JP6321761B1 - Manufacturing method of housing member - Google Patents

Abstract

A casing member capable of improving the quality of an outer tube, an electronic device using the casing member, and a method of manufacturing the casing member. A housing member has a structure in which a resin frame body is provided at an edge of a fiber reinforced resin plate in which a reinforcing fiber is mixed into a matrix resin. In the housing member 10, the frame body 32 is formed of a matrix resin 42 that constitutes the fiber reinforced resin plate 30. [Selection] Figure 3

Description

The present invention relates to a method for producing a for example notebook PC or the like housing-body member in the housing of an electronic device Ru is used for.

  The casings of various electronic devices such as notebook personal computers (notebook PCs), tablet personal computers (tablet PCs), smartphones, and mobile phones need to be lightweight, thin, and high in strength. Therefore, a prepreg plate (fiber reinforced resin plate) in which a matrix resin is impregnated with a reinforcing fiber such as carbon fiber is sometimes used for a housing of an electronic device.

  However, the fiber reinforced resin plate is very hard, and the machining is difficult because the fibers are stretched. Then, when using for the housing | casing of an electronic device, joining the resin-made frame body which is easy to machine processing, such as screwing and cutting, to the peripheral part of a fiber reinforced resin board is performed (refer patent document 1). ).

JP2013-232052A

  By the way, in the prior art of the said patent document 1, the member for housing | casing is comprised by joining the frame body by injection-molding a thermoplastic resin to the edge of a fiber reinforced resin board. Examples of such a frame body joining method include a method of joining the frame body by insert molding and a method of joining the frame body using an adhesive or the like.

  However, in the method by insert molding, the frame body may be thermally contracted when the molded member is taken out from the mold. If it does so, a level | step difference and a clearance gap may be produced in the junction part of a frame body and a fiber reinforced resin board. Moreover, the method by adhesion | attachment may naturally produce a level | step difference and a clearance gap in the junction part of a frame body and a fiber reinforced resin board on account of the structure which adhere | attaches two members. When such a level | step difference and a clearance gap arise, the external appearance quality of the member for housing | casing will fall. In addition, when the surface of the housing member is coated, the uniformity of the surface coating is lowered due to the steps or gaps, and the appearance quality of the housing member may be further deteriorated.

The present invention has been made in consideration of the above problems of the prior art, and an object thereof is to provide a method of manufacturing a housing-body member that can be improved appearance quality.

The method for manufacturing a housing member according to the present invention is a method for manufacturing a housing member in which a resin frame is provided at the edge of a fiber-reinforced resin plate in which reinforcing fibers are mixed into a matrix resin containing a thermoplastic resin. The fiber reinforced resin plate is placed inside a mold and pressed and heated to allow the matrix resin to ooze out from the portion where the fiber reinforced resin plate is formed , and the leached matrix. the resin forming the frame member by curing by cooling after inflow into the cavity of the mold, thereby producing the fiber-reinforced resin plate housing member provided with the frame body to the edge of the It is characterized by doing.

  According to such a method, since the frame body can be simultaneously formed in the process of forming the fiber reinforced resin plate, the manufacturing efficiency is improved.

  After removing the housing member from the mold, the surface of the frame body may be formed into a desired size and shape by cutting or grinding the frame body. If it does so, the surface shape of the member for housing | casing can be planarized more by machining, and external appearance quality can be improved further. Furthermore, the product dimensions of the housing member can be formed with higher accuracy by machining such as cutting.

  ADVANTAGE OF THE INVENTION According to this invention, it can suppress that a level | step difference and a clearance gap arise in the boundary part of a fiber reinforced resin board and a frame body, and external appearance quality improves.

