JP7454392B2 - Composite molded product, display device using the composite molded product, and method for manufacturing the composite molded product - Google Patents

Description

The present invention has a metal base material molded by a casting method such as a die casting method, and a composite molded product in which the metal base material and a resin molded body are composited by insert molding or the like, and a composite molded product using the composite molded product. The present invention relates to a display device and a method for manufacturing a composite molded product.

The electronic device described in Patent Document 1 uses a housing in which a first member made of a metal material such as a magnesium alloy and a second member made of a synthetic resin material are combined by insert molding. has been done.

In the invention described in Patent Document 1, as shown in FIG. 6, a rear wall is formed to stand up on a first member formed of a metal material, and a recess is formed on the inner surface of the rear wall in the thickness direction of the rear wall. A recessed portion is formed. Further, the first member is provided with a plurality of openings that penetrate vertically at positions spaced inwardly from the rear wall. The second member insert-molded from a synthetic resin material is fixed to the lower and upper surfaces of the first member, and further, a part of the resin material penetrates vertically into the inside of the recess formed in the wall. By filling the inside of the opening, the first member and the second member are fixed to each other.

Patent No. 6508403

The first member described in Patent Document 1 is expected to be formed by a casting method such as die casting using a metal material such as a magnesium alloy, but if the opening that penetrates the first member from top to bottom is formed by cutting, burrs generated during processing may be mixed into the second member, which is molded from a synthetic resin material, and may be exposed on the surface of the second member. For this reason, after cutting the opening, finishing processing is required to remove the burrs, which results in a significant increase in labor hours.

Further, in the electronic device described in Patent Document 1, a first member having a relatively low height in the vertical direction is used, and the recess is formed in the rear wall, and an opening that penetrates vertically is provided. , a second member made of a synthetic resin material is fixed to the inner portion of the rear wall. However, in a first member with a small vertical height dimension as described in Patent Document 1, it is difficult to firmly fix a second member with a small volume to the outward facing surface of the rear wall by insert molding. be.

The present invention solves the above-mentioned conventional problems, and eliminates the need for an extra deburring process when molding a metal base material by a casting method, and forms an anchor convex portion that penetrates into a resin molded body. The present invention aims to provide a composite molded product capable of producing a composite molded product, a display device using the composite molded product, and a method for manufacturing the composite molded product.

In addition, the present invention provides a method in which, when a metal base material having a height dimension in the front and back direction smaller than a width dimension in each direction in a plan view is used, the front and rear width dimensions formed on the metal base material are small and the length dimension is small. Provided is a composite molded product that allows a relatively small-volume resin molded product to be firmly fixed to a side surface extending in the direction, a display device using the composite molded product, and a method for manufacturing the composite molded product. It is intended to.

The present invention relates to a composite molded product having a metal base material molded by a casting method and a resin molded body fixed to a part of the metal base material,
The metal base material has a main body and an anchor protrusion protruding from the main body and inserted into the resin molded body,
The anchor protrusion is characterized in that it is located at least in one of a gate portion for introducing molten metal and an overflow portion for discharging molten metal when forming the main body by the casting method.

In the composite molded product of the present invention, the metal base material has a width dimension in each direction in a plan view seen from the front that is larger than a height dimension in the front-rear direction, and the width direction is oriented in the front-rear direction and the width dimension is larger than the height dimension in the front-back direction. It has a side surface whose intersecting direction is the longitudinal direction,
The anchor protrusion protrudes laterally from the side surface and extends along the longitudinal direction of the side surface.
It is preferable that at least a portion of the resin molded body is fixed to the side surface portion.

Further, in the composite molded product of the present invention, the metal base material has a width dimension in each direction in a plan view seen from the front that is larger than a height dimension in the front-rear direction, and a width direction is oriented in the front-rear direction. It has a side surface whose longitudinal direction is the direction that intersects with the direction,
The anchor convex portion protrudes laterally from the side surface portion and extends along the longitudinal direction of the side surface portion, and the side surface portion includes a front surface located forward of the anchor convex portion, and a front surface located in front of the anchor convex portion. It has a rear surface located rearward than the
The front surface and the rear surface are inclined toward the inside of the main body portion as they move away from the anchor convex portion in the front-rear direction,
It is preferable that at least a portion of the resin molded body is fixed to the front surface and the rear surface.

In the composite molded product of the present invention, an anchor recess is formed on at least one of a front surface of the side portion located forward of the anchor protrusion and a rear surface of the side portion located rearward of the anchor protrusion,
It is preferable that a part of the resin molded body is embedded in the anchor recess.

In the composite molded product of the present invention, the anchor recess has a side opening opened in the side surface portion and a height opening opened in the height direction facing in the front-rear direction,
The inner width dimension of the anchor recess in the longitudinal direction may gradually widen from the side opening toward the inside of the recess, and gradually narrow from the height direction opening toward the inside of the recess. preferable.

Next, the present invention has any of the above composite molded products,
The display cell is characterized in that a display cell is arranged inside a storage space surrounded by the side surface portion of the metal base material.

Furthermore, the present invention provides a method for manufacturing a composite molded article, in which a metal base material is molded by a casting method, and a resin molded body is fixed to the metal base material.
In the casting method, molten metal is injected into the cavity from the gate part of the mold, the molten metal is discharged from the overflow part of the mold, the molten metal in the cavity is solidified, and the metal base material is solidified. Molding the main body,
forming an anchor convex portion protruding from the main body portion by leaving a portion of the solidified metal in at least one of the gate portion and the overflow portion;
The present invention is characterized in that the anchor convex portion is inserted into the resin molded body when the resin molded body is molded.

