JP2012017135A - Case and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thin case at low cost in which the required strength is ensured.SOLUTION: The case 1 includes: a cover 2, which is three-dimensionally formed by bending a blank 12 consisting of a sheet material with two or more areas segmented by a bending line 13 along the bending line 13; and a bone member 3 fused with the cover 2 by the injection molding of a synthetic resin to reinforce the cover 2. The bone member 3 connects end rims while extending along at least a pair of adjacent end rims in a different area of the cover 2.

Description

  The present invention relates to a housing and a manufacturing method thereof.

  For example, a housing in which a space is formed is used in various fields in order to house an electronic device or to circulate a fluid such as air. It is well known that when such a casing is manufactured from a synthetic resin, injection molding, vacuum / compression molding, bending molding, or the like is used. (For example, refer to Patent Documents 1 and 2.)

JP 2009-18560 A JP 2002-160791 A

  By the way, the demand for reducing the thickness of the casing has increased in recent years.For example, if the reduction in thickness is achieved by injection molding, the flow resistance of the resin increases due to the reduction in the thickness, so a larger injection pressure. The equipment cost is increased due to the need for a larger molding machine capable of generating metal and a mold having high strength and accuracy, and until there is a stable product with many limitations on the molding technology and many problems to be overcome. It is well known that a long time is required.

  In addition, when vacuum / compressed air forming is used, an uneven extension action works depending on the shape of the casing, and therefore when the deep shape is formed, the thickness becomes uneven, and as a result, the strength of the casing may be reduced.

  In addition, when forming a case by bending a sheet material, the corners of the case are not connected together, so the strength of the case is not sufficient, and the shape is limited to simple ones. is there.

  The present invention has been made in view of the above-described problems of the prior art, and an object of the present invention is to provide a thin housing having a required strength at a low cost.

  In order to solve the above-described problems, the housing according to the present invention is formed by bending a blank (12) made of a sheet material having a plurality of regions partitioned by a bend line (13) along the bend line (13). And a bone member (3) fused to the cover portion (2) by synthetic resin injection molding in order to reinforce the cover portion (2). It is a body (1), and the bone member (3) extends along at least a pair of adjacent edge portions in different regions of the cover portion (2) to connect the edge portions.

  According to this, since the adjacent edges of the cover part (2) are connected by the injection-molded bone member (3), even if the thickness of the cover part (2) is reduced, The required strength can be ensured, and a housing having a deep shape that is difficult to achieve by vacuum forming can be produced without generating uneven thickness portions. Furthermore, since the thickness of the casing is equal to the thickness of the material of the sheet material, a thin casing having a desired thickness can be easily obtained without using a large facility as in the case of thin-wall injection molding. .

  In the present invention, the bone member (3) may extend along the open end edge of the cover portion (2). Thereby, even if the cover part (2) is formed from a thin sheet material, the thin open end edge part can be reinforced.

  In the present invention, the bone member (3) may extend along the bending portion (17) of the cover portion (2) along the bending line (13). Thereby, reinforcement of a bending part (17) is attained.

  In the present invention, the bone member (3) may be formed as a frame-like frame. Thereby, the effect that the whole intensity | strength of a bone member (3) and hence the intensity | strength of a housing | casing increases is acquired.

  In the present invention, adjacent regions defined by the bend line (13) may be partially connected to each other with respect to the entire length of the region in the bend line direction. According to this, it is possible to increase the degree of freedom of the shape of the cover part (2), and it is also possible to reduce the press pressure required for bending.

  In the present invention, the end edge portion of the cover portion (2) can be embedded in the bone member (3). Thereby, the joint strength between the edge part of a cover part (2) and a bone member (3) can be raised.

  In the present invention, the bone member (3) has a pair of edge portions from the thickness (t2) of the portion where the bone member (3) is fused to the pair of edge portions of the cover portion (2). It may be formed so that the thickness (t1) of the central portion between the two is small. By forming the bone member (3) in this way, cooling of the entire corner portion is promoted, and it becomes possible to suppress warping due to the shrinkage of the bone member (3) synthetic resin.

