JP2006056227A - Method for forming mold layer on surface of metal molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing an electronic device case, a chassis and the like which are thin, and have necessary strength, wide selection of an appearance design and stable supply. <P>SOLUTION: A metal molded article 1 is set in resin shaping dies 3 and 4, and in the process which forms a resin mold layer 2 to cover the surface of the metal molded article, a part of a resin mold layer is made to enter in an opening 1e prepared at the metal mold article to have the structure connecting them together. In addition, the metal mold article is formed from magnesium, a magnesium alloy, aluminum, an aluminum alloy, stainless steel, titanium and the like, and the resin mold layer is formed from a polycarbonate and the like. The resin mold layer is injected from the back side of the metal molded article making an opening 1d prepared to pass through the metal molded article 1 as a filling opening. After the end of the forming process, the process to prepare a clear coat layer or a coating layer on the surface of the resin mold layer may be added, or the process to prepare a coating layer on the surface of the resin mold layer and to prepare a clear coat layer on the top of it may be added. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present technology relates to a method of manufacturing a case of an electronic device or the like, a so-called casing or the like.

  In recent years, with the booming market of mobile digital products such as digital cameras, mobile phones, MD headphone stereos, system notebooks, etc., the supply of housings for these products has been insufficient compared to the demand. It is in.

There are the following types of casings that are conventionally supplied to the market for such products.
(1) An aluminum plate with a thickness of about 0.8 mm is used as the material, press-molded, subjected to surface treatment such as blasting or anodizing, and if a special color is required, it is painted. A light and textured material is obtained, and the strength is medium.
(2) Molding a magnesium material to a thickness of 0.8 mm, surface treatment, blasting, anodizing, etc., and painting if special color is required. A light and textured material can be obtained, and the strength is high.
(3) A 0.4 mm-thick stainless steel plate is used as the material, press-molded, and if surface treatment is required, blasting, hairline processing, etc. are performed, and in some cases, further painting or clear coating is applied. A thin, high-quality product is obtained, and the strength is high.
(4) A titanium material having a thickness of 0.3 to 0.4 mm is used as a material, press-molded, and if surface treatment is required, blasting, hairline processing, etc. are performed, and painting or clear coating is applied depending on circumstances. A thin, high-quality product is obtained, and the strength is high.
(5) Mold using a resin material, and if surface treatment is required, apply paint. Light, inexpensive and stable supply can be obtained, and there are abundant colors. Even if it is painted, the adhesion of the coating film is good.

Problems to be solved by the invention

The above-described conventional methods for manufacturing various cases have the following problems.
In the case of {circle around (1)}, the degree of difficulty in press working is high, and the anodized processing company seems to be insufficient, resulting in high costs and unstable supply.
In the case of {circle around (2)}, the yield of the magnesium forming is poor, and the anodizing processor is insufficient, resulting in high cost and unstable supply.
The items {circle around (3)} and {circle around (4)} are highly difficult to press, resulting in high costs and unstable supply.
In the case of (5), sufficient strength cannot be obtained, and if it is attempted to increase the strength, the thickness becomes thick, and the quality of the material is poor, so that a high-class feeling cannot be obtained.

In other words, the above is as follows.
(1) We would like to use a resin molded product that is inexpensive and can be stably supplied. However, if the product is made smaller and thinner, there is a limit in strength and a high-quality appearance cannot be achieved.
(2) If the casing is produced by a method other than resin molding, the rough surface of the fabric during material processing cannot be covered by the secondary processing alumite processing or painting processing, and the yield is poor and the cost is affected. In addition, the level of difficulty is high, and the manufacturer is limited and a stable supply cannot be expected. Under these circumstances, market prices have been stable at high prices.
In the present invention, the conventional method for manufacturing a casing in such a situation has a high-class feeling, a stable supply state is obtained, the thickness is thin, the cost is not high, it is light, and the strength is sufficient It is a problem to be able to obtain.

Means to solve the problem

  In order to solve the above problems, in the present invention, a step of molding a metal molded product with a metal molding die, and setting the metal molded product in a resin molding die so as to cover the surface of the metal molded product A method of forming a mold layer on a surface of a metal molded product, comprising: a step of forming a resin mold layer into a laminated structure, wherein the resin mold layer and the metal molded product have a structure in which the resin molded layer and the metal molded product are firmly bonded to each other Was used. (Hereinafter, this section is referred to as a main solution section.)