In the present invention, when a metal base material is formed by a casting method, the anchor convex portion is formed by leaving a portion of the metal located in the gate portion and the overflow portion in a state of protruding from the main body portion. When forming a metal base material using a casting method such as die casting, it has traditionally been a process to cut the hardened metal material at the gate and overflow areas, and to go through a deburring process if necessary. It is. According to the present invention, it is possible to form an anchor protrusion free of burrs with approximately the same number of man-hours as in the conventional process for forming metal base materials. When a metal base material and a resin molded body are combined by insert molding or the like, by inserting the anchor convex portion into the resin, it becomes possible to firmly fix the metal base material and the resin molded body .

Further, the present invention provides a flat metal base material having a large width in each direction in a plan view when viewed from the front and a small width in the front-rear direction of the side surface. An anchor convex portion extending from the anchor convex portion is formed, and an anchor concave portion is formed on at least one of the surfaces of the side portion located in front and rearward of the anchor convex portion. With this structure, it is possible to firmly fix a relatively small-volume resin molded body to a relatively small-area band-shaped side portion that has a small width in the front-rear direction and extends long in the longitudinal direction.

A perspective view of a display device using a composite molded product according to an embodiment of the present invention, viewed from the front; An exploded perspective view of the display device shown in FIG. A perspective view showing a composite molded product molded by insert molding included in the display device shown in FIG. An exploded perspective view showing the metal base material and resin molded product separated from each other in the composite molded product shown in FIG. A perspective view including a cross section taken along the line V-V of the composite molded product shown in FIG. A perspective view including a cross section of the metal base material shown in FIG. 4 cut along the VI-VI line, A side sectional view showing the cross section shown in FIG. It is a cross-sectional view of a mold when molding a metal base material by a die-casting method, showing a cavity for molding the part shown in FIG. 7, and a cross-sectional view taken by cutting FIG. 14 along the line VIII-VIII. It shows the anchor recess formed above the anchor convex part in the side part of the metal base material, (A) is a partial plan view, (B) is a partial side view, A perspective view including a cross section taken along the line XX of the composite molded product shown in FIG. A perspective view including a cross section taken along the line XI-XI of the metal base material shown in FIG. A side sectional view showing the cross section shown in FIG. It is a cross-sectional view of a mold when molding a metal base material by a die-casting method, showing a cavity for molding the part shown in FIG. 12, and a cross-sectional view taken by cutting FIG. 14 along the line XIII-XIII. A plan view illustrating the process of forming a metal base material by die-casting and leaving an anchor protrusion,

FIG. 1 shows a display device 1 according to an embodiment of the present invention, and FIG. 2 shows an exploded perspective view of the display device 1.
The display device 1 is mounted on a vehicle, and the Z1 direction is the front and the Z2 direction is the rear. When installed in the vehicle interior, the Z1 direction is directed into the vehicle interior, and the Z2 direction is directed toward the forward direction of the vehicle. The Y1 direction is upward, the Y2 direction is downward, the X1 direction is to the left when facing the screen, and the X2 direction is to the right when facing the screen.

As shown in the exploded perspective view of FIG. 2, the casing 2 of the display device 1 is made up of a composite molded product 3, which is a front case, and a rear case 4, which is located further back (in the Z2 direction). It is configured. The composite molded product 3, which is the front case, is formed by fixing at least a portion of a resin molded body 30 made of a synthetic resin material around a metal base material 10. The rear case 4 is made of synthetic resin material. As shown in FIG. 1, when the composite molded product 3 and the rear case 4 are combined, the outer surface of the resin molded body 30 of the composite molded product 3 and the outer surface of the rear case 4 are continuous, forming a resin case surface. be done.

As shown in FIG. 2, a storage space (storage recess) 11 that is open to the front (Z1 direction) is formed in the metal base material 10 of the composite molded product 3, and a backlight is provided inside this storage space 11. Unit 5 is housed. The metal base material 10 has support plate portions 12a, 12b on both left and right sides, and a translucent front panel 6 is installed and fixed on the front surface of the support plate portions 12a, 12b. A liquid crystal display cell 7 is fixed to the rear surface of the front panel 6 facing backward (Z2 direction). A capacitive sensing touch panel is interposed between the front panel 6 and the liquid crystal display cell 7. When the front panel 6 is installed and fixed in front of the metal base 10, a transmissive liquid crystal display cell 7 is stacked in front of the backlight unit 5. Further, as shown in FIG. 1, the front panel 6 is fixed in a state surrounded by peripheral wall portions 31a, 32a, 33a, 34a, and 35a of the front portion of the resin molded body 30.

In FIG. 3, a composite molded article 3 is shown. In plan view when viewed from the front (Z1 direction) to the rear, the composite molded product 3 has a width dimension in the front-back direction (Z1-Z2 direction) is larger than the height dimension. In other words, the composite molded product 3 has a flat shape in which the width in the left-right direction (X1-X2 direction) and the width in the up-down direction (Y1-Y2 direction) are sufficiently larger than the width in the front-back direction (Z1-Z2 direction). It is.

