Method of manufacturing metal cover with blind holes therein
First Claim
1. A method of manufacturing a metal cover with blind holes therein, comprising the steps of:
- preparing a metal substrate;
stamping the metal substrate into a three-dimensional shape;
covering the metal substrate, after stamping thereof, with an erosion-resistant protective film formed by electrophoretic deposition;
cutting the protective film, controlled by a predetermined pattern procedure, to form holes in the protective film on the metal substrate, thus exposing areas of the metal substrate, the cutting being performed by a cutting machine, the predetermined pattern being programmed in a computer, the cutting machine being controlled by the computer, according to the predetermined pattern;
etching the metal substrate at the exposed areas to form blind holes; and
removing a remainder of the protective film on the metal substrate, thus obtaining the metal cover.
3 Assignments
0 Petitions
Accused Products
Abstract
An exemplary method of manufacturing a metal cover (1) with blind holes (3) therein includes: step (60), preparing a metal substrate; step (62), covering the metal substrate with a protective film formed by electrophoretic deposition; step (64), forming holes in the protective film according to an intended pattern of the blind holes in the metal cover, thus exposing the metal surface through the holes; step (66), etching the metal substrate in the exposed areas to form the blind holes; and step (68), removing a remainder of the protective film from the metal substrate, thereby obtaining the finished metal cover. The method involving etching is relatively low-cost. Additionally, because electrophoretic deposition is used to cover the metal substrate with the protective film, the protective film can be formed on all surfaces of the metal substrate. Thus the method is especially advantageous for manufacturing a metal cover having a three-dimensional shape.
28 Citations
20 Claims
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1. A method of manufacturing a metal cover with blind holes therein, comprising the steps of:
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preparing a metal substrate; stamping the metal substrate into a three-dimensional shape; covering the metal substrate, after stamping thereof, with an erosion-resistant protective film formed by electrophoretic deposition; cutting the protective film, controlled by a predetermined pattern procedure, to form holes in the protective film on the metal substrate, thus exposing areas of the metal substrate, the cutting being performed by a cutting machine, the predetermined pattern being programmed in a computer, the cutting machine being controlled by the computer, according to the predetermined pattern; etching the metal substrate at the exposed areas to form blind holes; and removing a remainder of the protective film on the metal substrate, thus obtaining the metal cover. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 20)
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13. A method of manufacturing a metal cover with blind holes therein, comprising the steps of:
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preparing a metal substrate; stamping the metal substrate into a three-dimensional shape; selectively covering areas of a surface of the metal substrate, after stamping thereof, with a protective mask, the areas being particularly where blind holes are to be formed; covering remaining portions of the metal substrate with a protective film formed by electrophoretic deposition; removing the protective mask, thus exposing said areas of the surface of the metal substrate; etching the metal substrate at the exposed areas to form the blind holes; and washing the metal substrate using a methylbenzene solvent so as to remove a remainder of the protective film on the metal substrate, thus obtaining the metal cover. - View Dependent Claims (14, 18, 19)
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15. A method of manufacturing a metal cover with blind holes therein, consisting essentially the steps of:
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preparing a metal substrate; stamping metal substrate into a three-dimensional shape; dipping into the metal substrate, after stamping thereof, into a cathodic electrophoretic deposition bath containing amino epoxy resin for forming a protective film; forming holes in the protective film on the metal substrate, thus exposing areas of the metal substrate, the forming of the holes being achieved by a laser machine burning off the protective film where the holes are formed, the laser machine being controlled by a computer according to a predetermined pattern procedure programmed therein; etching the metal substrate at the exposed areas to form blind holes; and washing the metal substrate using a methylbenzene solvent so as to remove a remainder of the protective film on the metal substrate, thus obtaining the metal cover. - View Dependent Claims (16, 17)
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Specification