  Further, in the above main solution means, the range where the resin mold layer covers the surface of the metal molded product is the entire surface or most of the surface.

  In the above main solution means, the metal forming mold is a mold such as a mold for magnesium and a magnesium alloy, a mold for press, a mold for die casting, or the like.

  Further, in the above main solution means, the material of the metal molded product is magnesium and a magnesium alloy, aluminum and an aluminum alloy, stainless steel, titanium and the like.

  In the main solution means, the resin to be molded so as to cover the surface of the metal molded product with the resin molding die is a polycarbonate material or the like.

  Further, in the above main solution means, the resin mold layer molded so as to cover the surface of the metal molded product with the resin molding die passes through an opening provided so as to penetrate the metal molded product, and It was decided to be injection molded from the back side direction.

  Moreover, in the said main solution means term, it decided to add the process of providing a clearcoat layer on the resin mold layer surface after completion | finish of a shaping | molding process.

  Moreover, in the said main solution means term, after the completion | finish of a formation process, it decided to add the process of providing a coating layer on the resin mold layer surface.

  Moreover, in the said main solution means term, after the shaping | molding process completion | finish, the process of providing a coating layer on the resin mold layer surface, and also providing a clear coat layer on the surface of the said coating layer was added.

The invention's effect

  Since the metal molded product is molded by the metal molding die, and then the resin molded layer is molded so as to cover the surface of the metal molded product by setting the metal molded product in the resin molding die, There is an advantageous effect that a mobile digital product housing such as a mobile phone, an MD headphone stereo, and a system notebook can be inexpensively and stably supplied.

  By thinning the resin mold layer covering the surface of the thin metal molded product, there is an advantageous effect that it can be made small and thin like a case made of only a metal material.

  Since a metal molded product exists on the inner side, the strength is sufficient, and the outer side is constituted by a resin mold layer having a wide degree of freedom in design, so that there is an advantageous effect that the appearance can be given a high-class appearance.

  Since it is possible to cover the rough surface of the metal molded product, which is difficult to avoid, with the resin mold layer covering the surface, there is no need for secondary treatment of the metal molded product, and there is an advantageous effect that there is no decrease in yield and cost rebound. .

  Since the difficulty of the manufacturing technique is lower than the case where it is composed only of a metal molded product, the manufacturer is not limited and there is an advantageous effect that a stable supply state can be obtained.

  The process consists of molding a metal molded product with a metal mold and molding the resin mold layer into a laminated structure so as to cover the surface of the metal molded product by setting the metal molded product in the resin mold. And a structure in which a part of the resin mold layer is inserted into an opening provided in the metal molded product and fixedly bonded to each other.

  As the mold for forming the metal molded product, a mold for magnesium, a mold for the alloy, a mold for press, and a mold for die casting are used.

  The metal molded product is formed of magnesium and magnesium alloy, aluminum and aluminum alloy, stainless steel, titanium, and the like, and the resin mold layer is formed of polycarbonate and the like.

  The resin mold layer that is molded so as to cover the surface of the metal molded product with the resin molding die is configured to be injection-molded from the back side direction of the metal molded product through an opening provided to penetrate the metal molded product. .

    After completion of the molding process, add a step of providing a clear coat layer on the surface of the resin mold layer, add a step of providing a coating layer on the surface of the resin mold layer, or provide a coating layer on the surface of the resin mold layer. A step of providing a clear coat layer is added.

  FIG. 1 is a cross-sectional view of a main part for explaining a product (for example, a part of a housing of a digital camera) according to the present embodiment, wherein 1 is a metal molded product and 2 is a resin mold layer. The metal molded product 1 of the present embodiment is formed by pressing a stainless steel material having a thickness of 0.2 to 0.4 mm, and a slightly larger opening 1a (use is not described) is provided in front of the main surface. The peripheral edge is bent into an edge to form an edge 1b. Reference numeral 1c denotes an attachment hole provided in the edge portion 1b for an attachment target component (not shown), and reference numerals 1d and 1e denote holes for fixing a resin mold layer to be described later. A dish-like process 1s is also applied to the peripheral back surface side of the opening 1a. 1d is an opening for injecting resin when molding a resin mold layer described later. In this embodiment, it is provided at two places as shown in the figure.