  In the present invention, a synthetic resin sheet material is preferably used.

  The manufacturing method of the housing | casing by this invention differs from the cover part (2) formed in three dimensions from the blank (12) which consists of a sheet | seat material which has several area | region divided by the bending line (13), and the said area | region different from A method for manufacturing a housing (1) comprising a bone member (3) extending along at least a pair of adjacent edge portions and connecting the edge portions, wherein the blank (12) can be bent. And a step of preparing a mold capable of injection molding of a synthetic resin, a step of preparing a blank (12), a step of setting the blank (12) in one mold of the mold, and the other of the mold A cavity formed in the mold by the step of bending the cover part (2) by clamping the mold of the mold to one mold, and one mold of the mold, the other mold and the cover part (2) The bone member (3) is formed by injecting resin into Is characterized in that comprises the steps of, the steps of retrieving the housing to open the mold, the.

  According to this, since the adjacent edges of the cover part (2) are connected by the injection-molded bone member (3), even if the thickness of the cover part (2) is reduced, It is possible to easily obtain a casing having a required strength without using a large molding machine. Further, since the bone member (3) is injection-molded in a state where the shape of the cover portion is constrained by the mold and finally the shape is fixed, it occurs in the bent portion of the cover portion (2) outside the die. It becomes possible to fix the cover part (2) in a predetermined shape without considering the spring back to be obtained.

It is a perspective view of the housing | casing by embodiment of this invention comprised from a cover part and a bone member. It is a perspective view of the blank which consists of a sheet | seat material for a cover part. It is a perspective view of the cover part bend-molded. It is an expanded sectional view of a pair of edge part which forms the corner of a cover part, and the bone member fuse | fused there. It is an expanded sectional view of the bending part of a cover part, and the bone member fuse | fused there. It is an expanded sectional view of a pair of edge part which forms the corner of the cover part of the housing | casing by the modification of embodiment of this invention, and the bone member fuse | fused there. It is an expanded sectional view of the bending part of the cover part of the housing | casing by another modification of embodiment of this invention, and the bone member fuse | fused there.

Hereinafter, the housing | casing 1 which concerns on embodiment of this invention, and its manufacturing method are demonstrated with reference to FIGS.
FIG. 1 shows a completed product of a housing 1 according to an embodiment of the present invention. The housing 1 is for reinforcing a cover portion 2 that forms a space inside the housing 1 and the cover portion 2. And a bone member 3 that extends along the ridge line portion and the open end edge portion of the cover portion 2 and is fused to the cover portion 2. The housing 1 is formed by a cover portion 2 and has a right side surface portion 4 and a left side surface portion 5 having the same step-like outline, an upper surface portion 6 having the largest area, and a first front surface portion 7 adjacent to the upper surface portion 6. And an intermediate part 8 adjacent to the first front part 7 and a trapezoidal second front part 9 adjacent to the intermediate part 8. However, the lower surface 11 and the back surface 10 of the housing 1 are open, and only the bone member 3 extends below the back surface 10. Further, the upper surface portion 6 has a stepped shape on the side close to the rear surface 10 and is bent at a slight angle on the front surface side. As a result, the upper surface portion 6 has the largest first portion 6a in the central portion. The second portion 6b on the side close to the back surface 10, the third portion 6c having a narrow width between the first portion 6a and the second portion 6b, and the fourth portion 6d on the side close to the front surface are included.

  In this embodiment, the cover portion 2 is formed by bending a blank 12 made of a synthetic resin and having a thickness of 0.3 mm. As a material for the sheet material, for example, a sheet made of a synthetic resin material such as polypropylene, ABS, polyethylene, polystyrene, polyoxyethylene, polyacetal, or a multilayer sheet obtained by laminating them can be used. In the present embodiment, the thickness of the sheet material is preferably selected from the range of 0.1 mm to 0.5 mm. However, the term “sheet material” in the present specification is used to mean a plate-shaped material having a uniform thickness, and therefore the thickness is not limited to 0.1 mm to 0.5 mm. For example, thicker materials are also included in the “sheet material”. Further, the sheet material is not intended to be limited to a synthetic resin, and a metal sheet material can also be used in the present invention.

  FIG. 2 shows the blank 12 in a developed state of the cover part 2. The blank 12 has a developed shape for realizing the three-dimensional shape of the cover part 2 shown in FIG. In FIG. 2, virtual eight bend lines 13a to 13h are indicated by alternate long and short dash lines, and the blank 12 is formed by the eight bend lines 13a to 13h so that the right side surface portion 4, the left side surface portion 5, The first front surface portion 7, the second front surface portion 9, the intermediate portion 8, and the first portion 6a to the fourth portion 6d of the upper surface portion 6 are partitioned into a plurality of regions. In addition, in this specification, in order to make description easy to understand, the plurality of regions of the blank 12 are also referred to as, for example, the right side surface portion 4 and the top surface portion 6 described above of the cover portion 2 to which they correspond.

  In the present embodiment, for example, the second portion 6b and the fourth portion 6d of the upper surface portion 6 of the blank 12 are continuous without changing their widths, while the left and right side surface portions 4 and 5 and the upper surface portion 6 are continuous. Slits 14a, 14c extending from the front side and slits 14b, 14d extending from the back side are formed between the left and right side portions 4, 5 and the second portion 6b of the upper surface portion 6 as a result. Are connected to each other by narrow connecting portions 15a and 15b that are partially provided only on the side. In other words, the left and right side surface portions 4 and 5 and the second portion 6b of the upper surface portion 6 are partially connected to each other only in the vicinity of the central portion with respect to their entire lengths in the directions of the bending lines 13g and 13h. Further, the second portion 6b, the third portion 6c, and the fourth portion 6d of the upper surface portion 6 and the right side surface portion 4 and the left side surface portion 5 are regions defined by common bend lines 13g and 13h, respectively. Is completely separated. In this way, by partially connecting adjacent regions partitioned by the bend lines 13g and 13h, it becomes possible to increase the degree of freedom of the shape of the cover part 2 and reduce the press pressure required for bending. It is also possible to do.

  FIG. 3 shows the cover portion 2 in a state where the blank 12 is bent along the fold line 13, that is, the cover portion 2 before the bone member 3 is fused. In the present embodiment, since the blank 12 is bent using a dedicated mold (not shown) that realizes the shape of FIG. 3, FIG. 3 is a cover that can be taken in the mold. The shape of the part 2 is shown.

  As described above, the bone member 3 of the present embodiment extends along the ridge line portion of the cover portion 2. By the way, as can be seen from FIG. 3, the ridge line portion of the cover portion 2 includes a portion formed by a pair of adjacent but separated edges in different regions and a bent portion in which the different regions are continuous. It is out. The portion formed of the pair of adjacent but separated edges of the cover part 2 extends along, for example, an arrow line indicated by reference numerals 16a and 16b, and the bent part is, for example, bent lines 13a to 13h. Respectively shown by corresponding bent portions 17a to 17h. Thus, in the present embodiment, the bone member 3 is formed along the plurality of the pair of end edges and also along the bent portion 17. Further, in the present embodiment, the bone member 3 may extend along the open end edge of the cover portion 2, and only the bone member 3 may extend where there is no cover portion 2 as in the lower portion of the back surface 10. In the present embodiment, the bone member 3 extending to each portion is formed as a frame-like frame in which portions extending at the above-described end edge portion, the bent portion 17 and the like are integrally continuous.