The metal base material 10 of the composite molded product 3 is molded by a casting method, and is molded by a die-casting method using a metal material such as a magnesium alloy or an aluminum alloy. The metal base material 10 and the resin molded body 30 fixed around the metal base material 10 are fixed together by a composite molding method. The composite molding method is so-called insert molding in which the metal base material 10 is housed in a mold and the resin molded body 30 is injection molded around the metal base material 10. Alternatively, a so-called outsert method may be used in which a mold is installed on a part of the outside of the metal base material and the resin molded body 30 is fixed to the outside part of the metal base material. Although the metal base material 10 and the resin molded body 30 are fixed together and cannot be easily separated, in FIG. 4, the metal base material 10 and the resin molded body 30 are They are intentionally shown separated.

As shown in FIGS. 3 and 4, the metal base material 10 has a width dimension in the left-right direction (X1-X2 direction) and a width dimension in the up-down direction (Y1-Y2 direction) in the front-back direction (Z1-Z2 direction). is a flat rectangle that is sufficiently larger than the dimensions of . The metal base material 10 has a storage space 11 with an open opening at the front (Z1 direction). The storage space 11 has a rectangular shape in which the width dimension in the left-right direction (X1-X2 direction) is larger than the width dimension in the vertical direction (Y1-Y2 direction), and as described above, the backlight unit 5 is located inside the storage space 11. stored inside. A support plate portion 12a is formed on the left side (X1 side) of the storage space 11, and a support plate portion 12b is formed on the right side (X2 side) of the metal base material 10. The left and right sides of the front panel 6 are bonded and fixed to the front surfaces of the support plate parts 12a and 12b.

FIG. 5 shows a cross section of the composite molded product 3 taken along the line VV, and FIGS. 6 and 7 show cross sections of the metal base material 10 taken along the line VI-VI. On the upper side (Y1 side), the metal base material 10 is integrally formed with an upper side wall part 13 that stands up from the bottom surface 11a of the storage space 11 toward the front (Z1 direction). FIG. 10 shows a cross section of the composite molded product 3 taken along the line XX, and FIGS. 11 and 12 show cross sections of the metal base material 10 taken along the line XI-XI. A lower side wall portion 14 rising forward from the bottom surface 11a of the storage space 11 is integrally formed on the lower side (Y2 side) of the metal base material 10.

As shown in FIG. 4, the front end surface 13a of the upper side wall portion 13 and the front end surface 14a of the lower side wall portion 14 are located in the same plane parallel to the XY plane, and the left and right support plate portions 12a, The front surface of 12b, front end surface 13a, and front end surface 14a are also located in the same plane parallel to the XY plane.

As shown in FIG. 4, the upper side wall portion 13 located above the metal base material 10 has substantially the same structure within the range of length La extending in the left-right direction (X1-X2 direction). The length dimension La substantially matches the length of the long side of the rectangular storage space 11 extending in the left-right direction (X1-X2 direction). 5, 6, and 7 show the detailed structure of the upper side wall portion 13 within the range of length La. The lower side wall portion 14 located below the metal base material 10 has substantially the same structure within the length dimension Lb on both left and right sides. 10, 11, and 12 show the detailed structure of the lower side wall portion 14 within the length dimension Lb.

As shown in FIG. 4, in the metal base material 10, there is a line extending from the downward (Y2 direction) surface of the lower side wall 14 to the rear (Z2 direction) in the range of the length Lc at the center of the lower side wall 14. An extension wall portion 10a extending from the rear end of the extension wall portion 10a and a support portion 10b extending downward (in the Y2 direction) from the rear end portion of the extension wall portion 10a are integrally formed.

As shown in FIGS. 5, 6, and 7, the upper side wall portion 13 has a side surface portion 16 facing upward (Y1 direction). In the side surface portion 16, the front-rear direction (Z1-Z2 direction) is the width direction, and the left-right direction (X1-X2 direction) perpendicular to the front-rear direction is the longitudinal direction, and the length direction dimension is sufficiently larger than the width direction dimension. It has a large band shape. An anchor convex portion 17 that protrudes upward (Y1 direction) is integrally formed in the middle portion of the side surface portion 16 in the front-rear direction (Z1-Z2 direction). As shown in FIGS. 10, 11, and 12, the lower side wall portion 14 has a side surface portion 18 facing downward (Y2 direction). The width direction of the side surface portion 18 is also the front-rear direction (Z1-Z2 direction), and the longitudinal direction is the left-right direction (X1-X2 direction) perpendicular to the front-rear direction, and the length direction dimension is sufficiently larger than the width direction dimension. It has a large band shape. An anchor convex portion 19 that protrudes downward (in the Y2 direction) is integrally formed in the middle portion of the side surface portion 18 in the front-rear direction.

As shown in FIG. 4, the support plate part 12a located on the left side of the metal base material 10 has an edge 12c facing leftward (X1 direction), and the support plate part 12b located on the right side also faces rightward. It has an edge 12d facing (X2 direction). An anchor protrusion 25 that protrudes to the left is formed on the entire circumference of the edge 12c, and an anchor protrusion 25 that protrudes in the right direction (X2 direction) is also formed on the entire circumference of the edge 12d. The width dimension in the front-rear direction of the anchor protrusions 25 provided on the edges 12c and 12d is approximately equal to that of the anchor protrusions 19 provided on the lower side wall portion 14.

As shown in FIGS. 6 and 11, the metal base material 10 has an anchor convex portion 17 provided on the upper side wall portion 13, an anchor convex portion 19 provided on the lower side wall portion 14, and support plate portions 12a, 12b. The main body portion 15 is a portion excluding the anchor convex portions 25 provided on the edges 12c and 12d, and further excluding the extension wall portion 10a and the support portion 10b.

