Extrusion method for fabricating a compact tube with internal features

• US 8,650,925 B2
• Filed: 06/28/2007
• Issued: 02/18/2014
• Est. Priority Date: 01/05/2007
• Status: Expired due to Fees

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Hankey, M. Evans, Sanford, Emery
• Primary Examiner(s): SULLIVAN, DEBRA M
• Application Number:
  US11/824,442
• Publication Number:
  US 20080163663A1
• Time in Patent Office: 2,427 Days
• Field of Search: 723/52, 723/58, 723/59, 722/67, 723/40, 723/552, 723/556, 723/702.7, 722/56, 723/56, 295/57, 298/884.52, 298/900.5, 298/900.53, 470/29, 470/31
• US Class Current: 72/267
• 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, from a longitudinal member having an elongated axis, a tube that includes an internal wall extending from an inner surface of the tube and perpendicular to the elongated axis, the method comprising:

using impact extrusion to form an indentation in the longitudinal member, wherein the indentation provides a cavity extending from a first end of the longitudinal member to a predetermined location within the longitudinal member; and

machining the longitudinal member in between the predetermined location and a second end of the longitudinal member to provide the internal wall and to create a lumen extending between the cavity and the second end, wherein;

a portion of the lumen has a cross-section substantially equal to a cross-section of the cavity;

the internal wail defines a transition region having a cross-section less than the cross-section of the cavity and the second end in at least one dimension; and

the internal wall is non-annular.

2. The method of claim 1, wherein the machining further provides a feature selected from the group consisting of a protrusion, an aperture, a snap, a shelf, and any combination thereof.

3. The method of claim 1, wherein:

the cavity provides a tube portion having a tube wall thickness; and

the tube wall thickness is substantially equal to a finished tube wall thickness.

4. The method of claim 1, wherein:

the cavity provides a tube portion having a tube wall thickness; and

the machining comprises removing material from a non-cavity portion of the longitudinal member to provide the internal wall.

5. The method of claim 4, wherein a portion of the non-cavity portion comprises substantially similar tube wall thickness as the cavity portion.

6. The method of claim 1, wherein the longitudinal member has an oval cross-sectional shape.

7. A method for forming, from a longitudinal member having an elongated axis, a tube that includes an internal wall extending from an inner surface of the tube and perpendicular to the elongated axis, the method comprising:

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

removing a portion of the machinable tube portion to form the internal wall and to create a lumen extending between the first cavity and the second cavity, wherein;

a cross-section of the first cavity is substantially equal to a cross-section of the second cavity after the removing;

the internal wall is non-annular; and

the lumen has a cross-section less than the cross-section of the first cavity in at least one dimension.

8. The method of claim 7, wherein the first tube wall thickness is substantially equal to a finished tube wall thickness.

9. The method of claim 7, wherein the first predetermined location and the second predetermined location do not overlap.

10. The method of claim 7, wherein the removing comprises machining a portion of the machinable tube portion to have a machined tube wall thickness substantially equal to the first tube wall thickness.

11. The method of claim 7, wherein the removing further forms a feature selected from the group consisting of a protrusion, an aperture, a snap, a shelf, and any combination thereof.

12. The method of claim 7, wherein the longitudinal member has an oval cross-sectional shape.

13. A method for forming, from a longitudinal member having an elongated axis, a tube that includes an internal wall extending from an inner surface of the tube and perpendicular to the elongated axis, the method comprising:

using impact extrusion to form an indentation in the longitudinal member, wherein the indentation provides a cavity extending from a first end of the longitudinal member to a predetermined location within the longitudinal member; and

machining the longitudinal member between the predetermined location and a second end of the longitudinal member to provide the internal wall and to create a lumen extending between the cavity and the second end, wherein the internal wall extends from only a portion of the tube'"'"'s circumference.

14. The method of claim 13, wherein the internal wall extends from less than half of the tube'"'"'s circumference.

15. The method of claim 13, wherein a portion of the lumen has a cross-section substantially equal to a cross-section of the cavity.

16. The method of claim 13, wherein the machining further provides a feature selected from the group consisting of a protrusion, an aperture, a snap, a shelf, and any combination thereof.

17. The method of claim 13, wherein:

the cavity provides a tube portion having a tube wall thickness; and

the tube wall thickness is substantially equal to a finished tube wall thickness.

18. The method of claim 13, wherein:

the cavity provides a tube portion having a tube wall thickness; and

machining comprises removing material from a non-cavity portion of the longitudinal member to provide the internal wall.

19. The method of claim 18, wherein a portion of the non-cavity portion comprises substantially similar tube wall thickness as the cavity portion.

20. The method of claim 13, wherein the longitudinal member has an oval cross-sectional shape.

21. A method for forming, from a longitudinal member having an elongated axis, a tube that includes an internal wall extending from an inner surface of the tube and perpendicular to the elongated axis, the method comprising:

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

removing a portion of the machinable tube portion to form the internal wall and to create a lumen extending between the first cavity and the second cavity, wherein the internal wall extends from only a portion of the tube'"'"'s circumference.

22. The method of claim 21, wherein the internal wall extends from less than half of the tube'"'"'s circumference.

23. The method of claim 21, wherein a cross-section of the first cavity is substantially equal to a cross-section of the second cavity after the removing.

24. The method of claim 21, wherein the first tube wall thickness is substantially equal to a finished tube wall thickness.

25. The method of claim 21, wherein the first predetermined location and the second predetermined location do not overlap.

26. The method of claim 21, wherein the removing comprises machining a portion of the machinable tube portion to have a machined tube wall thickness substantially equal to the first tube wall thickness.

27. The method of claim 21, wherein the removing further forms a feature selected from the group consisting of a protrusion, an aperture, a snap, a shelf, and any combination thereof.

28. The method of claim 21, wherein the longitudinal member has an oval cross-sectional shape.