JPH05124060A - Resin molded form and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a resin molded form, which has high strength, is thinned and lightened, and a resin molded form, in which the surface of the resin molded form is decorated, and manufacture thereof. CONSTITUTION:An aluminum plate 3 with through-holes and a resin section 2 are monolithic-molded, and ribs 5 and bosses 6 integrally connected by the through-holes are formed simultaneously on the reverse side of the resin section 2. Structure in which an outer frame 4 is also monolithic-molded simultaneously so that the aluminum plate 3 intrudes to a root in specified size along the end sections of the aluminum plate 3 is formed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molding and a method for manufacturing the same, and more particularly to a resin molding reinforced by a metal plate and a method for manufacturing the same.

In recent years, OA (office automation) devices such as notebook personal computers (hereinafter referred to as "notebook personal computers"), electronic organizers, and telephones are required to be portable, so that it is important to reduce the weight and thickness of products. There is.

[0003]

2. Description of the Related Art Conventionally, a resin is used for a housing of a portable device represented by a notebook computer, an electronic notebook, a telephone and the like, from the viewpoint of weight reduction, aesthetics and insulation.

The weight of the case usually accounts for 30 to 50% of the weight of these products, and if the case can be made lighter, it can greatly contribute to the weight reduction of the product.

For this reason, the housing is being made thinner in order to reduce the weight of the housing. However, the strength of general-purpose plastic ABS resin (acrylonitrile-butadiene-styrene resin), which is commonly used for housings, is insufficient. There was a limit to thinning due to the problem of.

Therefore, a thin-walled housing is manufactured by using high-strength engineering plastics such as aromatic polyamide and PPS (polyphenylene sulfide).

[0007]

However, compared with ABS resin, the above-mentioned engineering plastics are more difficult to be injection-molded by a mold, and furthermore, the surface after molding is coated,
There is a problem that it is difficult to plate.

Further, there is a problem that the strength is still insufficient even if the above engineering plastic is used.

Therefore, the present invention has been made in view of the above problems, and is a thin and lightweight resin molded product having high strength, which is suitable for a housing of portable OA equipment and the like, and the resin molded product whose surface is decorated. An object is to provide a body and a method for producing the body.

[0010]

[Means for Solving the Problems] The above problems include a metal plate,
This is solved by a resin molded body having a structure in which a resin layer is integrally molded so as to cover one surface of the metal plate.

The metal plate may have a through hole, and the metal plate may have a projecting portion integrally connected to the through hole on the side opposite to the surface on which the resin layer is formed.

Further, the resin layer has a rising portion integrally formed with the resin layer from an end portion of the metal plate, and the end portion of the metal plate has a structure in which the rising portion is bite into the rising portion by a predetermined dimension. You can also do it.

A resin injection gate of an injection molding die may be arranged near the through hole of the metal plate on the projecting portion for molding.

Further, the above-mentioned problem is a structure in which a metal plate, a resin layer covering one surface of the metal plate, and a skin material covering the surface of the resin layer opposite to the metal plate are integrally formed. It can also be solved.

The skin material may be a film made of the same material as the molding resin.

The resin molding is combined with a step of arranging the skin material on one of dies composed of an upper die and a lower die and arranging the metal plate on the other die, and the die. Manufactured by a manufacturing method including a step of injecting a molding resin into a space formed between the skin material and a metal plate, and a step of taking out a resin molded body integrally molded of the resin from the two molds. can do.

[0017]

In the structure in which the metal plate and the resin portion are integrally molded as described above, the metal plate acts to reinforce the resin.

The fact that the metal plate has the through holes enables the resin to flow through the through holes on both surfaces of the metal plate during injection molding.

Further, by making the end portion of the metal plate bite into the resin portion by a predetermined size, the resin portion can hold the metal plate.

By injecting the resin from the protruding portion of the metal plate near the through hole, the resin can flow through the through hole to form a resin portion on the opposite side sandwiching the metal plate. Even if the use gate is arranged only on the protruding portion side, the resin will be completely filled in the mold.

Further, in the structure in which the metal plate and the resin portion are integrally molded, and the skin material is integrally molded on the surface of the resin portion on the opposite side of the metal plate, the metal plate reinforces the resin portion and at the same time the skin material is the surface of the resin molded body. Will function as.

When the surface material is made of the same material as the molding resin, the surface material acts so as to firmly adhere to the molding resin.

By disposing and molding the skin material and the metal plate in the mold when manufacturing this resin molded body, it becomes possible to integrally mold the skin material, the resin portion and the metal plate in this order. ..