As shown in FIG. 6, the upper side wall portion 13 and its side surface portion 16 have an elongated shape in which the dimension in the longitudinal direction (X1-X2 direction) is sufficiently larger than the dimension in the width direction (Z1-Z2 direction). . The anchor convex portion 17 is located midway in the front-rear direction (Z1-Z2 direction) of the side surface portion 16, and is provided along the longitudinal direction (X1-X2 direction) of the side surface portion 16. The width direction of the anchor convex portion 17 is the front-rear direction (Z1-Z2 direction), and the longitudinal direction is the left-right direction (X1-X2 direction). The anchor convex portion 17 has a rail shape in which a length L1 in the longitudinal direction is sufficiently longer than a width W1 in the width direction. The length dimension L1 is 10 times or more the width dimension W1. The anchor convex portion 17 extends continuously over almost the entire length La without interruption. Alternatively, it may extend long in the left-right direction with interruptions at several places.

The metal base material 10 is formed by a casting method such as a die casting method, and the anchor convex portion 17 is located at a gate portion for introducing molten metal into the cavity in which the main body portion 15 of the mold is cast. .

As shown in FIGS. 5, 6, and 7, the side surface portion 16 of the upper side wall portion 13 has a front surface 16a located forward (in the Z1 direction) with the anchor convex portion 17 in between, and a front surface 16a located on both sides of the anchor convex portion 17. It has a rear surface 16b located at the rear (Z2 direction). As shown in the cross-sectional view of FIG. 7, the front surface 16a is inclined at an angle α toward the inside of the main body portion 15 (Y2 direction) as it moves away from the anchor convex portion 17 toward the front (Z1 direction). ing. The rear surface 16b is inclined at an angle β toward the inside of the main body portion 15 (Y2 direction) as it moves away from the anchor convex portion 17 toward the rear (Z2 direction). That is, the front surface 16a is inclined at an angle α toward the inside of the main body 15 with respect to the front-back plane K parallel to the is tilted inward by an angle β. The angle α and the angle β may be the same angle or different angles. As shown in FIG. 7, the front surface 16a and the rear surface 16b are inclined planes extending in the left-right direction (X1-X2 direction), which is the longitudinal direction. It may be a convex curved surface or a concave curved surface with a small curvature that slopes inward.

A front-back plane K, which serves as a reference for the inclination angle of the front surface 16a and the rear surface 16b, is a plane perpendicular to the bottom surface 11a of the storage space 11. As shown in FIG. 7, the front-rear plane K extends in the front-rear direction (Z1-Z2 direction), and this front-rear plane K extends in the front-rear direction (Z1-Z2 direction). This corresponds to the direction in which the molds 41 and 42 are separated.

A plurality of anchor recesses are provided on at least one of the front surface 16a located in front of the anchor convex portion 17 and the rear surface 16b located behind the anchor convex portion 17. As shown in FIGS. 6 and 9, in the metal base material 10 of the embodiment, anchor recesses 21 and 22 are provided only on the front surface 16a. The anchor recesses 21 and 22 are located on the sides (front) of the anchor protrusion 17 and are arranged at regular intervals along the longitudinal direction (X1-X2 direction) of the anchor protrusion 17.

As shown in the partial plan view of FIG. 9A and the partial side view of FIG. It has a height direction opening 21b opened forward (Z1 direction) in a height direction. Regarding the inner width dimension of the anchor recess 21 in the longitudinal direction, that is, the left-right direction (X1-X2 direction), as shown in FIG. It gradually becomes wider toward the width dimension E2 on the back side (inward of the recess). Further, as shown in FIG. 9(B), the inner width dimension extends from the width dimension G1 of the height direction opening 21b toward the width dimension G2 on the back side (Z2 direction) (inward of the recess). ) gradually narrows.

As shown in FIGS. 6 and 9(A), most of the anchor recesses 21 have a depth that is halfway through the thickness of the upper side wall 13 from the side opening 21a downward (in the Y2 direction). It is formed like this. However, as shown in FIG. 9(A), some of the anchor recesses 22 are formed to penetrate the upper side wall portion 13 in the vertical direction (Y1-Y2 direction).

As shown in FIGS. 9(A) and 9(B), the anchor recess 22 penetrating the upper side wall 13 is connected to a side opening 22a opened in the front surface 16a of the side wall 16 in the height direction, which is the front-rear direction. It has a height direction opening 22b that is open to the front (Z1 direction). Regarding the inner width dimension of the anchor recess 22 in the longitudinal direction, that is, the left-right direction (X1-X2 direction), as shown in FIG. gradually widens toward the width dimension F2 of the opening (inward of the recess). Further, as shown in FIG. 9(B), the inner width dimension extends from the width dimension H1 of the height direction opening 21b toward the width dimension H2 on the back side (Z2 direction) (inward of the recess). ) gradually narrows.

In the range of length dimension Lb of the metal base material 10 in FIG. 4, as shown in FIG. It has a long shape with a large dimension in the X1-X2 direction). The anchor convex portion 19 is provided along the longitudinal direction (X1-X2 direction) of the side surface portion 18 at an intermediate portion of the side surface portion 18 in the front-rear direction (Z1-Z2 direction). The width direction of the anchor convex portion 19 is the front-rear direction (Z1-Z2 direction), and the longitudinal direction is the left-right direction (X1-X2 direction) along the longitudinal direction of the side surface portion 18. The anchor convex portion 19 has a rail shape in which a length L2 in the longitudinal direction is sufficiently longer than a width W2 in the front-rear direction (Z1-Z2 direction). The length dimension L2 is 10 times or more the width dimension W2. The anchor convex portion 19 extends continuously over almost the entire length of the length dimension Lb shown in FIG. 4 without interruption. Alternatively, it may extend long in the left-right direction with interruptions at several places within the range of the length dimension Lb.