FIG. 1 is a perspective view of an electronic device including a casing using a casing member according to an embodiment of the present invention. FIG. 2 is a plan view schematically showing the configuration of the back cover of the housing. FIG. 3 is a cross-sectional view schematically showing a cross-sectional shape along the line III-III in FIG. 4A is a cross-sectional view schematically showing a method for manufacturing the housing member shown in FIG. FIG. 4B is a cross-sectional view showing a state in which the reinforcing fibers and the matrix resin are compressed with a mold from the state shown in FIG. 4A. 4C is a cross-sectional view showing a state where the mold is opened from the state shown in FIG. 4B. FIG. 5 is an enlarged cross-sectional view of the main part of the housing member according to the first modification. FIG. 6A is a cross-sectional view schematically showing a method for manufacturing the housing member shown in FIG. 5. FIG. 6B is a cross-sectional view showing a state in which the reinforcing fibers and the matrix resin are compressed with a mold from the state shown in FIG. 6A. 6C is a cross-sectional view showing a state where the mold is opened from the state shown in FIG. 6B. FIG. 7 is an enlarged cross-sectional view of the main part of the housing member according to the second modification. FIG. 8A is a cross-sectional view schematically showing a method for manufacturing the housing member shown in FIG. 7. FIG. 8B is a cross-sectional view showing a state in which the reinforcing fibers and the matrix resin are compressed with a mold from the state shown in FIG. 8A. FIG. 8C is a cross-sectional view showing a state where the mold is opened from the state shown in FIG. 8B. FIG. 9 is an enlarged cross-sectional view of a main part of the housing member according to the third modification. FIG. 10A is a cross-sectional view schematically showing a method for manufacturing the housing member shown in FIG. 9. FIG. 10B is a cross-sectional view showing a state in which the reinforcing fiber is compressed and bent with a mold from the state shown in FIG. 10A. FIG. 10C is a cross-sectional view showing a state in which the reinforcing fibers are further compressed and bent from the state shown in FIG. 10B with a mold. FIG. 10D is a cross-sectional view showing a state in which the reinforcing fibers and the matrix resin are compressed with a mold from the state shown in FIG. 10C. FIG. 10E is a cross-sectional view showing a state where the mold is opened from the state shown in FIG. 10D. FIG. 11 is an enlarged cross-sectional view of the main part of the housing member according to the fourth modification. 12A is a cross-sectional view schematically showing a method for manufacturing the housing member shown in FIG. 12B is a cross-sectional view showing a state in which the reinforcing fibers and the matrix resin are compressed with a mold from the state shown in FIG. 12A. 12C is a cross-sectional view showing a state where the mold is opened from the state shown in FIG. 12B.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a housing member according to the present invention will be described in detail with reference to the accompanying drawings by exemplifying an electronic device using this member and giving a preferred embodiment.

  FIG. 1 is a perspective view of an electronic device 14 including a housing 12 using a housing member 10 according to an embodiment of the present invention. In this embodiment, the structure which used the housing | casing 12 using the member 10 for housing | casing as the cover body 16 of the electronic device 14 which is notebook type PC is illustrated.

  As shown in FIG. 1, the electronic device 14 includes a device main body (main body housing) 20 having a keyboard device 18 and a rectangular flat plate-shaped lid body 16 having a display device 22 composed of a liquid crystal display or the like. The electronic device 14 is a clamshell type in which the lid 16 is connected to the device body 20 by left and right hinges 24 so as to be opened and closed.

  The device body 20 is a flat box-shaped housing. The device main body 20 accommodates various electronic components such as a substrate, an arithmetic processing device, a hard disk device, and a memory (not shown). The keyboard device 18 is disposed on the upper surface of the device main body 20.

  The lid body 16 includes a housing 12 in which a back cover 12a and a front cover 12b are overlapped and connected. The lid body 16 is electrically connected to the apparatus main body 20 by a cable (not shown) that has passed through the hinge 24. The back cover 12a is a cover member that covers the side surface and the back surface of the lid body 16, and is configured by the housing member 10 according to the present embodiment. The lid 16 is connected to the device main body 20 via a hinge 24 that is screwed to the back cover 12a (see also FIG. 2). The front cover 12b is a resin cover member that covers the front surface of the lid body 16, and an opening for exposing the display device 22 made of, for example, a liquid crystal display is provided in most of the front cover 12b.

  Next, the configuration of the back cover 12a of the housing 12 constituting the lid 16 and the housing member 10 forming the back cover 12a will be specifically described.

  First, the overall configuration of the back cover 12a will be described. FIG. 2 is a plan view schematically showing the configuration of the back cover 12a of the housing 12, and is a view of the back cover 12a serving as the back of the lid body 16 as viewed from the inner surface side.

  As described above, the back cover 12 a is formed by the housing member 10. As shown in FIG. 2, the housing member 10 has a structure in which a resin frame body 32 is provided on the outer end face 30 a of a lightweight and high-strength fiber-reinforced resin plate 30. The back cover 12 a has a frame body 32 formed with a peripheral portion and wall portions 34 serving as side surfaces of four sides, and a fiber-reinforced resin plate 30 formed with a plate-like portion that supports the back surface of the display device 22.

  In the housing 12 (lid 16), a plurality of (two in FIG. 2) fixing screws 36 are provided for the wide portion 32a provided on the left and right pair of frame bodies 32 on one edge side (lower edge in FIG. 2) of the back cover 12a. Is used to fix the hinge 24. The frame body 32 on the other edge side (upper edge in FIG. 2) of the back cover 12a is provided with a belt-like portion 32b extending in the left-right direction, and an antenna 38 for wireless communication is disposed in this portion.

  Next, a specific configuration of the housing member 10 will be described. FIG. 3 is a cross-sectional view schematically showing a cross-sectional shape along the line III-III in FIG. 2, and in the thickness direction at a portion including the fiber reinforced resin plate 30 and the frame body 32 of the housing member 10. It is sectional drawing.

  As shown in FIG. 3, the housing member 10 includes a fiber reinforced resin plate 30 and a frame body 32 provided on the outer end face 30 a of the fiber reinforced resin plate 30.

  The fiber reinforced resin plate 30 is a prepreg in which a reinforced fiber 40 is impregnated with a matrix resin 42 (see FIGS. 4A and 4B). The fiber reinforced resin plate 30 may have a structure in which an intermediate layer (not shown) is provided between two or three or more fiber reinforced resin plates 30 to increase the section modulus in the plate thickness direction.

  In this embodiment, the reinforcing fiber 40 is a carbon fiber, and the fiber reinforced resin plate 30 is a carbon fiber reinforced resin plate (CFRP plate). The reinforcing fibers 40 are provided side by side in one direction of the fiber reinforced resin plate 30 or in a mesh shape. The reinforcing fibers 40 may be other than carbon fibers, and various materials such as metal fibers such as aluminum fibers and stainless fibers, and inorganic fibers such as glass fibers may be used.

  As the matrix resin 42, a thermosetting resin or a thermoplastic resin is used. Examples of the thermosetting resin constituting the matrix resin 42 include unsaturated polyesters, vinyl esters, epoxies, phenols, urea melamines, polyimides, copolymers thereof, modified products, and at least two polymer alloys thereof. Is given.

  Examples of the thermoplastic resin constituting the matrix resin 42 include polyolefins such as polyethylene (PE), polypropylene (PP), and polybutylene, polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), and acrylonitrile-styrene copolymer. Styrenic resins such as polymers (AS), polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), liquid crystal polyester, and polyoxymethylene (POM), polyamide (PA), polycarbonate (PC), polymethyl methacrylate (PMMA), polyvinyl chloride (PVC), polyphenylene sulfide (PPS), polyphenylene ether (PPE), modified PPE, thermoplastic polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polysulfone (PSU), modified PSU, polyethersulfone (PES), polyketone (PK), polyetherketone (PEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyarylate (PAR), polyethernitrile (PEN), thermoplastic phenol resin, phenoxy resin, epoxy resin, polytetrafluoroethylene ( PTFE) and other thermoplastic resins, polystyrene-based, polyolefin-based, polyurethane-based, polyester-based, polyamide-based, polybutadiene-based, polyisoprene-based, fluorine-based thermoplastic elastomers, and their copolymers and modified products as well as Or more blends include polymer alloys and the like.

  The frame body 32 is formed by a matrix resin 42 that forms the fiber reinforced resin plate 30. That is, the frame body 32 is formed of the same material as the matrix resin 42. The frame body 32 is preferably made of a material that does not include the reinforcing fibers 40. However, the frame body 32 may include a small amount of the reinforcing fibers 40, and may be made of a material including the reinforcing fibers 40 as long as the density is lower than that of the fiber reinforced resin plate 30.

  In the case of the configuration example shown in FIG. 3, the upper surface and the side surface of the frame body 32 are configured by cutting surfaces 44 a and 44 b. The cutting surface 44a on the upper surface side is formed flush with the surface 30b of the fiber reinforced resin plate 30 without any step or gap. The cutting surfaces 44a and 44b are planes obtained by cutting the resin frame body 32 with, for example, a computer numerical control (CNC) machine tool. The cutting surfaces 44a and 44b may be formed of ground surfaces that have been ground.

  The casing member 10 is provided with such a frame body 32, so that the wall portion 34, the fastening portion of the fixing screw 36, and the like are provided on the peripheral portion of the fiber reinforced resin plate 30 having a low degree of freedom of machining such as bending and cutting. Can be easily provided. Further, it is possible to improve the degree of design freedom such as installing the antenna 38 on the frame body 32 made of a nonconductive material at a position away from the fiber reinforced resin plate 30 that is a conductive material (see FIG. 2). Although FIG. 2 illustrates a configuration in which the frame body 32 is provided on the entire circumference of the outer end face 30a of the fiber reinforced resin plate 30, the frame body 32 may be provided only on a part of the outer end face 30a.

  Next, one procedure for manufacturing the housing member 10 will be described. 4A to 4C are explanatory views showing one procedure of the method for manufacturing the housing member 10 shown in FIG.

  First, one procedure of the manufacturing method when a thermosetting resin is used for the matrix resin 42 will be described. In this case, as shown in FIG. 4A, the reinforcing fibers 40 are disposed inside a mold 48 having a core 46 that is one mold part and a cavity 47 that is the other mold part, and a matrix resin 42 is provided. Inject the raw material liquid.

  The raw material liquid for the matrix resin 42 may be unreacted or may be in a state of being reacted to some extent. This raw material liquid may be injected into the mold 48. Alternatively, the raw material liquid of the matrix resin 42 is formed in a layered or thin plate shape and sandwiched as an intermediate layer between the upper and lower reinforcing fibers 40, or the reinforcing fiber 40 is impregnated to some extent with the raw material liquid of the matrix resin 42 May be placed in the mold 48. That is, a precursor of the fiber reinforced resin plate 30 in which the reinforcing fiber 40 and the raw material liquid of the matrix resin 42 are blended may be disposed. The raw material liquid may be in a state of reacting to some extent, for example, in a slurry state, a jelly state, or a gel state. That is, the thermosetting resin is in a state such as a slurry, a jelly, or a gel in a state of being cured by about 10 to 20% when the fully cured state is 100%, for example. 4A to 4B illustrate the molding process of the fiber reinforced resin plate 30 by illustrating the matrix resin 42 having no solid shape before curing in a solid plate shape, and the same applies to each configuration example described later. is there.

  4B, between the core 46 and the cavity 47, the raw material liquid of the reinforcing fiber 40 and the matrix resin 42 or the precursor of the above-described fiber reinforced resin plate 30 is compressed and heated. Then, as shown by the solid line arrow in FIG. 4B, the raw material liquid of the matrix resin 42 before curing oozes out from the portion where the fiber reinforced resin plate 30 is formed and flows into the cavity space 48 a of the mold 48. In the example shown in FIG. 4B, the cavity space 48 a has a shape that swells in the upper part and the side part from the space in which the fiber reinforced resin plate 30 is formed.

  As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fibers 40 and cured to form the fiber reinforced resin plate 30, and at the same time, the matrix resin 42 flowing into the cavity space 48a is cured to cure the frame body 32. The prototype 50 is formed.

  When the mold 48 is opened, as shown in FIG. 4C, a casing member in which a prototype 50 having an outer shape larger than that of the frame body 32 shown in FIG. 3 is integrally provided at the edge of the fiber reinforced resin plate 30. 10 is molded. Therefore, a part of the prototype 50 is cut or (and / or) ground with a predetermined machine tool along a cut line C indicated by a one-dot chain line in FIG. 4C. Specifically, the surplus portion 50a of the prototype 50 that protrudes above the surface 30b of the fiber reinforced resin plate 30 and the prototype 50 that protrudes to the side of the side surface (cutting surface 44b) of the frame body 32 shown in FIG. The excess portion 50b is removed by cutting.

  This completes the manufacture of the housing member 10 in which the frame body 32 is integrally provided at the edge of the fiber reinforced resin plate 30 (see FIG. 3). In the housing member 10, the cutting surface 44 a along the surface 30 b of the fiber reinforced resin plate 30 forms the surface of the frame body 32. For this reason, a smooth flat surface without a step or a gap is formed on the surface of the boundary portion (outer end face 30a) between the fiber reinforced resin plate 30 and the frame body 32. That is, the surface 30b and the cutting surface 44a of the fiber reinforced resin plate 30 that are on the root side in the standing direction of the wall portion 34 are the outer surface of the housing 12 (the back cover 12a). Is formed by a flat surface having no steps or gaps. For this reason, the external appearance quality of the housing | casing 12 is ensured. The side surface of the frame body 32 is also formed by a cutting surface 44b. For this reason, the member 10 for housing | casing is formed in the width dimension, ie, the width dimension between the wall parts 34 and 34 which the housing | casing 12 opposes by machining. For this reason, the dimensional accuracy of the housing | casing 12 is ensured.

  Next, one procedure of a manufacturing method when a thermoplastic resin is used for the matrix resin 42 will be described. In this case, as shown in FIG. 4A, a resin film or a resin powder or a resin fiber made of a matrix resin 42 formed by impregnating a reinforcing resin 40 with a matrix resin 42 inside the mold 48 or curing the reinforcing fiber 40. A fiber-reinforced resin plate 30 having a shape in which is inserted is disposed. Subsequently, as shown in FIG. 4B, the fiber reinforced resin plate 30 is compressed and heated between the core 46 and the cavity 47. Then, as shown by the solid line arrow in FIG. 4B, the molten matrix resin 42 oozes out from the portion where the fiber reinforced resin plate 30 is formed and flows into the cavity space 48 a of the mold 48.

  As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fibers 40 and cured to form the fiber reinforced resin plate 30, and the matrix resin 42 that has flowed into the cavity space 48a by the subsequent cooling is cured. A prototype 50 of the frame body 32 is formed. Therefore, as in the case where a thermosetting resin is used for the matrix resin 42 described above, a part of the prototype 50 is cut or (and / or) ground along the cut line C as shown in FIG. 4C. Thereby, manufacture of the member 10 for housing | casing in which the frame body 32 was integrally provided in the edge of the fiber reinforced resin board 30 is completed (refer FIG. 3). Also in this case, the casing member 10 is formed with a smooth flat surface (cutting surface 44a) having no steps or gaps on the surface of the boundary portion (outer end surface 30a) between the fiber reinforced resin plate 30 and the frame body 32. . Further, the width dimension of the housing member 10 is also formed with high dimensional accuracy by the cutting surface 44b.

  Next, another configuration example of the housing member will be described. FIG. 5 is an enlarged cross-sectional view of the main part of the housing member 10A according to the first modification.

