formed in the middle mold cavity  44 , the right body  223  is formed in the right mold cavity  45 , and a side connecting portion  6  is formed in each side runner channel  46 . In the present embodiment, a left side connecting portion  61  is formed in each left side runner channel  461 , and a right side connecting portion  62  is formed in each right side runner channel  462 . Further, a first upper connecting portion  7  is formed in each first upper runner channel  47 , and a second upper connecting portion  8  is formed in each second upper runner channel  48  to connect the corresponding left side connecting portion  61  or the corresponding right side connecting portion  62 . 
     In the present embodiment, multiple second upper connecting portions  8  are arranged in two rows in the Y-axis direction, and multiple first upper connecting portions  7  are arranged in a row in the X-axis direction. The first upper connecting portions  7  in the row are located between the second upper connecting portions  8  in the two rows in the Y-axis direction, and each first upper connecting portion  7  and each second upper connecting portion  8  in the two rows adjacent thereto are staggered in the X-axis direction (referring to  FIG. 10  and  FIG. 11 ). 
     S 3 : as shown in  FIG. 14  to  FIG. 18 , a joint of each left side connecting portion  61  and the left body  221 , a joint of each first upper connecting portion  7  and the middle body  222 , and a joint of each right side connecting portion  62  and the right body  223  are respectively disconnected, thus obtaining the upper formed member  2 A. 
     In the present embodiment, the step S 3  is further divided into steps S 3 - 1 , S 3 - 2  and S 3 - 3  which are sequentially performed. 
     As shown in  FIG. 14  and  FIG. 15 , in the step S 3 - 1 , the upper mold  40  is moved upward to drive the first upper connecting portions  7  and the second upper connecting portions  8  to move upward. The first upper connecting portions  7  are disconnected from the middle body  222 , forming the upper broken surfaces  2221  at the upper end of the middle body  222 . The second upper connecting portions  8  are disconnected from the corresponding left side connecting portions  61  or the corresponding right side connecting portions  62 , and the first upper connecting portions  7  and the second upper connecting portions  8  are moved upward to be completely separated from the upper mold  40 . 
     As shown in  FIG. 10  and  FIG. 16 , in the step S 3 - 2 , the upper metal sheet  21 , the side connecting portions  6  and the upper body  22  are moved upward to be completely separated from the lower mold  41 . 
     As shown in  FIG. 17  and  FIG. 18 , in the step S 3 - 3 , the left side connecting portions  62  are pulled downward to be disconnected from the left body  221 , and the left side connecting portions  61  are removed, thereby forming the left side broken surfaces  2211  on the left body  221 ; and the right side connecting portions  62  are pulled downward to be disconnected from the right body  223 , and the right side connecting portions  62  are removed, thereby forming the right side broken surfaces  2231  on the right body, thus obtaining the upper formed member  2 A formed by the upper metal sheet  21 , the left body  221 , the middle body  222  and the right body  223 . 
     As shown in  FIG. 2  and  FIG. 3 , after the step S 3 , it is also necessary to bend the protruding portions  213  downward in the Z-axis direction to obtain a final product of the upper formed member  2 A. 
     As shown in  FIG. 2  to  FIG. 4 , the lower formed member  2 B includes a lower metal sheet  23  and a lower body  24  injection molded together with the lower metal sheet  23 . The lower metal sheet  23  and the upper metal sheet  21  have the same structures. That is, the lower metal sheet  23  also includes multiple through holes, multiple through slots and multiple protruding portions. The lower body  24  has a structure similar to that of the upper body  22 . That is, the lower body  24  also includes a left body, a middle body and a right body separated from one another. The left body and the right body of the lower body  24  are provided symmetrically relative to the middle body of the lower body  24 . The left body, the middle body and the right body of the lower body  24  are aligned with the left body  221 , the middle body  222  and the right body  223  of the upper body  22  respectively. Each of the left body and the right body of the lower body  24  is provided with multiple clamping blocks fixed with the through slots of the lower metal sheet  23 , and the middle body of the lower body  24  is provided with multiple protruding blocks fixed with the through holes of the lower metal sheet  23 . Specific descriptions of the lower metal sheet  23  and the lower body  24  may refer to corresponding descriptions of the upper metal sheet  21  and the upper body  22 , and are not hereinafter elaborated. The method for manufacturing the lower formed member  2 B is the same as the method for manufacturing the upper formed member  2 A. Specific descriptions of the method may refer to corresponding descriptions of the method for manufacturing the upper formed member  2 A, and are not hereinafter elaborated. 
     To sum up, the formed member having a metal sheet and the method for manufacturing the same according to certain embodiments of the present invention has the following beneficial effects: 
     (1) In the present invention, the liquid insulating material  5  flows into the mold cavity  42  from the first upper runner channels  47  and the side runner channels  46 . That is, a manner of feeding the liquid insulating material  5  from the side runner channels  46  is additionally adopted. With the premise that the quantity of the first upper runner channels  47  is unchanged, the side runner channels  46  are additionally provided by fully utilizing the space of the mold cavity  42 , thereby increasing a flow rate of the liquid insulating material  5  flowing into the mold cavity  42 , and further implementing uniform plastic feeding and completely filling the formed member  2  by to injection molding. 
     (2) The lower surfaces of the protruding portions  213  cover the corresponding side runner channels  46 , such that no closing structures are required to be additionally provided above the corresponding side runner channels  46 , thereby simplifying the structure of the mold  4 , and ensuring the liquid insulating material  5  to flow into the left mold cavity  43  and the right mold cavity  45  from the side runners  46  along the lower surfaces of the corresponding protruding portions  213 . 
     (3) A first upper connecting portion  7  is formed in each first upper runner channel  47 , and a second upper connecting portion  8  is formed in each second upper runner channel  48 . The first upper connecting portions  7  are arranged in a row in the X-axis direction, and are located between the second upper connecting portions  8  in the two rows in the Y-axis direction. Each first upper connecting portion  7  and each second upper connecting portion  8  in the two rows adjacent thereto are staggered in the Y-axis direction, such that the first upper connecting portions  7  and the second upper connecting portions  8  do not interfere with one another, ensuring the quantities of the first upper runner channels  47  and the second upper runner channels  48  to be sufficiently provided based on the practical need. 
     The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. 
     The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to activate others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.