  The resin mold layer 2 is formed so as to cover most of the surface of the metal molded product 1. The resin mold layer 2 of the present embodiment is formed by molding a polycarbonate material. A slightly larger opening 2a is provided in front of the main surface 2m of the surface, and the center is coincident with the opening 1a of the metal molded product 1. . The peripheral edge of the main surface 1a is bent into an edge shape along the edge 1b of the metal molded product 1 to form an edge 2b. Reference numerals 2d and 2e denote resin portions that have entered the holes 1d and 1e of the metal molded product 1, respectively.

  FIG. 2 is a sectional view showing a state where the metal molded product 1 described in FIG. 1 is set in a mold 3 for molding the resin mold layer 2.

  As is well known, a resin mold is composed of a movable mold and a fixed mold, but only one of them is shown as a mold 3 in FIG. The metal molded product 1 is set on the protruding portion 3 a of the mold 3. Since the protruding portion 3a of the mold 3 is set so as to conform to the internal size shape of the metal molded product 1, it can be set with an appropriate degree of fitting. Arrow A indicates the injection direction of the resin. Thus, the resin is injection-molded toward the opening 1d of the metal molded product 1 through a path (not shown) of the mold 3.

  FIG. 3 is a sectional view showing a state in which a resin is injection-molded in a mold. The mold 4 is processed so as to mold and form the resin mold layer 2 with the mold 3. In FIG. 3, the two molds are closed and directed toward the opening 1d of the metal molded product 1 in the direction of arrow A. Resin injected from the gate G on the mold 3 side forms the resin mold layer 2. As described above, the resin mold layer 2 is formed by molding a polycarbonate material so as to cover most of the surface of the metal molded product 1, and a slightly larger opening 2a is provided in front of the main surface 2m. The peripheral edge of the surface is shaped to be bent along the edge 1b of the metal molded product 1 to form the edge 2b. Reference numerals 2d and 2e denote resin portions that have entered the openings 1d and 1e of the metal molded product 1, and these are firmly fixed to each other.

  Further, on the back side of the opening 2a in front of the main surface 2m, the back side of the opening 1a of the metal molded product 1 is subjected to dish-like processing 1s, and the diameter of the opening 1a is slightly larger than the diameter of the opening 2a. Due to the small setting, the resin also enters this portion, and the fixation is made stronger.

  Thus, according to this embodiment, the resin mold layer can be molded so as to be firmly bonded to the surface of the metal molded product, and the mold layer can be formed in a so-called wrapping shape.

  In this embodiment, the metal molded product is formed by magnesium molding. FIG. 4 is shown as a partial cross-sectional view in that example. No. 21 is a metal molded product such as a casing formed by magnesium chixso molding, and the surface roughness of the surface tends to be conspicuous due to the nature of the material and molding means, so that it has been covered by conventional coating. According to the present invention, it is possible to hide the roughness of the background by so-called coating molding so that the resin mold layer 22 is molded and wrapped around the surface of a metal molded product 21 such as a casing formed by magnesium chixso molding. Since the manufacturing process and the like are the same as those in the first embodiment, description thereof is omitted.

  In this embodiment, the target product is a case of a hinged mobile phone, and FIG. In general, mobile phone housings require hinges, but if the entire body including the hinges is made of resin, the strength is insufficient, and the appearance can be maintained if steel plates that provide sufficient strength are pressed. Absent. According to the present embodiment of FIG. 5, the above-described problem is solved by molding the resin mold layer 32 on the surface including the hinge portion 32h in the case 31 made by press molding including the hinge portion 31h. Covering. As an example, the casing 31 is made of a 0.8 mm steel plate and the resin mold layer is 0.4 mm.

  6 to 7 show an example of a stacked state. The thing of FIG. 6 is the same as that of what was demonstrated in Example 1, Comprising: With respect to the layer of the metal molded product 41 which pressed the steel material of thickness 0.4mm, for example, it comprises a resin mold layer as thickness 0.4mm, Although the total thickness is 0.8 mm, it seems that it can be reduced to about 0.6 mm along the direction of thinning, which is a market requirement.

  In FIG. 7A, the resin mold layer 52 is formed of a color resin with respect to the layer of the metal molded product 51, and the selection range of the appearance design can be expanded without providing a process such as painting.

  In FIG. 7B, the resin mold layer 52 is formed of a color resin with respect to the layer of the metal molded product 51, and the clear coat layer 53 is further provided thereon, so that the fabric color is high quality. Can do.

  In FIG. 7C, a resin mold layer 52 is formed on the layer of the metal molded product 51, and a coating layer 53 is formed on the resin mold layer 52, and a clear coat layer 54 is further provided. If the metallic coating is made of silver and the clear coat layer 54 is formed thereon, the fabric color can be further improved.

    In addition, since the partial sectional view is used in the description of each embodiment, the number of gates for injecting the resin indicated by the arrow A direction and the metal molded product and the resin mold layer are bonded and fixed. Although the number of openings and the number of holes or the shape thereof are partially illustrated, they can be increased or decreased and the shape can be changed without being limited to the contents of the drawings depending on the purpose.

    In the description of each of the above embodiments, the metal mold for forming the metal molded product is used for pressing and for magnesium. However, the present invention is not limited to this, and a mold for magnesium alloy and a mold for die casting are used. The material to be used may be formed of magnesium alloy, aluminum and aluminum alloy, stainless steel, titanium or the like, and is not limited to the above embodiment. Furthermore, although the resin mold layer is made of a polycarbonate material, it is not limited to this.

    It is sectional drawing of the part of the housing | casing which complete | finished the process of this invention.     It is a fragmentary sectional view in the forming process which set components in the metal mold | die of this invention.     It is a fragmentary sectional view in the shaping | molding process in which the product exists in the metal mold | die of this invention.     It is a fragmentary sectional view which shows the relationship between the layer of a metal molded product, and the resin mold layer.     It is a fragmentary sectional view of a product provided with a hinge.     It is a fragmentary sectional view which shows the thickness relationship between the layer of a metal molded product, and the resin mold layer.     (A), (B), and (C) are partial cross-sectional views showing an embodiment in a laminated state.

Explanation of symbols

1, 21, 31, 41, 51 Metal molded product 2, 22, 32, 42, 52 Resin mold layer 3, 4 Mold

Claims (9)

  A step of molding a metal molded product with a metal molding die, and a step of setting the metal molded product in a resin molding die and molding a resin mold layer into a laminated structure so as to cover the surface of the metal molded product. And the resin mold layer and the metal molded product have a structure in which they are firmly bonded to each other.   2. The method of forming a mold layer on the surface of a metal molded product according to claim 1, wherein the resin mold layer covers the surface of the metal molded product over the entire surface or a majority of the surface.   2. The method of forming a mold layer on the surface of a metal molded product according to claim 1, wherein the metal mold is a mold for magnesium and a magnesium alloy, a mold for press, a mold for die casting, or the like. .   2. The method of forming a mold layer on the surface of a metal molded product according to claim 1, wherein the material of the metal molded product is magnesium and a magnesium alloy, aluminum and an aluminum alloy, stainless steel, titanium, or the like.   The resin for forming the resin mold layer so as to cover the surface of the metal molded product with the resin molding die is a polycarbonate material or the like, and the mold layer is molded on the surface of the metal molded product according to claim 1. Method.   The resin mold layer that is molded so as to cover the surface of the metal molded product with the resin molding die is injection-molded from the back side direction of the metal molded product through an opening provided so as to penetrate the metal molded product. The method of shape | molding a mold layer on the surface of the metal molded product of Claim 1 characterized by these.   2. The method of forming a mold layer on the surface of a metal molded product according to claim 1, further comprising the step of providing a clear coat layer on the surface of the resin mold layer after completion of the forming step.   2. The method of forming a mold layer on the surface of a metal molded product according to claim 1, further comprising the step of providing a coating layer on the surface of the resin mold layer after completion of the forming step.   The mold layer is formed on the surface of the metal molded product according to claim 1, further comprising a step of providing a coating layer on the surface of the resin mold layer after the molding step and further providing a clear coat layer on the surface of the coating layer. How to mold.

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