  The bone member 3 is formed by being fused to the cover portion 2 by injection molding in a state where the bent cover portion 2 remains in a mold (not shown). The bone member 3 is molded from a plastic material such as polypropylene, ABS, polycarbonate, polyacetal, and polybutylene terephthalate, and the melting point or heat distortion temperature of the material is usually lower than that of the cover portion 2.

  FIG. 4 shows a bone member fused to the edge of the first portion 6 a of the upper surface 6 and the edge of the right surface 4 as an example of a pair of adjacent edges forming the corner of the cover 2. FIG. As shown in FIG. 4, in this embodiment, the end edge portion of the cover portion 2 is embedded in the bone member 3, that is, the bone member 3 on the outer surface and the inner surface of the end edge portion and the end surface between them. It is combined with the bone member 3 so as to be in contact with. Although not shown, the open end edge portion of the cover portion 2 is also coupled to the bone member 3 so as to be embedded in the bone member 3 in the same manner.

  FIG. 5 is an enlarged cross-sectional view of the bent portion 17a between the intermediate portion 8 and the second front surface portion 9 and the bone member 3 fused thereto as an example of the bent portion of the cover portion 2. As shown in FIG. 5, the bone member 3 is fused and extends not only on the outer surface side of the bent portion of the cover portion 2 but also on the inner surface side.

  Next, the manufacturing method of the housing 1 according to the embodiment of the present invention will be described below. Although the manufacturing method of the housing 1 according to the embodiment of the present invention is described as manufacturing the housing 1 of the above-described embodiment, it is not limited to the application to the manufacture of the housing 1 of the above-described embodiment. Of course.

  In the manufacturing method according to the embodiment of the present invention, when manufacturing the housing 1, first, a mold (not shown) capable of bending the blank 12 made of a sheet material and capable of injection molding of a synthetic resin is prepared. To do. This mold can be manufactured using a well-known technique, and corresponds to a cavity mold (not shown) having a concave shape corresponding to the outer surface contour of the housing 1 and the inner surface contour of the housing 1. A slide structure that includes a core mold (not shown) having a convex portion that can perform injection molding of the bone member 3 and that can take out a molded product having an undercut portion. It is comprised so that it may also have.

  Next, a blank 12 having the shape shown in FIG. 2 is prepared.

  Next, the blank 12 is set at a predetermined position on the outer end surface (not shown) of the cavity mold (not shown) which is one of the molds.

  Next, the core mold is moved toward the cavity mold and finally clamped. As a result, the cover portion 2 having the shape shown in FIG. 3 is formed inside the mold. At this time, a cavity (not shown) having a shape corresponding to the contour of the bone member 3 is defined by the cavity mold, the core mold, and the cover portion 2.

  Next, the bone member 3 fused to the cover portion 2 is formed by injection-filling synthetic resin into the cavity formed in the mold.

  Next, the mold 1 is opened and the molded housing 1 is taken out. In the above, when the molding process of one casing 1 is completed and it is desired to continuously mold the casing 1, the blank 12 is prepared from the stage of preparing the blank 12 or when many blanks 12 are prepared. May be repeated from the stage of setting the cavity mold.

(Other embodiments)
In the above-described embodiment, the bone member 3 is formed not only on the pair of adjacent edge portions of the cover portion 2 but also on the open edge portion and the bent portion, and is integrally formed in a frame shape. In the present invention, the bone member 3 may be formed on at least a pair of adjacent edge portions of the cover portion 2. Therefore, an embodiment in which the bone member 3 does not extend along the open end or the bent portion, or an embodiment in which the bone member 3 is not integrally formed in a frame shape is possible according to the present invention.

  FIG. 6 is shown as a modification of the above-described embodiment, and similarly to FIG. 4, the edge of the first portion 6 a of the upper surface 6 as an example of a pair of adjacent edges of the cover 2. It is an expanded sectional view of the edge part of a part and the right side surface part 4, and the bone member 3 fuse | fused there. In FIG. 6, the bone member 3 is such that the thickness t1 of the central portion between the two edge portions is smaller than the thickness t2 of the portion where the bone member 3 is fused to the edge portion of the cover portion 2. Is formed. By forming in this way, cooling of the whole corner part is accelerated | stimulated and the curvature by shrinkage | contraction of a bone member synthetic resin can be suppressed.