  As illustrated in FIG. 5, the housing member 10 </ b> A has a configuration in which a second frame body 60, which is another frame body, is provided on the housing member 10 illustrated in FIG. 3. The second frame body 60 is joined to the frame body 32. In the configuration example shown in FIG. 5, the second frame body 60 is joined to the frame body 32 and at the same time, joined to the back surface opposite to the front surface 30 b of the fiber reinforced resin plate 30. The second frame body 60 is formed of, for example, a thermosetting resin such as epoxy, a thermoplastic resin, a metal such as aluminum or magnesium, ceramics, or the like. Further, the second frame body 60 may be configured to include reinforcing fibers such as carbon fibers, metal fibers, and glass fibers. The joining position of the second frame body 60 may be changed.

  6A to 6C are explanatory views showing one procedure of the method for manufacturing the housing member 10A shown in FIG.

  The procedure of the manufacturing method of the housing member 10A is substantially the same as that of the housing member 10 described above except that the second frame body 60 is used. That is, first, as shown in FIG. 6A, the reinforcing fiber 40 and the second frame body 60 are disposed inside the mold 48 and a raw material liquid for the matrix resin 42 which is a thermosetting resin is injected. Alternatively, the raw material liquid of the matrix resin 42 is formed in a layered or thin plate shape and sandwiched as an intermediate layer between the upper and lower reinforcing fibers 40, or the reinforcing fiber 40 is impregnated to some extent with the raw material liquid of the matrix resin 42 May be placed in the mold 48. When the matrix resin 42 is a thermoplastic resin, the fiber reinforced resin plate 30 may be disposed inside the mold 48 as in the case of the housing member 10 described above. The core 46 is provided with a notched portion 48 b for arranging the second frame body 60.

  Subsequently, as shown in FIG. 6B, the raw material liquid of the reinforcing fiber 40 and the matrix resin 42 is compressed and heated between the core 46 and the cavity 47. 6B, the raw material liquid of the matrix resin 42 before curing oozes out from the portion where the fiber reinforced resin plate 30 is formed and flows into the cavity space 48a of the mold 48. When the matrix resin 42 is a thermoplastic resin, the molten matrix resin 42 flows into the cavity space 48a. As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fibers 40 and cured by cooling to form the fiber reinforced resin plate 30, and at the same time, the matrix resin 42 flowing into the cavity space 48a is also cured by cooling. Thus, the prototype 50 of the frame body 32 is formed. At this time, the second frame body 60 is joined to the fiber reinforced resin plate 30 and the prototype 50 via the matrix resin 42.

  Therefore, as shown in FIG. 6C, a part of the prototype 50 is cut or (and / or) ground by the cut line C. Thereby, the manufacturing of the housing member 10A in which the frame body 32 is integrally provided at the edge of the fiber reinforced resin plate 30 and the second frame body 60 is joined is completed (see FIG. 5). As a result, in the housing member 10A, a smooth flat surface (cutting surface 44a) having no steps or gaps is formed on the surface of the boundary portion (outer end surface 30a) between the fiber reinforced resin plate 30 and the frame body 32. The width dimension of the housing member 10A is also formed with high dimensional accuracy by the cutting surface 44b.

  FIG. 7 is an enlarged cross-sectional view of a main part of the housing member 10B according to the second modification.

  As illustrated in FIG. 7, the housing member 10 </ b> B has a configuration in which a second frame body 62, which is another frame body, is provided on the housing member 10 illustrated in FIG. 3. The second frame body 62 is joined to the frame body 32. In the configuration example shown in FIG. 7, the second frame body 62 is joined to the outer surface of the frame body 32 opposite to the fiber reinforced resin plate 30. In the housing member 10 </ b> B, a wall portion 34 is formed by the frame body 32 and the second frame body 62, and an outer surface of the wall portion 34 is configured by the second frame body 62. The second frame body 62 is made of, for example, a thermosetting resin such as epoxy, a thermoplastic resin, or a metal such as aluminum or magnesium. Further, the second frame body 62 may include a reinforcing fiber such as carbon fiber, metal fiber, or glass fiber. The joining position of the second frame body 62 may be changed.

  The upper surface, the lower surface, and the side surface of the second frame body 62 are configured by cutting surfaces 44a, 44b, and 44c. The cutting surface 44c is a flat surface obtained by cutting or grinding the second frame body 62 with, for example, a computer numerical control (CNC) machine tool, like the cutting surface 44a.

  8A to 8C are explanatory views showing one procedure of the method for manufacturing the housing member 10B shown in FIG.

  The procedure of the method for manufacturing the housing member 10B is substantially the same as that of the housing member 10A described above. That is, first, as shown in FIG. 8A, the reinforcing fibers 40 are arranged inside the mold 48 and a raw material liquid for the matrix resin 42 which is a thermosetting resin is injected. Alternatively, the raw material liquid of the matrix resin 42 is formed in a layered or thin plate shape and sandwiched as an intermediate layer between the upper and lower reinforcing fibers 40, or the reinforcing fiber 40 is impregnated to some extent with the raw material liquid of the matrix resin 42 May be placed in the mold 48. In addition, the prototype 64 of the second frame body 62 is disposed in the notched portion 48 c provided in the cavity 47. The prototype 64 of the second frame body 62 is such that the outer shape of the upper and side portions is larger than that of the second frame body 62. When the matrix resin 42 is a thermoplastic resin, the fiber reinforced resin plate 30 may be disposed inside the mold 48 as in the case of the housing members 10 and 10A described above.

  Subsequently, as shown in FIG. 8B, the raw material liquid of the reinforcing fiber 40 and the matrix resin 42 is compressed and heated between the core 46 and the cavity 47. Then, as shown by the solid line arrow in FIG. 8B, the raw material liquid of the matrix resin 42 before curing oozes out from the portion where the fiber reinforced resin plate 30 is formed and flows into the cavity space 48 a of the mold 48. When the matrix resin 42 is a thermoplastic resin, the molten matrix resin 42 flows into the cavity space 48a. As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fibers 40 and cured by subsequent cooling to form the fiber reinforced resin plate 30. At the same time, the matrix resin 42 flowing into the cavity space 48a is also thereafter The original 50 of the frame body 32 is formed by being cured by cooling. At this time, the prototype 64 of the second frame body 62 is joined to the prototype 50 via the matrix resin 42 that forms the prototype 50 of the frame body 32.

  Therefore, as shown in FIG. 8C, a part of the prototypes 50 and 64 is cut or (and / or) ground by the cut line C. Specifically, the excess portion 50a of the prototype 50 protruding above the surface 30b of the fiber reinforced resin plate 30 and the excess portion 50b of the prototype 50 protruding below the frame body 32 shown in FIG. 7 are removed by cutting. . Further, the surplus portion 64a of the prototype 64 projecting from the upper portion of the second frame body 62 and the surplus portion 64b of the prototype 64 projecting to the outer side are removed by cutting. Thereby, the manufacture of the housing member 10B in which the frame body 32 is integrally provided at the edge of the fiber reinforced resin plate 30 and the second frame body 62 is further joined is completed (see FIG. 7). As a result, the housing member 10 </ b> B has a step on the surface of the boundary portion (outer end face 30 a) between the fiber reinforced resin plate 30 and the frame body 32 and the surface of the boundary portion between the frame body 32 and the second frame body 62. Smooth flat surfaces (cut surfaces 44a and 44b) without gaps are formed. The width dimension of the housing member 10B is also formed with high dimensional accuracy by the cutting surface 44c.

  FIG. 9 is an enlarged cross-sectional view of a main part of the housing member 10C according to the third modification.

  As illustrated in FIG. 9, the housing member 10 </ b> C has a configuration in which a bent shape portion 66 is provided at the edge of the fiber reinforced resin plate 30, as compared with the housing member 10 illustrated in FIG. 3. In the housing member 10 </ b> C, a wall portion 34 is configured by the fiber reinforced resin plate 30 and the frame body 32. The bent portion 66 is integrally formed of the same material as the fiber reinforced resin plate 30. The bent shape portion 66 and the frame body 32 have lower surfaces formed by a cutting surface 44d. The cutting surface 44d is a flat surface obtained by cutting or grinding the frame body 32 and the bent shape portion 66 with, for example, a computer numerical control (CNC) machine tool, like the cutting surface 44a.

  10A to 10E are explanatory views showing one procedure of the method for manufacturing the housing member 10C shown in FIG.

  The procedure of the manufacturing method of the housing member 10C is substantially the same as that of the housing member 10 described above except that the reinforcing fiber 40 is bent by the mold 48 and the bent portion 66 is formed. That is, first, as shown in FIG. 10A, the reinforcing fibers 40 are arranged inside the mold 48 and a raw material liquid of a matrix resin 42 which is a thermosetting resin is injected. Alternatively, the raw material liquid of the matrix resin 42 is formed in a layered or thin plate shape and sandwiched as an intermediate layer between the upper and lower reinforcing fibers 40, or the reinforcing fiber 40 is impregnated to some extent with the raw material liquid of the matrix resin 42 May be placed in the mold 48. When the matrix resin 42 is a thermoplastic resin, the fiber reinforced resin plate 30 may be disposed inside the mold 48 as in the case of the housing member 10 described above.

  Subsequently, as shown in FIGS. 10B and 10C, the raw material liquid of the reinforcing fiber 40 and the matrix resin 42 is compressed and heated, and at the same time, the edge of the reinforcing fiber 40 is compressed and bent by the core 46 and the cavity 47. Thus, a prototype 68 of the bent portion 66 is formed. Then, as shown by the solid line arrow in FIG. 10D, the raw material liquid of the matrix resin 42 before curing oozes out from the portion where the fiber reinforced resin plate 30 and the bent shape portion 66 are formed and enters the cavity space 48 a of the mold 48. Inflow. When the matrix resin 42 is a thermoplastic resin, the molten matrix resin 42 flows into the cavity space 48a. As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fiber 40 and cured to form the fiber reinforced resin plate 30, and the reinforcing fiber 40 is bent at the edge of the fiber reinforced resin plate 30. A prototype 68 of the bent shape portion 66 is formed. At the same time, the matrix resin 42 that has flowed into the cavity space 48a is cured, and the master 50 of the frame body 32 is formed.

  Therefore, as shown in FIG. 10E, a part of the prototypes 50 and 68 are cut or (and / or) ground by the cut line C. Specifically, the excess portion 50a of the prototype 50 protruding above the surface 30b of the fiber reinforced resin plate 30 and the excess portion 50b of the prototype 50 protruding on the side of the frame body 32 shown in FIG. 9 are removed by cutting. To do. Further, the surplus portion 68a of the original pattern 68 protruding to the lower portion of the bent shape portion 66 is cut and removed together with the lower portion of the surplus portion 50b. This completes the manufacture of the housing member 10C in which the bent portion 66 and the frame body 32 are integrally provided at the edge of the fiber reinforced resin plate 30 (see FIG. 9). As a result, the casing member 10 </ b> C has a step or a gap on the surface of the boundary portion (outer end surface 30 a) between the fiber reinforced resin plate 30 and the frame body 32 and the surface of the boundary portion between the frame body 32 and the bent shape portion 66. Smooth flat surfaces (cutting surfaces 44a and 44d) are formed. The width dimension of the housing member 10C is also formed with high dimensional accuracy by the cutting surface 44b. In the case member 10 </ b> C, the strength of the wall 34 is improved because the bent portion 66 that is the edge of the fiber reinforced resin plate 30 is disposed on the wall 34.

  FIG. 11 is an enlarged cross-sectional view of a main part of the housing member 10D according to the fourth modification.

  As shown in FIG. 11, the casing member 10D has almost the same configuration as the casing member 10C shown in FIG. 9, but the manufacturing method is different. 11 is different from the case member 10C shown in FIG. 9 in the bending angle of the bent shape portion 66, the bending angle may be changed.

  12A to 12C are explanatory views showing one procedure of the method for manufacturing the housing member 10D shown in FIG.

  The procedure of the method for manufacturing the housing member 10D is the same as the case of the housing member 10 described above except that the fiber reinforced resin plate 30 provided with the bent shape portion 66 by bending the edge portion in advance in another molding process is used. It is substantially the same. That is, first, as shown in FIG. 12A, a reinforcing fiber 40 in which a bent shape that becomes a prototype of the bent shape portion 66 is arranged in advance at the edge portion inside the mold 48 and a matrix resin 42 that is a thermosetting resin. Inject the raw material liquid. When the matrix resin 42 is a thermoplastic resin, the fiber reinforced resin plate 30 in which the bent shape portion 66 is formed inside the mold 48 may be disposed as in the case of the housing member 10 described above.

  Subsequently, as shown in FIG. 12B, the raw material liquid of the reinforcing fiber 40 and the matrix resin 42 is compressed and heated between the core 46 and the cavity 47. Then, as indicated by solid arrows in FIG. 12B, the raw material liquid of the matrix resin 42 before curing oozes out from the portion where the fiber reinforced resin plate 30 and the bent shape portion 66 are formed, and enters the cavity space 48a of the mold 48. Inflow. When the matrix resin 42 is a thermoplastic resin, the molten matrix resin 42 flows into the cavity space 48a. As a result, inside the mold 48, the matrix resin 42 is impregnated into the reinforcing fiber 40 and cured by subsequent cooling to form the fiber reinforced resin plate 30 having the bent portion 66 at the edge, and at the same time, the cavity space 48a. The matrix resin 42 that has flowed into the frame is cured to form the prototype 50 of the frame body 32.

  Therefore, as shown in FIG. 12C, a part of the original 50 is cut or (and / or) ground by the cut line C. Thereby, the manufacture of the housing member 10D in which the frame body 32 is integrally provided at the edge of the fiber reinforced resin plate 30 is completed (see FIG. 11). As a result, in the housing member 10D, a smooth flat surface (cutting surface 44a) without a step or a gap is formed on the surface of the boundary portion (outer end surface 30a) between the fiber reinforced resin plate 30 and the frame body 32. Further, the width dimension of the housing member 10D is also formed with high dimensional accuracy by the cutting surface 44b. In the housing member 10 </ b> D, the bent portion 66, which is the edge of the fiber reinforced resin plate 30, is disposed on the wall portion 34, so that the strength of the wall portion 34 is improved.

  In addition, in the case members 10 and 10A to 10D according to the above-described configuration examples, the configuration in which the frame body 32 and the bent shape portion 66 are cut by the cut line C is illustrated. However, since these casing members 10, 10 </ b> A to 10 </ b> D are formed by the matrix resin 42 constituting the fiber reinforced resin plate 30 in the frame body 32, the boundary between the frame body 32 and the fiber reinforced resin plate 30. There are no joints in the portion, and the occurrence of gaps and steps is suppressed. For this reason, in the casing members 10, 10 </ b> A to 10 </ b> D, it is possible to form the frame body 32 having a desired product size in the molding process using the mold 48 and to omit the subsequent cutting process. It is.

  As described above, in the housing member 10 (10A to 10D) according to the present embodiment, the resin frame body 32 is provided at the edge of the fiber reinforced resin plate 30 in which the reinforced fibers 40 are mixed into the matrix resin 42. In this configuration, the frame body 32 is formed by the matrix resin 42.

  As described above, in the housing member 10 (10 </ b> A to 10 </ b> D), the frame body 32 provided at the edge of the fiber reinforced resin plate 30 is formed by the matrix resin 42 that forms the fiber reinforced resin plate 30. For this reason, for example, even if the temperature drops after being taken out from the mold 48, it is possible to suppress the occurrence of a step or a gap at the boundary portion between the fiber reinforced resin plate 30 and the frame body 32 due to thermal contraction of the matrix resin 42, and the like. When coating the surface, the uniformity is ensured. As a result, the appearance quality of the casing member 10 (10A to 10D) is improved. Further, the provision of the frame body 32 improves the degree of freedom in processing the product and increases the use of the product. In addition, since the frame body 32 can be simultaneously formed in the process of forming the fiber reinforced resin plate 30, the manufacturing efficiency is improved.

  The housing member 10 (10A to 10D) has cutting surfaces (or grinding surfaces) 44a, 44b, and 44d on the surface of the frame body 32. That is, the housing member 10 (10A to 10D) is formed by forming the frame body 32 with the matrix resin 42 that forms the fiber reinforced resin plate 30, and cutting or grinding it to form a product shape. Therefore, the casing member 10 (10A to 10D) can further improve the appearance quality by planarizing the surface shape. Furthermore, product dimensions can be formed with higher accuracy by machining such as cutting.

  In the casing member 10 (10A to 10D), the frame body 32 does not include the reinforcing fibers 40 or includes the reinforcing fibers 40 at a lower density than the fiber reinforced resin plate 30, and therefore machining such as cutting is performed. It can be carried out easily and smoothly.

  The housing member 10 </ b> A (10 </ b> B) has a second frame body 60 (62) joined to the frame body 32. For this reason, machining such as cutting can be performed on the second frame body 60 (62), and the appearance quality and the degree of freedom of processing of the product are further improved. At this time, the second frame body 60 (62) can be joined to the frame body 32 at the same time in the process of forming the fiber reinforced resin plate 30 and the frame body 32, and the manufacturing efficiency is not lowered.

  It should be noted that the present invention is not limited to the above-described embodiment, and it is needless to say that the present invention can be freely changed without departing from the gist of the present invention.

  For example, in the above-described embodiment, the configuration in which the casing member 10 (10A to 10D) is used as the casing 12 of the lid body 16 that configures the electronic device 14 is illustrated, but the casing member 10 (10A to 10D) is used. May be used for the device main body 20.

  The casing member 10 (10A to 10D) described above can be used as a casing member for various electronic devices such as a tablet PC, a desktop PC, a smartphone, or a mobile phone, in addition to a notebook PC.

10, 10A to 10D Housing member 12 Housing 12a Rear cover 12b Front cover 14 Electronic device 16 Lid 20 Device body 30 Fiber reinforced resin plate 30a External end surface 30b Surface 32 Frame body 34 Wall 40 Reinforcing fiber 42 Matrix resin 44a -44d Cutting surface 46 Core 47 Cavity 48 Mold 48a Cavity space 50, 64, 68 Prototype 50a, 50b, 64a, 64b, 68a Surplus part 60, 62 Second frame body 66 Bending shape part

Claims (3)

A method for manufacturing a housing member in which a frame body made of a resin is provided at an edge of a fiber-reinforced resin plate in which reinforcing fibers are mixed into a matrix resin containing a thermoplastic resin,
Place the fiber reinforced resin plate inside the mold and pressurize and heat to ooze the matrix resin from the part forming the fiber reinforced resin plate ,
Wherein the immersion matrix resin began looking to form the frame body by curing by cooling After inflow into the cavity of the mold, and thereby provided the frame member to the edge of the fiber-reinforced resin plate A method for manufacturing a housing member, comprising manufacturing the housing member. A method for manufacturing a housing member in which a frame body made of resin is provided at an edge of a fiber reinforced resin plate in which reinforcing fibers are mixed into a matrix resin containing a thermosetting resin ,
By placing a precursor of the fiber-reinforced resin plate in the interior of the mold by blending a raw material liquid of the reinforcing fibers and the matrix resin pressure and the fiber-reinforced resin plate material solution of the matrix resin by heating Ooze from the part that forms
Simultaneously curing the raw material liquid of the matrix resin in the interior of the mold to form the fiber-reinforced resin plate, cured by cooling the immersion matrix resin began seen After inflow into the cavity of the mold A method for manufacturing a housing member, comprising: forming the frame body, thereby manufacturing a housing member provided with the frame body at an edge of the fiber reinforced resin plate. In the manufacturing method of the member for cases according to claim 1 or 2 ,
After removing the housing member from the mold, the frame body is cut or ground to form a surface of the frame body in a desired size and shape. Production method.

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