[0024]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a perspective view of a casing of a notebook computer according to a first embodiment of the present invention, a part of which is sectioned so that the internal structure can be seen. 2 is a view showing the metal plate in FIG. 1, and FIG. 3 (A) is an enlarged sectional view of the boss portion in FIG.
(B) is an enlarged plan view of the rib portion, and (C) is an enlarged sectional view of the rib portion.

As shown in the sectional view of FIG. 1, the housing 1 has a structure in which an aluminum plate 3 having a thickness of 0.4 mm and a resin portion 2 are integrally molded to have a thickness of 1 mm. A metal surface is exposed over the entire surface except for the portion where the rib 5 and the boss 6 are provided, and the entire surface of the other surface is covered with the resin portion 2.

The resin portion 2 is formed to be larger than the aluminum plate 3, and an outer frame 4 is integrally formed with the resin portion 2 over the entire circumference so as to surround the aluminum plate 3 from a portion protruding from the aluminum plate 3. Has been formed.

As shown in FIG. 2, the aluminum plate 3 is provided with through holes 7 and 8 at predetermined positions, and bosses 6 and ribs 5 are formed on the aluminum plate 3 corresponding to the positions. ..

That is, as shown in FIGS. 3A and 3C, the boss 6 and the rib 5 are integrally connected and molded with the resin portion 2 through the through holes 7 and 8, and the aluminum plate 3 is It has a function of sandwiching and fixing together with the resin portion 3.

Further, as shown in FIG. 3 (A), the outer peripheral edge 3a of the aluminum plate 3 has a structure in which the outer frame 4 rising from the resin portion 2 toward the aluminum plate 3 is not easily rooted. The outer periphery of the aluminum plate 3 is also sandwiched and fixed by the resin portion 2 and the outer frame 4.

As described above, the housing 1 is integrally formed with the resin portion 2, the aluminum plate 3, the outer frame 4, the ribs 5 and the boss 6, and the aluminum plate 3 has the resin portion 2, the outer frame 4 and the ribs. Since it is sandwiched and fixed by the boss 6 and 5, the structure is strong against external force.

FIG. 5 shows a case (comparative example) in which the case according to the present example (the example) and the aluminum plate 3 according to the present example are not integrally formed, but have the same thickness, and only the resin is formed. It is a graph which compared intensity.

In the figure, the load on the horizontal axis is the load concentratedly applied to the central portions of the two housings, and the displacement on the vertical axis is the deflection amount of the part to which the weight is applied. As is clear from the figure, the displacement of the casing according to the present embodiment is about 1/3 of the displacement of the casing without the aluminum plate 3 integrally molded, and the casing according to the present embodiment has significantly improved strength. You can see that

The thickness of the casing 1 of the notebook computer according to this embodiment having the above structure is about 1 mm, but the thickness of the integrally molded aluminum plate 3 is the weight of the entire casing 1. 0.2-
0.6 mm is suitable.

Similar effects can be obtained by using an aluminum alloy plate or a light metal plate such as magnesium other than the aluminum plate.

If a stainless steel plate is used instead of the aluminum plate 3, the strength can be further improved. Further, the casing 1 according to the present embodiment has an effect that it is also excellent in electromagnetic wave shielding property because the metal plate is embedded over substantially the entire surface thereof.

Here, when the casing 1 is injection-molded by using a mold, a so-called pin gate is used as a resin injection port.

The pin gate is arranged on the top surface 6a of the boss 6 and the top surface 5a of the rib 5 at a portion close to the through holes 7 and 8.

In this way, the resin injected into the mold at the time of molding first enters the space in which the boss 6 and the rib 5 are formed, and immediately passes through the through holes 7 and 8 and the above-mentioned resin in the mold. The resin is filled in the space in which the resin portion 2 is formed, and the resin easily flows around the mold.

Therefore, as shown in FIG. 4, the runner formed at the time of injection molding is formed on the side of the boss 6 and the rib 5, and the cut-out portion of the runner is exposed on the surface side of the resin portion 2. Don't come

For this reason, the surface of the casing 1 can sufficiently maintain its appearance as a product without any post-treatment after injection molding.

Next, a second embodiment of the present invention will be described with reference to FIG. In the figure, (A) is a diagram showing a state before injection molding by a mold, (B) is a diagram showing a state during molding, and (C) is a diagram showing a cross section of the casing after molding. In the figure, the same components as those in the first embodiment shown in FIG. 1 are designated by the same reference numerals, and the description thereof will be omitted.