  FIG. 7 shows a modified example of the above-described embodiment. Similar to FIG. 5, the bent portion 17a between the intermediate portion 8 of the cover portion 2 and the second front surface portion 9 is fused thereto. It is an expanded sectional view of the made bone member 3. FIG. The cover portion 2 shown in FIG. 7 has a series of small holes 18 formed along the direction of the bend line 13 of the bent portion. As a result, the portion of the bone member 3 extending to the inner surface side of the bent portion and the portion of the bone member 3 extending to the outer surface side are connected via the small hole 18, and as a result, the bone member 3 and the cover portion 2 are joined. While becoming stronger, the moldability of the bone member 3 in the bent portion is improved.

  The housing 1 in the present invention can have various shapes, for example, the angle of the bent portion and the corner portion is not limited to a right angle, and the housing 1 has a shape including at least a curved surface. Also good.

DESCRIPTION OF SYMBOLS 1 Housing | casing 2 Cover part 3 Bone member 4 Right side part 6 Upper surface part 12 Blank 13a-13h Bending line 14a-14d Slit 15a, 15b Connection part 17a-17h Bending line

Claims (11)

A cover portion (2) formed three-dimensionally by bending a blank (12) made of a sheet material having a plurality of regions partitioned by a bend line (13) along the bend line (13);
A frame member (1) comprising a bone member (3) fused to the cover part (2) by injection molding of a synthetic resin in order to reinforce the cover part (2),
A casing (3), wherein the bone member (3) extends along at least one pair of adjacent edge portions of different regions of the cover portion (2) to connect the edge portions. 1).   The housing (1) according to claim 1, characterized in that the bone member (3) also extends along the open end edge of the cover part (2).   The housing (1) according to claim 2, characterized in that the bone member (3) also extends along the bending part (17) of the cover part (2) along the bending line (13). ).   Case (1) according to claim 3, characterized in that the bone member (3) is formed as a frame-like frame.   5. The region defined by the bend line (13) and adjacent to each other is partially connected to the entire length of the region in the bend line direction. 6. The housing (1) described in 1.   The casing (1) according to any one of claims 1 to 5, characterized in that an end edge of the cover (2) is embedded in the bone member (3).   The bone member (3) has a distance between the pair of edge portions from the thickness (t2) of the portion where the bone member (3) is fused to the pair of edge portions of the cover portion (2). The casing (1) according to claim 6, characterized in that the thickness (t1) of the central part of the casing is small.   The housing (1) according to any one of claims 1 to 7, wherein the sheet material is made of a synthetic resin. Along with at least a pair of edge portions adjacent to each other, the cover portion (2) formed three-dimensionally from a blank (12) made of a sheet material having a plurality of regions partitioned by a bending line (13) A manufacturing method of a housing comprising a bone member (3) extending and connecting the edge portion,
Preparing a mold capable of bending the blank (12) and capable of injection molding a synthetic resin;
Providing the blank (12);
Setting the blank (12) in one of the molds;
Bending the cover part (2) by clamping the other mold of the mold to the one mold; and
Molding the bone member (3) by injecting and filling resin into a cavity formed in the mold with the one mold, the other mold and the cover part (2) of the mold; When,
Opening the mold and taking out the casing. A method for manufacturing the casing (1).   10. The bone member (3) according to claim 9, characterized in that, in the step of forming the bone member (3), the bone member (3) is also formed along the open edge of the cover part (2). Manufacturing method of housing (1).   In the step of forming the bone member (3), the bone member (3) is formed along the bending portion (17) of the cover portion (2) along the bending line (13). The manufacturing method of the housing | casing (1) of Claim 9 or 10.

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