JP2006311324A - Resin molded product and resin molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To perform surface treatment of a housing satisfactorily when an inside has to be opened, such as a speaker grill. <P>SOLUTION: This resin molded product provided with resin sheets 20 where small holes 21 are continuously arrayed on at least a portion thereof and a resin molded product main body 10 where the resin sheets 20 are arranged integrally on the surface by insertion molding and an opening for opening a portion of the small holes 21 or the entire small holes 21 is provided constitutes a device so as to obtain a product excellent in both functional and design manners. In the opening, for example, speaker units 12L and 12R are arranged. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a resin molded product and a resin molding method suitable for application to an electronic device with a speaker such as a television receiver.

  2. Description of the Related Art Conventionally, a housing that constitutes an electronic device with a built-in speaker, such as a television receiver, is generally made of a resin molded product. Here, since the speaker outputs sound, in order to output the sound output from the speaker unit, a mechanism for satisfactorily outputting the sound from inside the housing in which the speaker unit is arranged is necessary. It is.

  FIG. 14 is a diagram illustrating a configuration example of a housing of a conventional television receiver. In this example, it is an example of a television receiver having a thin display unit such as a liquid crystal display panel, and a display unit 2 is provided at the center of the front surface of the housing 1 constituting the main body of the receiver molded with synthetic resin. It is arranged. Speaker units 4L and 4R are arranged inside the housing 1 on the left and right sides of the display unit 2, and the speaker grille 3 is attached to the front surface thereof.

  The speaker grill 3 is formed of a member separate from the casing 1 such as a metal punching metal sheet or a resin plate provided with a through hole, and is attached to a corresponding position of the casing 1 with an adhesive or the like. It is attached. By attaching the speaker grille 3, the sound output from the internal speaker units 4L and 4R is output to the outside of the housing 1 through the through holes provided in the speaker grille 3. . In order to function well as a speaker grill, a certain degree of aperture ratio is required.

Patent Document 1 discloses an example in which a speaker grill made of a metal punching metal sheet is bonded to the surface of a casing of a device.
Japanese Patent Laid-Open No. 5-183977

  As shown in FIG. 14, when a separate speaker grille is attached, it can be seen at a glance that the speaker grille is attached because the separate one is attached to the housing. There was a problem with the discomfort. Further, since a separate speaker grille is pasted by bonding or the like, a seam or the like with the casing becomes conspicuous at the periphery of the speaker grille, which is not preferable. Furthermore, since it is pasted by bonding or the like, a process of bonding with an adhesive or a double-sided adhesive tape is necessary when assembling the casing, and there is a problem that it takes time and effort to manufacture.

  The present invention has been made in view of the above points, and an object of the present invention is to make it possible to satisfactorily treat the surface of a housing when it is necessary to open the interior, such as a speaker grill.

  The present invention is provided with a resin sheet in which through holes are continuously arranged at least in part, and an opening for opening part or all of the through holes after the resin sheet is integrally formed on the surface by insert molding. A resin molded product provided with a resin molded product main body is configured to constitute a device.

  By doing in this way, the resin sheet by which the through-hole was continuously arranged by insert molding is attached in the state integrated with the housing | casing surface at the time of resin molding of the housing body.

  According to the present invention, by insert molding, the resin sheet in which the through holes are continuously arranged is attached in a state of being integrated with the surface of the casing, and the sheet integrated with the surface of the casing constituting the device main body is obtained. The state of the surface of the housing when the through-hole is formed and the inside of the housing needs to be opened is good both in terms of design and function. Further, there is no need to attach a separate sheet or the like after the casing is molded, and the manufacturing process can be simplified.

  Hereinafter, an embodiment of the present invention will be described with reference to FIGS.

  In this example, as an example applied to a television receiver which is an electronic device, as an example applied to a front frame as a front portion (so-called bezel portion) of a resin molded product constituting a housing of the television receiver. is there. FIG. 1 is a view showing the front frame 10. A display panel mounting opening 11 corresponding to the display screen size of the receiver is provided in the center of the front frame 10, and speaker units 12 </ b> L and 12 </ b> R are disposed inside the left and right sides of the opening 11. . Note that the speaker units 12L and 12R themselves are not necessarily fixed to the front frame 10, but are fixed inside the receiver so as to be disposed in a space (not shown) continuous with the front frame 10, for example. Also, the number of speaker units is not limited to one each on the left and right.

  Resin sheets 20 are attached to the left and right side surfaces of the display panel attachment opening 11 of the front frame 10. This resin sheet 20 is a sheet in which fine holes (through holes) are continuously arranged in a two-dimensional manner, and as shown in the manufacturing process described later, the front frame 10 is formed by insert molding at the time of resin molding of the front frame 10. Integrated and attached.

  FIG. 2 is an exploded view of the front frame 10 and the resin sheet 20. Note that FIG. 2 is an exploded view for the sake of explanation. Actually, the front frame 10 and the resin sheet 20 are integrated and molded, and thus cannot be disassembled in this way. . 1 and 2 show the size of the resin sheet by emphasizing the through-holes and showing the size larger than the actual size.

  As shown in FIG. 2, speaker placement openings 13 are provided at approximately the center of the left and right sides of the display panel mounting opening 11 of the front frame 10. Reinforcing ribs 14 are arranged vertically and horizontally. The edge on the front side of the reinforcing rib 14 has a shape that is in contact with the back surface of the resin sheet 20 without a gap when the resin sheet 20 is stuck. The shape (structure) of the reinforcing ribs 14 shown in FIG. 2 is an example, and for example, a plurality of thinner ribs may be arranged at narrow intervals.

  As will be described later in the process, the resin sheet 20 is pre-formed to adjust its shape before insert molding, and has a shape that is attached to the front frame 10 shown in FIG. 2 in advance.

  FIG. 3 is a view of the speaker arrangement opening 13 of the front frame 10 as viewed from the back side. Reinforcing ribs 14 are arranged vertically and horizontally in the speaker arrangement opening 13, and a resin sheet 20 is integrally attached to the front (front) side which is the opposite side in FIG. 3. Therefore, when the speaker arrangement opening 13 is viewed from the back surface side, the back surface of the resin sheet 20 is exposed, and the outside (front surface side) can be ventilated through the through hole 21 disposed in the resin sheet 20. It is in a state. In the case of this example, since the resin sheet 20 is integrated with the front frame 10 by insert molding, the edge 20a of the resin sheet 20 is in a state where there is no step or gap with the front surface of the front frame 10. .

  FIG. 4 is a cross-sectional view showing a configuration example of the resin sheet 20. As already described, in the resin sheet 20 of this example, the through holes 21 that are fine holes are continuously formed on one surface. An example of a specific arrangement state of the through holes 21 is shown. For example, the through holes 21 having a diameter of 0.35 mm are arranged vertically and horizontally at a pitch of 0.6 mm, and the aperture ratio is about 32%. The through hole 21 is provided, for example, in a punching process described later. As a configuration of the resin sheet 20, a printed layer 23 is formed by printing (or coating) on the back surface of a resin film 22 such as a PET film or a polycarbonate film, and a binder 24 is applied on the back surface. The binder 24 functions as an adhesive that sticks to the molded product body during insert molding, and a binder having high affinity with the resin material to be used is used. The resin film 22 has a thickness of about 0.2 mm to 0.5 mm, for example, and the printing layer 23 and the binder 24 have a thickness of about 10 μm to 20 μm, respectively. In addition, as a raw material which comprises the resin film 22, the thing whose melting temperature is higher than the resin raw material which comprises the front frame 10 is used.

  FIG. 5 is a diagram schematically showing a state in which the speaker unit 12R is arranged on the back side of the speaker arrangement opening 13 of the front frame 10 shown in FIG. On the back side of the speaker arrangement opening 13, a speaker unit arrangement space 15 is formed by a member constituting the front frame 10 or another member, and the speaker unit 12R is arranged in the space. The sound output from the speaker unit 12R is output to the outside through the through hole 21 of the resin sheet 20 attached to the surface of the speaker arrangement opening 13.

  Next, the manufacturing process of the resin sheet 20 and the front frame 10 configured as described above will be described with reference to FIGS. FIG. 6 is a diagram showing an outline of a state in which the through holes 21 are formed in the continuous resin sheet 100 that is the basis of the resin sheet 20 in the punching process. As shown in FIG. 6, the long resin sheet 100 is fed between the punching devices 51 and 52 by a fixed distance, sandwiched between the teeth 51a and 52a of the punching devices 51 and 52, and the teeth 51a and 52a pass through the holes. 21 is formed.

  Then, the long resin sheet 100 in which the through holes 21 are continuously formed is cut into necessary dimensions to form the printing layer 23 and the binder 24 shown in FIG. In order to arrange in a mold to be molded, preforming is performed to form a required shape in advance. That is, as shown in FIG. 7, the resin sheet 100 is cut out to a required size, and then preforming is performed with the resin sheet 20 having a shape arranged on the front frame 10. For the preforming, conventionally known preforming processes such as pressurization and heating can be applied.

  Then, as shown in FIG. 7, a resin sheet 20 having a predetermined shape is prepared, and the front frame 10 is previously placed in a mold for resin molding, and then a resin molding operation is performed, so-called insert molding is performed. . FIG. 8 is a view showing an outline of a mold for resin-molding the front frame 10, and is composed of a mold 61 and a mold 62. Here, the mold 61 is a fixed side and the mold 62 is movable. The core 63 having a shape corresponding to the molded product is formed on the mold 62, and a space (cavity) formed by joining both the molds 61 and 62 is filled with resin from the resin injection portion 64. The front frame 10 is resin-molded.

  At the time of molding, as shown in FIG. 8, two resin sheets 20 are arranged in advance in a predetermined position in the mold 61, and then the resin is filled as shown in FIG. At this time, the arrangement position of the resin sheet 20 may be determined by some method. By performing the insert molding in this way, when the front frame 10 that is a resin molded product is taken out from the mold, the resin sheet 20 is integrally attached to the surface of the front frame 10, and the resin sheet 20 There is no step or gap between the edge and the surface of the front frame 10. As the resin material constituting the front frame 10, for example, various resin materials generally used for resin molding such as ABS resin, polystyrene (PS), polycarbonate, and acrylic can be used. However, it is necessary to use a material having a lower melting temperature than the resin material constituting the resin sheet 20 so as not to melt the resin sheet 20 during resin molding. In the example of FIGS. 7 and 8, the resin sheet 20 is arranged in the fixed-side mold 61. However, the resin sheet may be arranged in any mold for insert molding. The resin injection portion 64 may be provided on any mold side.

  By manufacturing in this way, the front frame 10 shown in FIG. 1 is obtained. In the front frame 10 which is a part of the casing constituting the receiver body obtained in this way, the resin sheet 20 having the minute through holes 21 is at least in front of the arrangement positions of the speaker units 12L and 12R. The sound output from each of the speaker units 12L and 12R is output to the outside of the receiver through the through hole 21. In this case, the resin sheet 20 has an aperture ratio of about 32%, for example, when the through holes 21 are arranged under the conditions shown as an example described above, and this kind of speaker front arrangement member is used to output sound to the outside. There is a sufficient amount of opening, and a sufficiently good sound output process can be performed.

  And in appearance, it is a state in which minute through holes are arranged in a uniform state in the entire arrangement position of the resin sheet 20, and it is not known where the opening for the speaker is, and it is excellent in design. Become. In addition, the edge of the resin sheet 20 is integrated with the surface of the front frame 10 without any steps or gaps, and the resin sheet 20 has an excellent shape that is not conscious of being a separate member from the front frame 10. The change does not cause the resin sheet 20 to peel off. Further, there is no need to attach a sheet with an adhesive or the like to the front surface of the front frame 10 in the manufacturing process, and the manufacturing process can be simplified accordingly. Further, since the resin sheet 20 is integrated by insert molding, even when a molding distortion called “sink” occurs on the surface of the resin component (front frame 10) at the position where the resin sheet is disposed, There is also an effect that the portion where the distortion occurs is hidden by the resin sheet 20.

  In addition, it can also be set as the product excellent in design by printing a decorative pattern etc. beforehand as the resin sheet 20. FIG. For example, as shown in FIG. 10, by using a resin sheet 20 'on which a decorative pattern 23a is printed, the decorative pattern is applied simultaneously with the insert molding. The decorative pattern may be any pattern that can be expressed by printing or the like. For example, various patterns such as a woodgrain pattern, a hairline pattern, and a marble pattern are possible.

  In the example of FIG. 1, the through holes 21 are continuously formed on the entire surface of the resin sheet 20. However, the portions necessary for the output of the speaker sound (that is, the portions where the speaker arrangement openings 13 are located). The through holes 21 may be disposed only in (). In this case, as a configuration in which the through holes are not provided at the positions where the reinforcing ribs are disposed, all the through holes may communicate with the inside.

  As for the position of the speaker itself, not only the left and right sides of the screen shown in FIG. 1 but also other positions (for example, the lower part of the front frame) can be dealt with.

  Further, in the example of FIG. 1, two resin sheets 20 are prepared and the two sheets are attached to corresponding positions. However, a structure in which one resin sheet is attached may be used. That is, for example, as shown in FIG. 11, the resin sheet 30 may have a shape that covers the entire surface of the front frame 10, and the resin sheet 30 may be pasted by insert molding. FIG. 12 is an exploded view of the resin sheet 30 and the front frame 10. In the example of FIGS. 11 and 12, the through holes 31 are provided only at the speaker placement opening 13 and the upper and lower positions thereof, and the through holes 31 are not provided at other locations.

  In the above description, the example is applied to the speaker arrangement position of the television receiver (display device), but the present invention can also be applied to other electronic devices. For example, FIG. 13 shows an example of an audio device 40 incorporating speaker units 41L and 41R. The audio device 40 has a built-in audio signal source such as a disk playback unit and a tuner and is capable of audio output from the speaker units 41L and 41R. The external housing is obtained as a resin molded product. Here, the resin sheet 42 is integrally attached to the front surface of the arrangement position of the speaker units 41L and 41R by insert molding. The resin sheet 42 is continuously formed with through holes 43, and the sound output from the speaker units 41 </ b> L and 41 </ b> R is output to the outside through the through holes 43. When applied to audio equipment, the resin sheet of the present invention may be applied to the front grill of a so-called single speaker device.

  Moreover, it is good also as a structure which insert-molds the resin sheet which has the through-hole of this invention for the objectives other than the object for speaker outputs like the example of FIG.1 and FIG.13. For example, a similar resin sheet may be attached to the vent of the housing.

It is a perspective view which shows the structural example by one embodiment of this invention. It is a perspective view which decomposes | disassembles and shows the structural example of FIG. It is a partially broken perspective view which shows the principal part of the structure of FIG. It is sectional drawing which shows the example of the resin sheet by one embodiment of this invention. It is explanatory drawing which shows the example of speaker arrangement | positioning by one embodiment of this invention. It is explanatory drawing which shows the example of the punching process by one embodiment of this invention. It is explanatory drawing which shows the example of the preforming by one embodiment of this invention. It is sectional drawing which shows the example of the metal mold | die by one embodiment of this invention. It is sectional drawing which shows the example of the state currently shape | molded with the metal mold | die by the example of FIG. It is a perspective view which shows the modification (example which printed the decorative pattern) of the structure by one embodiment of this invention. It is a perspective view which shows the structural example by other embodiment of this invention. It is a perspective view which decomposes | disassembles and shows the structural example of FIG. It is a perspective view which shows the structural example by other embodiment of this invention. It is a perspective view which shows the structural example of the conventional television receiver.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Front frame, 11 ... Display panel attachment opening, 12L, 12R ... Speaker unit, 13 ... Speaker arrangement opening, 14 ... Reinforcement rib, 20, 20 '... Resin sheet, 21 ... Through hole, 22 ... Resin Film, 23 ... Print layer, 24 ... Binder, 30 ... Resin sheet, 31 ... Through hole, 32 ... Display panel mounting opening, 40 ... Audio equipment, 41L, 41R ... Speaker unit, 42 ... Resin sheet, 43 ... Through Hole, 51, 52 ... punching device, 61, 62 ... molding die, 100 ... resin sheet (sheet before preforming)

Claims (6)

A resin sheet in which through holes are continuously arranged at least in part,
A resin molded product comprising: a resin molded product main body provided with an opening for opening part or all of the through holes after the resin sheet is integrally arranged on a surface by insert molding. In the resin molded product according to claim 1,
The resin material constituting the resin sheet is made of a material having a curing temperature higher than that of the resin material constituting the resin molded product body, and is integrated by the insert molding. In the resin molded product according to claim 2,
A resin molded product, characterized in that the resin sheet is integrated without providing a step at a boundary between a portion whose surface is covered with the resin sheet and a portion whose surface is not covered with the resin sheet. In the resin molded product according to claim 1,
A resin molded product, wherein a speaker unit is disposed in a space continuous with an opening of the resin molded product main body, and a sound output from the speaker unit is output from the through hole. In the resin molded product according to claim 4,
A resin molded product, wherein the opening is provided with reinforcing ribs that contact the back surface of the resin sheet at a predetermined interval. In a state where the resin sheet in which at least a part of the through holes are continuously arranged is arranged in the mold for molding the main body, the resin for molding the main body is filled in the mold and insert molding is performed.
A resin molding method characterized in that the surface of the main body is covered with the resin sheet, and an opening for opening part or all of the through holes on the resin sheet is molded in the main body.

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