The metal base material 10 is molded by a casting method such as a die casting method, and the anchor convex portion 19 provided on the lower side wall portion 14 is made of molten metal filled in the cavity in which the main body portion 15 of the mold is cast. It is located at the overflow part for discharging the surplus.

As shown in FIGS. 10, 11, and 12, the side surface portion 18 of the lower side wall portion 14 has a front surface 18a located forward (in the Z1 direction) with the anchor convex portion 19 in between, and a front surface 18a located on both sides of the anchor convex portion 19. It has a rear surface 18b located at the rear (Z2 direction). As shown in the cross-sectional view of FIG. 12, the front surface 18a is inclined at an angle α toward the inside of the main body portion 15 (Y1 direction) as it moves away from the anchor convex portion 19 toward the front (Z1 direction). ing. The rear surface 18b is inclined at an angle β toward the inside of the main body portion 15 (Y1 direction) as it moves away from the anchor convex portion 17 toward the rear (Z2 direction). That is, the front surface 18a is inclined at an angle α toward the inside of the main body 15 with respect to the front-back plane K parallel to the is tilted inward by an angle β. The angle α and the angle β may be the same angle or different angles. The front surface 16a and the rear surface 16b are inclined planes extending in the left-right direction (X1-X2 direction), but the front surface 18a and the rear surface 18b are convex surfaces of small curvature that are inclined inward of the main body 15. It may be a curved surface or a concave curved surface.

A plurality of anchor recesses are formed in at least one of the front surface 18a located in front of the anchor convex part 19 and the rear surface 18b located in the rear thereof at regular intervals in the left-right direction (X1-X2 direction). . Anchor recesses 21 and 22 are formed in the front surface 18a in the range of length Lb shown in FIG. 4 . The anchor recesses 21 and 22 have the same structure and the same dimensions as those formed in the upper side wall portion 13 shown in FIGS. 9(A) and 9(B).

An extension wall portion 10a and a support portion 10b are formed in a region having a length dimension Lc at the center of the lower side wall portion 14 of the metal base material 10. It is located at an overflow part for discharging excess molten metal filled into the cavity for casting part 15. As shown in FIG. 4, in the range of the length Lc of the lower side wall 14, in the portion where the extension wall 10a is formed, the upper part of the lower side wall 14 is Anchor recesses 21, 22 of the same structure and dimensions as shown are formed in a plurality of locations.

As shown in FIG. 4, along the longitudinal direction of the edges 12c and 12d of the support plate parts 12a and 12b of the metal base material 10, that is, the edges 12c and 12d on both left and right sides of the metal base material 10, An anchor protrusion 25 is provided. At the edges 12c and 12d, a front surface is provided in front of the anchor protrusion 25, and a rear surface is provided in the rear of the anchor protrusion. The anterior and posterior surfaces are sloped at angles α and β similar to those shown in FIGS. 7 and 12. A plurality of anchor recesses 21 are formed at intervals on the front surface. The structure and dimensions of the anchor recess 21 are the same as those shown in FIGS. 9A and 9B.

FIG. 3 shows a composite molded product 3 in which a resin molded body 30 is fixed to the peripheral surface of a metal base material 10 by insert molding. In FIG. 4, the resin molded body 30 is intentionally shown separated from the metal base material 10. The resin molded body 30 is molded from a synthetic resin material such as polycarbonate or acrylic resin. As shown in FIGS. 3 and 4, the resin molded body 30 has an upper side wall fixing portion that is fixed to the side surface portion 16 of the upper side wall portion 13 in the metal base material 10 within a length dimension La shown in FIG. 31, a lower side wall fixing portion 32 fixed to the side surface 18 of the lower side wall 14 within a length dimension Lb, and a side surface portion and extension wall portion 10a of the lower side wall 14 within a length dimension Lc. It has an extension fixing part 33 fixed to the lower surface (Y2 side surface) of the. Furthermore, the resin molded body 30 has edge fixing parts 34 and 35 fixed to the surfaces of the edges 12c and 12d, and a base fixing part fixed to the rear (Z2 direction) surfaces of the support plate parts 12a and 12b. 36 and 37.

FIG. 5 shows the upper side wall fixing part 31 fixed to the upper side wall part 13 within the range of length La. The anchor protrusion 17 provided on the side surface 16 of the upper side wall 13 enters into the upper side wall fixing section 31, and the upper side wall fixing section 31 is fixed to the front surface 16a and rear surface 16b of the side wall 16. . Further, a part of the synthetic resin material constituting the upper side wall fixing portion 31 enters into the anchor recess 21 and the anchor recess 22 formed from the front surface 16a to the front end surface 13a of the upper side wall 13. As shown in FIG. 5, the front portion of the upper side wall fixing portion 31 of the resin molded body 30 is a peripheral wall portion 31a that protrudes further forward (in the Z1 direction) than the front end surface 13a of the upper side wall portion 13.

FIG. 10 shows the lower side wall fixing portion 32 fixed to the lower side wall portion 14 in the range of length Lb on both the left and right sides. The anchor protrusion 19 provided on the side surface 18 of the lower side wall 14 enters the lower side wall fixing section 32, and the lower side wall fixing section 32 is fixed to the front surface 18a and the rear surface 18b of the side wall 18. . Further, a part of the synthetic resin material constituting the lower side wall fixing portion 32 enters into the anchor recess 21 and the anchor recess 22 formed from the front surface 18a to the front end surface 14a of the lower side wall 14. As shown in FIG. 10, the front portion of the lower side wall fixing portion 32 of the resin molded body 30 is a peripheral wall portion 32a that protrudes further forward (in the Z1 direction) than the front end surface 14a of the lower side wall portion 14.

In the range of the length dimension Lc shown in FIG. 4, the extension fixing part 33 of the resin molded body 30 is fixed to the side surface of the lower side wall part 14 and the downward (Y2 direction) surface of the extension wall part 10a. . Here too, a portion of the synthetic resin material has entered the interior of the anchor recesses 21, 22. Further, the extended fixing portion 33 is formed with a peripheral wall portion 33a that projects further forward than the front end surface 14a of the lower side wall portion 14.

As shown in FIG. 4, on both the left and right edges of the composite molded product 3, the edge fixing parts 34 and 35 of the resin molded body 30 are fixed to the edges 12c and 12d of the support plate parts 12a and 12b. . Here too, the anchor protrusions 25 provided along the edges 12c, 12d enter inside the edge fixing parts 34, 35, and a part of the synthetic resin material forming the edge fixing parts 34, 35 is attached to the edge 12c. , 12d. Further, peripheral wall portions 34a, 35a are formed in the edge fixing portions 34, 35, and protrude further forward (in the Z1 direction) than the support plate portions 12a, 12b.

As shown in FIG. 2, the front panel 6 of the display device 1 is fixed to the front surface of the support plate parts 12a, 12b of the metal base material 10. It is housed in a space surrounded by 33a, 34a, and 35a.

As shown in FIG. 5, the upper side wall fixing portion 31 of the resin molded body 30 is fixed to a part of the side surface portion 16 having an elongated surface shape, and the upper side wall fixing portion 31 is elongated in the left-right direction. The thickness dimension in the vertical direction (Y1-Y2 direction) is also small, and the cross-sectional area and volume are also extremely small. As shown in FIG. 10, the lower side wall fixing part 32 of the resin molded body 30 is also fixed to a part of the elongated side part 18, and the lower side wall fixing part 32 is elongated in the left and right direction, and is elongated in the vertical direction ( The thickness dimension (Y1-Y2 direction) is also small, and the cross-sectional area and volume are also extremely small. The edge fixing parts 34 and 35 are similarly elongated and thin, and have a small cross-sectional area.

However, as shown in FIG. 5, the elongated rail-shaped anchor convex portion 17 extends in the longitudinal direction of the upper side wall fixing portion 31 and enters the inside of the upper side wall fixing portion 31 over a long range in the longitudinal direction. A synthetic resin material constituting the upper side wall fixing portion 31 is inserted into the plurality of anchor recesses 21 and 22 provided along the anchor convex portion 17. Therefore, even if the upper side wall fixing part 31 is thin and elongated, the upper side wall fixing part 31 can be firmly fixed to the upper side wall part 13 while maintaining its shape and dimensions without causing sink marks, deformation, or peeling. Become. This also applies to the lower side wall fixing section 32, the extension fixing section 33, and the edge fixing sections 34 and 35.

As shown in FIG. 9(A), in the anchor recesses 21 and 22, the width dimensions E1 and F1 of the side openings 21a and 22a opened to the side surface portion 16 are small, and the inner width dimension in the left and right direction is As it goes into the inside of the portion 15, it becomes wider and expands to the width dimensions E2 and F2. Therefore, when the synthetic resin material constituting the upper side wall fixing part 31 fixed to the side part 16 enters the inside of the anchor recesses 21 and 22 and is solidified, the upper side wall fixing part 31 is securely fixed in the anchor recesses 21 and 22. As a result, the upper side wall fixing portion 31 becomes difficult to peel off from the side surface portion 16.

Next, a method for casting the metal base material 10 and a method for manufacturing the composite molded product 3 will be explained.
FIG. 8 shows a cross section of the upper part of the mold and cavity for molding the metal base material 10 by die casting, and FIG. 13 shows a cross section of the lower part of the mold and cavity. FIG. 14 is an explanatory diagram showing an outline of the planar shape of the cavity formed by the mold. Note that FIG. 8 corresponds to a cross-sectional view of FIG. 14 taken along line VIII-VIII, and FIG. 13 corresponds to a cross-sectional view of FIG. 14 taken along line XIII-XIII.

As shown in FIGS. 8 and 13, a mold 40 used in the die casting method includes a first mold 41 and a second mold 42. The first mold 41 and the second mold 42 are joined at a mold mating surface S. The separation direction of the first mold 41 and the second mold 42 is the front-rear direction (Z1-Z2 direction).

When the first mold 41 and the second mold 42 are combined, as shown in FIG. is formed. The main body molding cavity C15 includes a storage space molding cavity C11 for molding the storage space 11, an upper side wall molding cavity C13 for molding the upper side wall 13, a lower side wall molding cavity C14 for molding the lower side wall 14, and left and right sides. Support plate molding cavities C12a and C12b are included in which the support plate parts 12a and 12b are molded. Further, extension molding cavities C10a and 10b for molding the extension wall portion 10a and the support portion 10b are formed extending downward (in the Y2 direction) from the main body molding cavity C15. In order to form the extension molding cavities C10a and 10b, the mold 40 is provided with inserts other than the first mold 41 and the second mold 42 as necessary.

As shown in FIG. 14, the mold 40 is provided with a gate portion Cg that is continuous with the upper side wall molding cavity C13 of the main body molding cavity C15, and an overflow portion Cf that is continuous with the lower side wall molding cavity C14. ing. FIG. 8 shows a partial cross section of the upper side wall molding cavity C13 and the gate part Cg, and FIG. 13 shows a partial cross section of the lower side wall molding cavity C14 and the overflow part Cf.

As shown in FIG. 14, the gate part Cg includes an anchor gate part Cg1 that extends long in the left-right direction (X1-X2 direction) continuously from the upper side wall molding cavity C13, and a plurality of A branch gate portion Cg2 is formed. An anchor overflow part Cf1 that extends in the left-right direction continuously from the lower side wall molding cavity C14, and a branched overflow part Cf2 that continues from the anchor overflow part Cf1 are formed on both left and right sides of the overflow part Cf. Furthermore, within the mold 40, a plurality of branch overflow portions Cf3 are formed which are continuous with the extension molding cavities C10a and 10b. Further, although not shown in FIG. 14, anchor overflow portions are continuously provided at the edges of the support plate molding cavities C12a and C12b provided on both left and right sides of the main body molding cavity C15.

The first mold 41 is provided with a molding part for molding the anchor recesses 21 and 22 on the upper side of the upper side wall part 13 shown in FIGS. 6 and 9. Similarly, the first mold 41 includes a molding part for molding the anchor recesses 21 and 22 in the upper part of the lower side wall part 14, and an anchor recess 21 in the edges 12c and 12d of the left and right support plate parts 12a and 12b. A molding section for molding is provided.

In the die casting method, as shown in FIGS. 8 and 13, a first mold 41 and a second mold 42 are joined at a mold matching surface S to assemble a mold 40. At this time, inserts for forming the extension wall portion 10a and the support portion 10b are combined as necessary.

Molten metal is injected into the main body molding cavity C15 from the branch gate portion Cg2 shown in FIG. 14 via the anchor gate portion Cg1. The surplus molten metal filled in the main body molding cavity C15 flows out from the anchor overflow part Cf1 to the branch overflow part Cf2, and flows out from the extension part molding cavities C10a, 10b to the branch overflow part Cf3. Anchor overflow portions are also provided at the edges of support plate molding cavities C12a and C12b provided on both left and right sides of main body molding cavity C15, and molten metal flows out from these anchor overflow portions as well.

After the mold 40 is cooled and the molten metal is solidified, the first mold 41 and the second mold 42 are separated from each other in the Z1-Z2 direction, and the solidified metal molded body is taken out. Also, if nesting is used, this nesting is also removed. When the mold 40 is opened, the main body portion 15, the extension wall portion 10a, and the support portion 10b are formed of metal material, and the shapes of the anchor gate portion Cg1 and the branch gate portion Cg2 remain, and similarly, the anchor overflow portion is formed. The shapes of Cf1 and branch overflow portion Cf2 remain. Further, the shapes of the branch overflow portion Cf3 and the anchor overflow portion extending from the support plate molding cavities C12a and C12b remain.

As shown in FIG. 7, the front surface 16a of the side surface 16 of the upper side wall 13 is inclined at an angle α toward the inside of the main body 15 with respect to the front-rear plane K parallel to the XZ plane. The rear surface 16b is inclined inward of the main body portion 15 by an angle β with respect to the front-rear plane K. Moreover, as shown in FIG. 8, the mold matching surface S of the first mold 41 and the second mold 42 corresponds to the rear surface (Z2 direction) of the gate portion Cg. Therefore, the first mold 41 and the second mold 42 can be separated without any problem in the direction of the front-back plane K while leaving the shape of the main body 15 and the gate part Cg continuous to the main body 15 intact. . As shown in FIG. 12, the front surface 18a of the side wall portion 18 of the lower side wall portion 14 is also inclined by an angle α from the front-back plane K, the rear surface 18b is also inclined by an angle β, and the mold matching surface S is on the rear side of the overflow portion Cf. (Z2 side) surface. Therefore, the first mold 41 and the second mold 42 can be opened without any problem while leaving the shapes of the main body 15 and the overflow portion Cf continuous with the main body 15 intact.

As shown in FIG. 9(B), the anchor recesses 21 provided in the upper part of the upper side wall part 13, the upper part of the lower side wall part 14, and the left and right edges 12c, 12d have an inner width dimension of the front (Z1 The anchor recess 22 also gradually widens from H2 to H1 as it goes forward. Therefore, even in the molded portions of the anchor recesses 21 and 22, the first mold 41 can be separated from the solidified metal molded body without any problem.

The overall shape of the metal molded body taken out from the mold 40 is the same as the spatial shape within the mold shown in FIG. In the metal molded body, a portion corresponding to the anchor gate portion Cg1 is cut along the cutting line (a) shown in FIGS. 8 and 14, and the side surface portion of the upper side wall portion 13 is cut as shown in FIGS. An anchor convex portion 17 that protrudes upward (in the Y1 direction) from 16 remains continuous with the main body portion 15 . In the metal molded body, when the part corresponding to the anchor overflow part Cf1 is cut along the cutting line (b) shown in FIGS. The protruding anchor convex portion 19 remains continuous with the main body portion 15.

Further, the anchor convex portion 25 shown in FIG. 4 is formed by cutting the metal material at the anchor overflow portion extending from the support plate molding cavities C12a and C12b. Furthermore, the metal part molded in the support plate molding cavities C12a and C12b shown in FIG. left in the same state.

After the metal molded body is cut along the cutting lines (a), (b), and (c), the cut surfaces of the anchor convex portions 17, 19, 25 and the support portion 10b are deburred to form the metal base material 10. Complete. As shown in FIGS. 6, 9, and 11, the anchor recesses 21, 22 molded with the first mold 41 have curved cross sections at all corners exposed on the surface. When separated from the mold 41, burrs are hardly left on the surfaces of the anchor recesses 21 and 22. Further, as described above, by deburring the cut surfaces of the anchor convex portions 17, 19, 25 and the support portion 10b, no burrs remain on the metal base material 10. Therefore, when the metal base material 10 and the resin molded body 30 are fixed together by insert molding, defects such as metal burrs being mixed into the inside of the molten resin forming the resin molded body 30 are less likely to occur.

When molding a metal base material by a casting method, it is essential to cut the metal molded product at the gate part and overflow part and deburr the cut part. By cutting along the cutting line and removing burrs, it is possible to form a burr-free anchor protrusion. Therefore, it becomes possible to form a burr-free anchor convex portion without increasing the number of man-hours compared to the conventional method.

Note that the anchor protrusion 17 shown in FIG. 6 and the anchor protrusion 19 shown in FIG. It has an elongated shape or rail shape with large dimensions. However, in the present invention, the cross-sectional shape of the anchor convex portion located at at least one of the gate portion and the overflow portion may be circular, oval, or the like.

In the present invention, the anchor recess may be formed on the rear surface of the side surface of the side wall, or the anchor recess may be formed on both the front surface and the rear surface. Further, the anchor convex portion may be located only in the gate portion or may be located only in the overflow portion.

1 Display device 3 Composite molded product 10 Metal base material 11 Storage space 13 Upper side wall portion 13a Front end portion 14 Lower side wall portion 14a Front end portion 15 Main body portion 16 Side wall surface 16a Front surface 16b Rear surface 17 Anchor convex portion 18 Side portion 18a Front surface 18b Rear surface 19 Anchor convex portion 21 Anchor recess 21a Side opening 21b Height opening 22 Anchor recess 22a Side opening 22b Height opening 30 Resin molded body 31 Upper side wall anchoring portion 32 Lower side wall anchoring portion 40 Mold 41 First mold 42 Second mold C13 Upper side wall molding cavity C14 Lower side wall molding cavity C15 Main body molding cavity Cg Gate portion Cf Overflow portion

Claims (7)

In a composite molded product having a metal base material molded by a casting method and a resin molded body fixed to a part of the metal base material,
The metal base material has a main body part and an anchor convex part that protrudes from the main body part and enters the resin molded body,
The composite molded article is characterized in that the anchor convex portion is located at at least one of a gate portion through which molten metal is introduced and an overflow portion through which molten metal is discharged when the main body portion is molded by the casting method. The metal base material has a width dimension in each direction in a plan view viewed from the front that is larger than a height dimension in the front-rear direction, and the width direction is oriented in the front-rear direction and the direction intersecting the front-rear direction is the longitudinal direction. It has a side part with a
The anchor convex portion projects laterally from the side surface portion and extends along the longitudinal direction of the side surface portion,
The composite molded article according to claim 1, wherein at least a portion of the resin molded body is fixed to the side surface portion. The metal base material has a width dimension in each direction in a plan view viewed from the front that is larger than a height dimension in the front-rear direction, and the width direction is oriented in the front-rear direction and the direction intersecting the front-rear direction is the longitudinal direction. It has a side part with a
The anchor convex portion protrudes laterally from the side surface portion and extends along the longitudinal direction of the side surface portion, and the side surface portion includes a front surface located in front of the anchor convex portion, and a front surface located in front of the anchor convex portion. It has a rear surface located rearward than the
The front surface and the rear surface are inclined toward the inside of the main body as they move away from the anchor convex portion in the front-rear direction,
The composite molded article according to claim 1, wherein at least a portion of the resin molded body is fixed to the front surface and the rear surface. An anchor recess is formed in at least one of a front surface of the side surface located forward of the anchor projection and a rear surface of the side surface located rearward of the anchor projection,
The composite molded article according to claim 2 or 3, wherein a part of the resin molded body enters into the anchor recess. The anchor recess has a side opening opened in the side surface and a height opening opened in a height direction facing in the front-rear direction,
An inner width dimension of the anchor recess in the longitudinal direction gradually widens from the side opening toward the inside of the recess, and gradually narrows from the height direction opening toward the inside of the recess. 4. The composite molded product described in 4. Comprising the composite molded article according to any one of claims 2 to 5 ,
A display device characterized in that a display cell is arranged inside a storage space surrounded by the side surface portion of the metal base material. In a method for manufacturing a composite molded product, the method includes molding a metal base material by a casting method and fixing a resin molded body to the metal base material,
In the casting method, molten metal is injected into the cavity from the gate part of the mold, the molten metal is discharged from the overflow part of the mold, the molten metal in the cavity is solidified, and the metal base material is solidified. Molding the main body,
forming an anchor convex portion protruding from the main body portion by leaving a portion of the solidified metal in at least one of the gate portion and the overflow portion;
A method for manufacturing a composite molded product, characterized in that, when molding the resin molded product, the anchor convex portion is inserted into the resin molded product.

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