JP3989453B2 - Intermediate unit and manufacturing method thereof - Google Patents

Description

  The present invention relates to an intermediate unit that is provided in the middle of a cord provided with a connecting portion connected to a portable device at one end and an earphone or a headphone at the other end, and a method for manufacturing the same.

  There exists what is shown by patent document 1 as a technique relevant to the intermediate unit comprised as mentioned above. In Patent Document 1, a remote control unit (intermediate unit of the present invention) interposed between a cord connecting a plug (connecting portion of the present invention) and an earphone includes an upper case and a lower case (casing of the present invention). The board is accommodated in the interior, and includes a switch button, a hold knob, and a volume knob. The board is held by ribs formed on the upper case and the lower case, the switch button, the hold knob and the volume knob are supported by the board, and the cord is held between the upper case and the lower case via a bush. ing.

JP-A-2-248194 (Specifications, FIGS. 1 to 4)

  As described in Patent Document 1, when a structure in which two members are stacked as the casing of the intermediate unit is adopted, it is easy to increase the size, and it is necessary to perform an operation of tightening with screws even when assembling. The work of fitting takes time. For these reasons, it is also desired to form a casing by forming a resin so as to be integrated with a substrate using a mold. Specifically, molding in a form in which a substrate is inserted by a so-called injection technique in which a mold is arranged in an area extending from a cord to a substrate and a resin is injected into the mold is desired. . However, since a relatively high pressure is applied when injecting the resin into the mold, there is room for improvement because the components provided on the substrate may be damaged or the components may be separated from the substrate. In addition, when the casing is formed by injecting resin into the mold, a strong force acts on the part even when the resin contracts due to heat dissipation after injection, and the part may be damaged in the same manner as described above. In some cases, parts were peeled off from the board.

  Such inconvenience often occurs when a relatively hard resin is used. Therefore, it is conceivable to form the casing using a resin having a flexible property. However, if a resin that is too flexible is used, the parts cannot be protected against an external impact, which is not feasible. there were.

  In addition, when the casing is hard, a strong force acts on the cord at the boundary between the case and the cord and the cord is easily damaged. In order to improve this inconvenience, it is necessary to attach a rubber bush or the like to the case. However, this work is troublesome and leads to an inconvenience of increasing the number of parts.

  An object of the present invention is to form an intermediate unit from a resin integrated with a cord and a board using a mold without damaging components provided on the board.

A feature of the present invention is an intermediate unit that is provided in the middle of a cord provided with a connect portion connected to a portable device at one end and an earphone or a headphone at the other end.
The intermediate unit is configured by a substrate on which a component is mounted and a casing that covers the substrate, and a wrapper portion made of a first resin formed by a first mold on the outer peripheral portion of the substrate excluding the mounting space for the component. And a covering portion made of a second resin formed by a second mold in a portion covering the wrapper portion and the component, and the second resin is set to be softer than the first resin.

  In this configuration, since the first mold forms the wrapper portion with the first resin in a portion excluding the component mounting space, the pressure does not act on the components provided on the substrate from the first resin. In addition, although the covering portion is formed with the second resin in the portion that covers the wrapper portion and the component by the second mold, since the second resin is softer than the first resin, the second resin is strong against the component. The force does not act, and even when an impact is applied from the outside, the wrapper portion can receive the impact. Therefore, it is possible to use a relatively hard resin for the wrapper part and a relatively soft resin for the covering part, and by simply performing molding according to a simple process, the parts provided on the board are not damaged, and the size is small. This makes it possible to construct an intermediate unit that is strong against impact and has a good sealing property.

  According to the present invention, the first resin is formed by injection of the first resin using the first mold having a restricting body for preventing the inflow of the first resin to the mounting space and the positioning space as the first resin. The second resin may be formed by injecting the second resin using the second mold set with reference to the positioning space.

  With this configuration, when the first resin is injected into the first mold, the restrictor prevents the first resin from flowing into the space in which the parts are provided and the positioning space. After the portion is formed, the position of the second mold can be determined based on the positioning space of the wrapper portion, so that the covering portion made of the second resin can be formed with high positional accuracy with respect to the wrapper portion.

  The present invention may be configured as an antenna unit in which a coil and a capacitor are mounted on the substrate as the components by soldering.

  With this configuration, it is possible to use this intermediate unit as an antenna unit by mounting a coil and a capacitor on a substrate by soldering. For example, a portable device has functions of a mobile phone, a television, a radio, etc. Then, it will increase the sensitivity of reception.

  In the present invention, the wrapper portion is formed in a portion extending over the substrate and the cord connected to the substrate, and the covering portion is formed on the wrapper portion and the cord exposed to the outside of the wrapper portion. An elastomer may be used for the second resin that is formed in the extending portion and forms the covering portion.

  With this configuration, the substrate and the cord are covered with the wrapper portion, so that even when tension is applied to the cord, the wrapper portion receives the tension acting on the cord, suppressing the inconvenience of separating the cord from the substrate, Since the cover portion made of elastomer is formed in the portion extending from the wrapper portion to the cord, even when a bending force acts at the boundary portion with the casing, the phenomenon that the force acts locally on the cord is eliminated. Thus, the cord can be flexibly bent with a relatively large radius.

The present invention provides a method of manufacturing an intermediate unit that is provided in the middle of a cord provided with a connecting part connected to a portable device at one end and an earphone or headphone provided at the other end.
The intermediate unit is configured by a substrate on which a component is mounted and a casing that covers the substrate, and a first mold having a structure that prevents the first resin from flowing into the mounting space of the component and the positioning space. After forming the wrapper portion by injection of one resin, the second mold is set with reference to the positioning space formed in the wrapper portion, and the outer surface of the wrapper portion is injected by injection of the second resin to the second mold. It is the point which produces the said casing by forming a coating | coated part.

  With this configuration, since the first mold forms the wrapper portion made of the first resin in the portion excluding the component mounting space, the pressure does not act on the components provided on the substrate from the first resin. In addition, the second resin is softer than the first resin, although the covering portion is formed with the second resin in the portion covering the wrapper portion and the component with the position of the second mold set with high accuracy with respect to the wrapper portion. Therefore, a strong force is not applied to the component from the second resin, and even when an impact is applied from the outside, the wrapper can receive an impact applied to the component. Therefore, it is possible to use a relatively hard resin for the wrapper portion and a relatively soft resin for the covering portion, and the components provided on the board can be damaged only by molding in a relatively simple process. Therefore, it is possible to construct an intermediate unit that is small and resistant to impact and has a good sealing property.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
As shown in FIG. 1, a plug 11 (an example of a connecting portion) connected to a jack portion 2 of a main body case 1 of a mobile phone T as a portable device is provided at one end of a cord 12, and the other end portion of the cord 12 is provided. An earphone 13 (may be a headphone) is provided, and an antenna unit A (an example of an intermediate unit) and a microphone / switch unit M are provided at an intermediate position of the cord 12 to constitute a hands-free set.

  The mobile phone T includes a plurality of keys 3, a liquid crystal display 4, and a rod antenna 5 in the main body case 1. The mobile phone T functions as a telephone by including a communication device inside the main body case 1 and receives a television broadcast. By incorporating the tuner, the television broadcast image is displayed on the liquid crystal display 4.

  In the hands-free set, the plug 11 is connected to the jack portion 2, and when the user sets the earphone 13 to the ear, the user hears the voice from the mobile phone T via the earphone 13, and the user's voice is a microphone switch. A so-called hands-free use in which the electret type microphone 17 provided in the unit M is received and sent out from the mobile phone T is made possible. Further, when a call is made to the cellular phone T, a call is realized by responding (off-hook) by operating the switch 18 of the microphone / switch unit M. As will be described later, the antenna unit A includes a component 22 (see Parts and FIG. 4) for receiving radio waves of television broadcasting, and the reception sensitivity is improved by using a part of the cord 12 as an antenna. Functions to enhance.

  As shown in FIG. 2, the microphone / switch unit M includes a substrate 16, a microphone 17, and a push-type switch 18 inside a case 15, and transmits sound to the microphone 17 in the case 15. A through-hole 17A is formed, and the operation part 18A of the switch 18 is provided in a state of penetrating the case 15, and is configured to reveal an off-hook state and an on-hook state by pressing the operation part 18A. ing.

  In the antenna unit A, a substrate 21 constituting an antenna circuit is built in a casing AC as a component 22 with a chip-type coil and a chip-type capacitor. The casing AC is formed by resin injection molding using a mold. Has been. The present invention is characterized by the structure of the antenna unit A as an intermediate unit and the method of manufacturing the antenna unit A.

  That is, as shown in FIGS. 3 and 4, the substrate 21 is formed in an octagonal shape with an insulating material such as glass epoxy, and a wiring is formed by a printed wiring technique using copper foil, and a plurality of surfaces are formed on both front and back surfaces. A land portion 21A is formed, and the component 22 is fixed to the land portion 21A by soldering. The cord 12 has a structure including a plurality of conductors 12B (comprised of copper wires) covered with an insulator inside a protective sheath 12A, and soldered ends of the plurality of conductors 12B. Is connected to the land portion 21A.

  The casing AC is formed of a relatively hard first resin R1 such as polypropylene or nylon, and after forming the wrapper portion 25, the casing AC covers the wrapper portion 25 and is softer than the first resin R1. The covering portion 26 is laminated using a second resin R2 (an example of an elastomer). The second resin R2 is ideally the same material as the protective sheath 12A of the cord 12, but it is preferable to use a material having the same degree of flexibility as the protective sheath 12A.

  The casing AC uses a first mold M1 (an example of a first mold) shown in FIGS. 4 to 7 and inserts a substrate 21. The first resin R1 is injected into the first mold M1. After forming the wrapper portion 25 as shown in FIG. 8 and FIG. 9 by performing (injection), this molded product is used for the wrapper portion 25 using a second mold M2 (an example of the second mold) shown in FIG. 3 is inserted into the second mold M2 to form a covering portion 26 as shown in FIG.

  The first mold M1 is composed of a main mold 31 and a sub mold 32, and four first pins 33 (which determine the position of the substrate 21 by contacting the end of the substrate 21 inside the mold on the main mold 31 side). An example of a restricting body) and two second pins 34 that determine the position by contacting the back side of the substrate 21 are formed. The sub mold 32 is formed with a wall portion 35 (an example of a regulating body) that prevents the first resin R1 from flowing into the space in which the component 22 provided on the substrate is mounted. The second mold M2 includes a main mold 41 and a sub mold 42, and positioning protrusions 43 are formed inside the main mold 41 and the sub mold 42, respectively.

  As shown in FIGS. 4 to 6, in the state where the substrate 21 soldered with the conductor 12B of the cord 12 is set inside the mold and the main mold 31 and the sub mold 32 of the first mold M1 are combined, the wall In a state where the portion 35 surrounds the mounting space of the component 22, the end portion of the wall portion 35 is in contact with the surface of the substrate 21, and the second pin 34 is in contact with the back surface side of the substrate 21. Displacement in the direction along the surface of the substrate 21 is prevented by the first pin 33 contacting the edge of the substrate 21. In this state, by injecting the first resin R1 into the mold inside the first mold M1, the first resin R1 is sent to the outer peripheral portion of the board excluding the mounting space of the component 22, and the first pin, the second pin, The wrapper portion 25 having a space in which the first resin R1 is not filled is formed in the portion where the slag exists.

  As shown in FIGS. 8 to 10, in this molded product, a wrapper portion 25 is formed from a portion of the protective sheath 12 </ b> A of the cord 12 to a portion of the substrate 21, and the first resin R <b> 1 is made of the wall portion 35. An open space S1 that is prevented from flowing in is formed on the surface side of the substrate 21, and a hole-shaped positioning space S2 through which the first pin 33 is inserted is formed.

  As shown in FIG. 10, when the molded product is set inside and the main mold 41 and the sub mold 42 of the second mold M2 are combined, the positioning space S2 formed in the wrapper portion 25 is By engaging the protrusion 43, the position of the molded product is determined, and in this state, the second resin R2 is coated on the outer periphery of the first resin R1 by injecting the second resin R2 into the mold. 26.

  As shown in FIG. 3, the molded product formed in this way is in a form in which the covering portion 26 covers the entire outer periphery of the wrapper portion 25, the second space R <b> 1 is filled with the second resin R <b> 2, and the positioning space S <b> 2 is filled. Most of the portions are filled with the second resin R2, and the sleeve 26S made of the second resin R2 covers the portion of the protective sheath 12A of the cord 12 exposed from the wrapper portion 25. The sleeve 26S is thinner toward the end side, and is formed into a bellows shape by forming a plurality of annular grooves on the outer periphery of the intermediate portion, so that no local force acts on the cord 12, and the end side It functions to bend smoothly with a light force.

  That is, in the antenna unit A, the first resin R1 is formed at a portion excluding the mounting space of the parts (components) when the first resin R1 made of relatively hard polypropylene or the like is injected. Thus, no pressure acts on the component 22 provided on the substrate, and no pressure acts on the component from the resin when the temperature of the first resin R1 decreases after molding. Next, although the covering portion 26 is formed so as to cover the wrapper portion 25 and the component 22 with the second resin R2 made of relatively soft polyurethane or the like, the second resin R2 is softer than the first resin R1. A strong force does not act on the component 22 from the second resin R2, and even when a strong impact is applied from the outside during use, the wrapper 25 can receive an impact applied to the component. Protected and has good sealing performance.

  Further, since the first resin R1 is formed in a portion extending between the substrate 21 and the cord 12, the substrate 21 and the cord 12 are strongly connected, and the second resin R2 is formed in a portion extending between the wrapper portion 25 and the cord 12. Therefore, the cord 12 exposed from the antenna unit A is allowed to bend flexibly, and the feeling of use is good and the cord 12 is hardly damaged at the boundary portion with the antenna unit A.

[Another embodiment]
The present invention may be configured as follows in addition to the embodiment described above.

  The present invention is directed to a controller that includes a microphone / switch unit composed of a wrapper portion and a covering portion, or a portable audio device as a portable device, and an earphone cord connected to the audio via a plug. It consists of a wrapper part and a covering part.

Perspective view showing mobile phone and hands-free set Side view and front view of antenna unit and microphone / switch unit Vertical side view of the antenna unit Longitudinal front view showing a state where the substrate is set inside the first mold Cross-sectional plan view showing a state where the substrate is set inside the first mold Vertical side view showing a state where the substrate is set inside the first mold in the separated state Longitudinal side view showing a state in which the first resin is injected into the first mold Longitudinal front view of molded product with first resin Cross-sectional plan view of molded product with the first resin Longitudinal side view showing a state in which a molded product of the first resin is set inside the second mold in the separated state

Explanation of symbols

2 Connecting part 12 Cord 13 Earphone 21 Substrate 22 Component 25 Wrapper part 26 Covering part 33 Restricting body 35 Restricting body A Intermediate unit AC Casing M1 First type M2 Second type R1 First resin R2 Second resin S2 Positioning space T Portable device

Claims (5)

An intermediate unit that is provided in the middle of a cord provided with a connecting part connected to a portable device at one end and an earphone or headphone provided at the other end,
The intermediate unit is configured by a substrate on which a component is mounted and a casing that covers the substrate, and a wrapper portion made of a first resin formed by a first mold on the outer peripheral portion of the substrate excluding the mounting space for the component. And an intermediate unit in which the second resin is set to be softer than the first resin.   The first resin is formed by injecting the first resin using the first mold having a restricting body for preventing the inflow of the first resin into the mounting space and the positioning space of the component, 2. The intermediate unit according to claim 1, wherein the two resins are formed by injection of the second resin using the second mold set with the positioning space as a reference.   The intermediate unit according to claim 1, wherein the intermediate unit is configured as an antenna unit in which a coil and a capacitor are mounted on the substrate as the components by soldering.   The wrapper portion is formed in a portion extending over the substrate and the cord connected to the substrate, and the covering portion is formed in a portion extending over the wrapper portion and the cord exposed to the outside of the wrapper portion. The intermediate unit according to any one of claims 1 to 3, wherein an elastomer is used for the second resin forming the covering portion. A method of manufacturing an intermediate unit that is provided in the middle of a cord provided with a connecting part connected to a portable device at one end and an earphone or headphone provided at the other end,
The intermediate unit is configured by a substrate on which a component is mounted and a casing that covers the substrate, and a first mold having a structure that prevents the first resin from flowing into the mounting space of the component and the positioning space. After forming the wrapper portion by injection of one resin, the second mold is set with reference to the positioning space formed in the wrapper portion, and the outer surface of the wrapper portion is injected by injection of the second resin to the second mold. A method of manufacturing an intermediate unit that creates the casing by forming a covering portion.

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