As shown in FIG. 6C, the housing 10 according to the present embodiment is formed as a structure in which a film 9 is integrally formed on the outside of the resin portion 2 of the above-mentioned first embodiment and laminated. Here, the integral molding means that the film 9 and the aluminum plate 3 are integrally formed of resin.

That is, as shown in FIG. 6A, in the case 10, first, a resin injection molding die 11 (upper die) is provided with a film 9 for surface coating, and the other die 12 is placed. The aluminum plate 3 is placed on the (lower mold), and then a resin (polycarbonate resin) is injected as shown in FIG. 6 (B) to form the film 9, the resin portion 2, the aluminum plate 3, and the outside. The frame 4 and the boss 6 are integrally molded.

Since the film 9 is pre-patterned and colored, the appearance of the housing 10 can be beautifully decorated without any coating process after the housing 10 is molded. If a polycarbonate film made of the same material as the resin portion 2 is used as the material of the film 9, the adhesiveness with the resin portion 2 is improved.

In this embodiment, the film 9 has a thickness of 50.
The thickness of this film is 10-100 μm.
The degree is desirable. The reason for this is that if the thickness is 10 μm or less, the strength is too thin and the strength is insufficient, and if it is 100 μm or more, the thickness is too large and the moldability at the time of resin injection is lowered.

[0046]

As described above, since the resin molded product according to the present invention has a structure in which the metal plate and the resin portion are integrally molded, the resin molded product is high in strength and thin while maintaining the appearance of the resin-only molded product. A molded body can be obtained.

Further, a through hole is provided in the metal plate to be integrally formed, and a projecting portion integrally connected to the resin portion on the surface is provided through the through hole, and the end portion of the metal plate is hard to be inserted into the resin portion. Thus, the connection between the metal plate and the resin portion can be made very strong.

Therefore, when it is used as a casing of a portable office automation equipment or the like, a strong, thin, and lightweight casing can be easily manufactured, and the device itself can be made thin and lightweight. ..

Further, by integrally molding the skin material at the time of molding this resin molded body, it is possible to easily manufacture a resin molded body having an aesthetic appearance that does not require coating after molding.

[Brief description of drawings]

FIG. 1 is a perspective view of a first embodiment of the present invention.

FIG. 2 is a perspective view of components of the first embodiment.

FIG. 3 is an enlarged view of a main part of the first embodiment.

FIG. 4 is a view showing a runner at the time of molding a casing.

FIG. 5 is a diagram comparing the strengths of housings.

FIG. 6 is a diagram illustrating a structure and a description method of a second embodiment.

[Explanation of symbols]

 1 Housing 2 Resin Part 3 Aluminum Plate 4 Outer Frame 5 Rib 6 Boss 7,8 Through Hole 9 Film 11,12 Mold

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Takashi Muratani, 1015 Kamiodanaka, Nakahara-ku, Kawasaki-shi, Kanagawa, within Fujitsu Limited

Claims (7)

[Claims] 1. A resin molded body characterized by a structure in which a metal plate (3) and a resin layer (2) are integrally molded so as to cover one surface of the metal plate (3). 2. The metal plate (3) has through holes (7, 8), and the through hole is provided on the opposite side of the surface of the metal plate (3) on which the resin layer (2) is formed. The resin molding according to claim 1, which has a protruding portion (5, 6) integrally connected with (7, 8). 3. The resin layer (2) has a rising portion (4) integrally formed with the resin layer (2) from an end portion of the metal plate (3), and the metal plate (3). ) Outer edge (3
The resin molding according to claim 1 or 2, wherein a) has a structure in which the rising portion (4) is inserted into the rising portion (4) by a predetermined size. 4. A resin injection gate of an injection molding die is arranged on the protrusions (5), (6) near the through holes (7), (8) of the metal plate (3). The resin molded body according to claim 3, wherein the resin molded body is formed by molding. 5. A metal plate (3), a resin layer (2) covering one surface of the metal plate (3), and a skin material covering the surface of the resin layer (2) opposite to the metal plate. (9) A resin molded body having a structure integrally formed with. 6. The resin molding according to claim 5, wherein the skin material (9) is a film made of the same material as the molding resin. 7. A mold (1 comprising an upper mold and a lower mold.
1, 12), the step of disposing the skin material (9) on one side, and disposing the metal plate (3) on the other die, and combining the metal molds (11, 12) with the skin material (9). )
A step of injecting a molding resin into a space formed between the metal plate (3) and the metal plate (3), and a step of taking out a resin molded body integrally molded by the resin from the two molds (11, 12). The method for producing a molded article according to claim 5, further comprising: