Compact tube with internal features and methods for fabricating the same

• US 20080163663A1
• Filed: 06/28/2007
• Published: 07/10/2008
• Est. Priority Date: 01/05/2007
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Sanford, Emery A., Hankey, M. Evans
• Granted Patent: US 8,650,925 B2
• Time in Patent Office: Days
• US Class Current: 72/348
• CPC Class Codes: B21C 23/18 by impact extrusion
• CPC Class Codes: B29C 48/001 Combinations of extrusion moulding with other shaping operations
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 7/00304 Overcurrent protection
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H04M 1/05 specially adapted for use on head, throat or breast
• CPC Class Codes: H04M 1/6058 involving the use of a headset accessory device connected to the portable telephone
• CPC Class Codes: H04R 1/1016 Earpieces of the intra-aural type
• CPC Class Codes: H04R 1/1025 Accumulators or arrangements for charging secondary cells per se H01M10/00; charging in general H02J7/00
• CPC Class Codes: H04R 1/1041 Mechanical or electronic switches, or control elements switches in general H01H
• CPC Class Codes: H04R 2201/107 Monophonic and stereophonic headphones with microphone for two-way hands free communication
• CPC Class Codes: H04R 2225/33 Aspects relating to adaptation of the battery voltage, e.g. its regulation, increase or decrease
• CPC Class Codes: H04R 2225/51 Aspects of antennas or their circuitry in or for hearing aids
• CPC Class Codes: H04R 2420/09 Applications of special connectors, e.g. USB, XLR, in loudspeakers, microphones or headphones
• CPC Class Codes: H04R 29/008 Visual indication of individual signal levels visual indication of stereophonic sound image H04S7/40
• CPC Class Codes: H04R 5/033 Headphones for stereophonic communication details thereof, e.g. relating to batteries, cables or control elements H04R1/10
• CPC Class Codes: Y02D 30/70 in wireless communication networks

Abstract

Methods for forming a tube that includes a feature extending from an inner surface of the tube are provided. The methods can include using a die and stamper, single impact extrusion, double impact extrusion, and progressive deep draw process.

Claims

1. A method for forming a tube that includes a feature extending from an inner surface of the tube, the method comprising:

extruding material to form a tube having a first thickness;

inserting a die into a first end of the tube;

inserting a stamper into a second end of the tube;

applying a force to the stamper to cold-work a portion of the tube located near the second end, the cold-worked portion having a second thickness that is greater than the first thickness; and

machining the cold-worked portion to create the feature.

2. The method of claim 1, wherein the die is inserted to a predetermined location within the tube, wherein the predetermined location is a desired location of the feature.

3. The method of claim 1, wherein extruding material to form a tube comprises extruding material to form a tube having a length that exceeds a finished tube length.

4. The method of claim 1, wherein the first thickness is substantially equal to a finished tube thickness.

5. The method of claim 1, wherein the feature is selected from the group consisting of a wall, a protrusion, an aperture, a snap, a shelf, and any combination thereof.

6. The method of claim 1, wherein at least one of the die and stamper are constructed to form a predetermined feature.

7. The method of claim 1, wherein the material is at least one of metal and plastic.

8. A method for forming from a material a tube that includes a feature extending from an inner surface of the tube, the method comprising:

using impact extrusion to form an indentation in the material, wherein the indentation provides a cavity extending from a first end of the material to a predetermined location within the material, the cavity providing tube portion having a wall thickness; and

machining the material located at a second end of the material to provide the feature and the tube.

9. The method of claim 8, wherein the feature is selected from the group consisting of a wall, a protrusion, an aperture, a snap, a shelf, and any combination thereof.

10. The method of claim 8, wherein the wall thickness is substantially equal to a finished tube wall thickness.

11. The method of claim 8, wherein machining comprises removing material from a non-cavity portion of the material to provide the feature.

12. The method of claim 11, wherein a portion of the non-cavity portion comprises substantially similar wall thickness as the cavity portion.

13. A method for forming from a material a tube that includes a feature extending from an inner surface of the tube, the method comprising:

using impact extrusion to form first and second indentations in the material, wherein the first indentation provides a first cavity extending from a first end of the material to a first predetermined location within the material, the first cavity providing a tube portion having a first wall thickness, and wherein the second indentation provides a second cavity extending from a second end of the material to a second predetermined location within the material, the second cavity providing a machinable tube portion having a second wall thickness; and

removing a portion of the machinable tube portion to form the tube and the feature.

14. The method of claim 13, wherein the first wall thickness is substantially equal to a finished tube wall thickness.

15. The method of claim 13, wherein the first predetermined location and the second predetermined location do not overlap.

16. The method of claim 13, wherein the first predetermined location and the second predetermined location overlap.

17. The method of claim 13, wherein the removing comprises machining a portion of the second cavity to have a wall thickness substantially equal to the first wall thickness.

18. The method of claim 13, wherein the feature is a wall.

19. A method for forming a finished tube including a feature extending from an inner surface of the tube, comprising:

using a progressive deep draw process to provide a workable tube, the workable tube comprising first and second cavities within the tube that are substantially adjacent to each other, the first cavity having a first wall thickness, the second cavity having a second wall thickness, and the workable tube having an open end and a closed end;

removing the closed end of the workable tube; and

machining the second cavity to form the feature and the finished tube.

20. The method of claim 19, wherein the first wall thickness is substantially equal to a finished tube wall thickness.

21. The method of claim 19, wherein the finished tube is constructed from metal or plastic.

22. The method of claim 19, wherein the feature is selected from the group consisting of a wall, a protrusion, an aperture, a snap, a shelf, and any combination thereof.

23. The method of claim 19, wherein a portion of the second cavity is machined to have a wall thickness substantially equal to the first wall thickness.